Zmotion ZMC408CE 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.

ZMC408CE 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 ...................................................................................................5
1.4. Hardware Installment........................................................................................5
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.................................................................................11
3.1. Power Input, CAN Communication Interface ..................................................11
3.1.1. Power Specification..............................................................................11
3.1.2. CAN Communication Specification & Wiring .......................................11
3.1.3. Basic Usage Method ............................................................................13
3.2. IN Digital Input & High-Speed Latch Port .......................................................14
3.2.1. Digital Input Specification & Wiring .....................................................15
3.2.2. Basic Usage Method ............................................................................16
3.3. OUT Digital Output & PWM Terminal ..............................................................17
3.3.1. Digital Output Specification & Wiring...................................................18
3.3.2. Basic Usage Method ............................................................................20
3.4. AD/DA Analog Input/Output............................................................................20
3.4.1. AD/DA Analog Input/Output Specification & Wiring............................21
3.4.2. Basic Usage Method ............................................................................22
3.5. RS232/RS485 Serial Port ................................................................................22
3.5.1. RS232/RS485 Communication Interface Specification & Wiring ........23

ZMC408CE Motion Controller Hardware Manual V1.5
3.5.2. Basic Usage..........................................................................................24
3.6. ETHERNET .......................................................................................................26
3.7. EtherCAT Bus Interface ...................................................................................27
3.8. AXIS Differential Pulse Axis Interface.............................................................29
3.8.1. AXIS Interface Signal Specification & Wiring.......................................31
3.8.2. Basic Usage Method ............................................................................33
3.9. MPG Handwheel Interface ..............................................................................35
3.9.1. MPG Handwheel Interface Specification & Wiring...............................36
3.9.2. Basic Usage Method ............................................................................38
Chapter IV Expansion Module ...........................................................................................39
4.1. CAN Bus Expansion.........................................................................................39
4.1.1. CAN Bus Expansion Wiring...................................................................39
4.1.2. CAN Bus Expansion Resource Mapping ..............................................41
4.2. EtherCAT Bus Expansion.................................................................................45
4.2.1. EtherCAT Bus Expansion Wiring...........................................................45
4.2.2. EtherCAT Bus Expansion Resource Mapping ......................................46
Chapter V Program & Applications....................................................................................49
5.1. ZDevelop Software Usage...............................................................................49
5.2. PC Upper-Computer Program Application .....................................................54
Chapter VI Run and Maintain ............................................................................................57
6.1. Regular Inspection and Maintenance .............................................................57
6.2. Common Problems..........................................................................................58

ZMC408CE Motion Controller Hardware Manual V1.5
Chapter I Production Information
1.1. Product Information
ZMC is the abbreviation of the network motion controller model launched by Zmotion
Technology.
ZMC408CE high-performance multi-axis motion controller is a stand-alone motion
controller that is compatible with EtherCAT bus and pulse type. The controller itself
supports 8 axes, but 32 axes can be expanded at most to achieve complex continuous
trajectory control requirements.
ZMC4 series high-performance multi-axis motion controllers can be applied in
robots (SCARA, Delta, 6 joints), 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
◆Support 8 axes motion control.
◆Pulse output mode: pulse / direction or dual pulses or quadrature pulse.
◆AXIS interface supports encoder position measurement, which can be configured as
handwheel input mode.
◆Specialized handwheel input interface.
◆Maximum pulse output frequency of each axis is 10MHZ.
◆IO can be expanded through ZCAN and EtherCAT bus, 4096 isolated inputs and 4096
isolated outputs can be extended at most.

ZMC408CE Motion Controller Hardware 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 can reach 300mA, which can
directly drive some kinds of solenoid valves.
◆Interfaces: RS232, EtherNET, EtherCAT, CAN.
◆Support up to 32 axes linear interpolation, arbitrary circular interpolation, helical
interpolation.
◆Support electronic cam, electronic gear, position latch, synchronous follow, virtual
axis and other functions.
◆Support 8-channel PWM output.
◆Support hardware comparison output, hardware timer, precision output when in
motion.
◆Support encoder position comparison, HW_PSWITCH2 supports 8 HWOP outputs.
◆Support high-speed hardware latch, encoder axis supports 4-channel, handwheel
axis only supports 2-channel, other axes support 4-channel.
◆A variety of program encryption methods to protect the intellectual property rights of
customers.

ZMC408CE Motion Controller Hardware Manual V1.5
1.3. System Frame
1.4. Hardware Installment
The ZMC408CE motion controller is installed horizontally with screws, and each controller
should be fastened with 4 screws.
→Unit: mm →Mounting Hole Diameter 4.5mm

ZMC408CE Motion Controller Hardware Manual V1.5
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)
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

ZMC408CE Motion Controller Hardware Manual V1.5
Chapter II Product Specification
2.1. Basic Specification
Item
Description
Model
ZMC408CE
Basic Axes
8
Max Extended Axes
32
Type of Basic Axes
Pulse axis / encoder axis / ECAT bus axis
Digital IO
24 inputs and 16 outputs, and each Axis axis has 2
additional inputs and 2 additional outputs.
Max Extended IO
4096
AD/DA
2 AD inputs, 0-10V. 2 DA outputs, 0-10V.
Max Extended AD/DA
512 ADs and 512 DAs.
Pulse Bit
64
Encoder Bit
64
Speed and Acceleration Bit
64
Highest Pulse Frequency
10MHz
Motion Buffer of Each Axis
4096
Array Space
320000
Program Space
32MByte
Flash Space
256MBye
Power Supply Input
24V DC input
Communication Interfaces
RS232, RS485, ETHERNET, CAN, EtherCAT
Dimension
221*144*50mm
2.2. Order Information
Model
Description

ZMC408CE Motion Controller Hardware Manual V1.5
ZMC408CE
8 axes, point to point, linear, circular, electronic cam, continuous
trajectory motion, robot structure.
ZMC408CE-16
16 axes, point to point, linear, circular, electronic cam, continuous
trajectory motion, robot structure.
2.3. Interface Definition
→Interface Description
Mark
Interface
Number
Description
POW
The led that indicates the
current state.
1
Power state: it lights when power is
conducted.

ZMC408CE Motion Controller Hardware Manual V1.5
RUN
1
Run state: it lights when runs normally
ALM
1
Error state: it lights when runs incorrectly
RS232
RS232 serial port
1
Use MODBUS_RTU protocol
RS485
RS485 serial port
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”
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.
CAN
CAN bus interface
1
Connect CAN expansion modules and CAN
equipment of other standards.
IN
Digital IO input port
24
Leakage type, the power is supplied by
internal 24V power supply. There are 4 high-
speed inputs, and IN0-3 have the latch
function.
OUT
Digital IO output port
16
Leakage type, the power is supplied by
internal 24V power supply. There are 8 high-
speed outputs, OUT0-7 have PWM, precision
output and PSO.
AD
Analog input port
2
12-bit resolution, 0-10V.
DA
Analog output port
2
12-bit resolution, 0-10V.
Axis
Pulse axis interface
8
Each interface includes differential pulse
output and differential encoder input.
MPG
Handwheel
1
5-24V handwheel signa input
2.4. Work Environment
Item
Parameters

ZMC408CE Motion Controller Hardware Manual V1.5
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

ZMC408CE Motion Controller Hardware Manual V1.5
Chapter III Wiring & Communication
3.1. Power Input, CAN Communication Interface
The power supply input adopts a 5Pin screw-type pluggable wiring terminal, and the
interval (means the gap distance between two ports) should be 3.81mm. This 5Pin
terminal is the power supply of the controller.
→Terminal Definition:
Terminal
Name
Type
Function
EGND
Input
Negative (-) terminal of power input
CANL
Input/output
CAN communication L
EARTH
Earthing
Protect
CANH
Input/output
CAN communication H
E+24V
Input
Positive (+) terminal of power input
3.1.1. Power Specification
→Specification
Item
Description
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. CAN Communication Specification & Wiring
The CAN interface of the controller adopts the standard CAN communication

ZMC408CE Motion Controller Hardware Manual V1.5
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
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,

ZMC408CE Motion Controller Hardware Manual V1.5
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.
→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

ZMC408CE Motion Controller Hardware Manual V1.5
"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.
(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. IN Digital Input & High-Speed Latch Port
The digital input adopts 3 groups of 10Pin (there are 3 groups of 10 terminals) screw-
type pluggable terminals, and the gap distance between terminals should be 3.81mm. In
addition, the high-speed latch function is integrated in digital input signal.

ZMC408CE Motion Controller Hardware Manual V1.5
→Terminal Definition
Terminal
Name
Type
Function 1
Function 2
IN0
NPN leakage type,
high-speed input
Input 0
High Speed
Latch
IN1
Input 1
IN2
Input 2
IN3
Input 3
IN4
NPN leakage type,
low-speed input
Input 4
/
IN5
Input 5
/
IN6
Input 6
/
IN7
Input 7
/
IN8
NPN leakage type,
low-speed input
Input 8
/
IN9
Input 9
/
IN10
Input 10
/
IN11
Input 11
/
IN12
Input 12
/
IN13
Input 13
/
IN14
Input 14
/
IN15
Input 15
/
IN16
NPN leakage type,
low-speed input
Input 16
/
IN17
Input 17
/
IN18
Input 18
/
IN19
Input 19
/
IN20
Input 20
/
IN21
Input 21
/
IN22
Input 22
/
IN23
Input 23
/
3.2.1. Digital Input Specification & Wiring
→Specification
Item
High-Speed Input (IN0-3)
Low-Speed Input (IN4-23)
Input mode
NPN leakage type, the input is triggered when there is low-
electric level
Frequency
＜100kHz
＜5kHz
Impedance
3.3KΩ
4.7KΩ
Voltage level
DC24V
DC24V

ZMC408CE Motion Controller Hardware Manual V1.5
The voltage to open
<15V
<14.5V
The voltage to close
>15.1V
>14.7V
Minimal current
-2.3mA (negative)
-1.8mA (negative)
Max current
-7.5mA (negative)
-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 (0-3) and low-speed digital input
IN (4-23) 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.
3.2.2. Basic Usage Method
(1) Please follow the above wiring instructions to wiring correctly.
(2) After powered on, please select ETHERNET or RS232 to connect to ZDevelop.