Zmotion ZMC408SCAN 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.

ZMC408SCAN Motion Controller Hardware Manual V1.5
Content
Chapter I Production Information........................................................................................4
1.1. Product Information ..........................................................................................4
1.2. Function Features..............................................................................................4
1.3. System Frame ...................................................................................................6
1.4. Hardware Installment........................................................................................6
Chapter II Product Specification .........................................................................................8
2.1. Basic Specification............................................................................................8
2.2. Interface Definition............................................................................................9
2.3. Work Environment ...........................................................................................11
Chapter III Wiring, Communication Configuration & .........................................................12
3.1. Power Input .....................................................................................................12
3.1.1. Power Specification..............................................................................12
3.1.2. CAN Communication Specification & Wiring .......................................13
3.1.3. Basic Usage Method ............................................................................15
3.2. IN Digital Input & High-Speed Latch Port .......................................................16
3.2.1. Digital Input Specification & Wiring .....................................................17
3.2.2. Basic Usage Method ............................................................................18
3.3. OUT (Digital Output, PWM Terminal, Hardware Comparison Output) ............19
3.3.1. Digital Output Specification & Wiring...................................................20
3.3.2. Basic Usage Method ............................................................................22
3.4. AD/DA Analog Input/Output............................................................................23
3.4.1. AD/DA Analog Input/Output Specification & Wiring............................23
3.4.2. Basic Usage Method ............................................................................24
3.5. RS232/RS485 Serial Port ................................................................................25
3.5.1. RS232 / RS485 Communication Interface Specification & Wiring ......26
3.5.2. Basic Usage..........................................................................................27

ZMC408SCAN Motion Controller Hardware Manual V1.5
3.6. U Disk ..............................................................................................................28
3.7. ETHERNET .......................................................................................................29
3.8. EtherCAT Bus Interface ...................................................................................30
3.9. AXIS Differential Pulse Axis Interface.............................................................32
3.9.1. AXIS Interface Signal Specification & Wiring.......................................34
3.9.2. Basic Usage Method ............................................................................35
3.10. MPG Handwheel Interface...........................................................................37
3.10.1. MPG Handwheel Interface Specification & Wiring...............................38
3.10.2. Basic Usage Method ............................................................................40
Chapter IV SCAN Galvanometer Interface.........................................................................41
4.1. SCAN Galvanometer Interface Specification & Wiring....................................42
4.2. Basic Usage Method .......................................................................................44
Chapter V LASER Interface................................................................................................45
5.1. LASER Interface Specification & Wiring..........................................................46
5.2. Basic Usage Method .......................................................................................50
Chapter VI EXIO Expansion IO ...........................................................................................52
6.1. EXIO Expansion IO Interface Description........................................................52
6.2. Basic Usage Method .......................................................................................54
6.2.1. FIBER Laser Adapter Board ..................................................................54
6.2.2. YAG Laser Adapter Board.....................................................................58
Chapter VII Expansion Module ..........................................................................................63
7.1. CAN Bus Expansion.........................................................................................63
7.1.1. CAN Bus Expansion Wiring...................................................................63
7.1.2. CAN Bus Expansion Resource Mapping ..............................................65
7.2. EtherCAT Bus Expansion.................................................................................69
7.2.1. EtherCAT Bus Expansion Wiring...........................................................69
7.2.2. EtherCAT Bus Expansion Resource Mapping ......................................70
Chapter VIII Program & Applications.................................................................................73
8.1. ZDevelop Software Usage...............................................................................73
8.2. PC Upper-Computer Program Application .....................................................78

ZMC408SCAN Motion Controller Hardware Manual V1.5
Chapter VIIII Run and Maintain .........................................................................................81
9.1. Regular Inspection and Maintenance .............................................................81
9.2. Common Problems..........................................................................................82

ZMC408SCAN Motion Controller Hardware Manual V1.5
Chapter I Production Information
1.1. Product Information
ZMC408SCAN Laser-Galvanometer Motion Controller is a kind of high-performance
fieldbus dual-SCAN motion controller launched by Zmotion. It is designed for industrial
laser + galvanometer + motion control. And multi-axis motion control can be achieved
through EtherCAT bus and pulse axis interface.
ZMC408SCAN bus controller supports EtherCAT bus connection, the fastest refresh
cycle is 500μs, and supports max 16 axes linear, spherical, circular, helical interpolation,
electronic cam, electronic gear, synchronous following, virtual axis setting etc. Real-time
motion control can be realized by using optimized network communication protocol.
One Computer can link with up to 256 ZMC controllers.
The laser galvanometer motion controller supports the galvanometer protocol of
XY2-100, and the controller has a SCAN galvanometer interface and a LASER laser
interface. This controller can be applied to metal or non-metal large-format splicing
marking and cutting, ordinary galvanometer marking, welding and cutting, motion axis +
galvanometer axis linkage marking and cutting, laser drilling and forming, etc., and it can
be adapted to optical fiber, ultraviolet, carbon dioxide and other lasers with different
functions.
1.2. Function Features
◆Motion control of up to 16 axes. (EtherCAT/pulse encoder axis/virtual axis)
◆4 AXIS interfaces support encoder position measurement and incremental drive
function, which can be configured as handwheel input mode.
◆1 MPG handwheel encoder interface supports 5-24V input.
◆20 leakage digital outputs, and 8 channels are high-speed outputs, they support

ZMC408SCAN Motion Controller Hardware Manual V1.5
hardware comparison output, PWM, etc., then 12 are low-speed digital outputs, the
max output current can reach 300mA, which can drive some solenoid valves directly.
◆24 leakage digital inputs, and 4 channels are high-speed inputs, 20channels are low-
speed inputs. In addition, high-speed input can be configured for latch signal.
◆1 100M EtherCAT interface, 4096 isolated inputs and 4096 isolated outputs can be
expanded through EtherCAT bus.
◆1 USB drive interface is used to update ZAR program, import and export controller
data and execute 3 file.
◆1 RS485, 1 RS232, 1 CAN and 1 100M ETHERNET interface support multi-expansion
applications.
◆2 12-bit voltage type analog outputs, output measuring range is 0-10V. 2 12-bit
voltage type analog inputs, input measuring range is 0-10V.
◆2 SCAN galvanometer interfaces support XY2-100 protocol and galvanometer
feedback.
◆1 “LASER” interface for controlling laser power, which supports IPG, YLR, YLS and
other laser power supplies.
◆1 EXIO interface is used to configurate IO expansion, and it can set outside expansion
of YAG, FIBER and laser power control interfaces of other types.
◆Linear interpolation of up to 16 axes, interpolation of random spherical interpolation,
helical and spline.
◆Support electronic cam, electronic gear, position latch, synchronous follow, virtual
axis, etc.
◆Support hardware comparison output (HW_PSWITCH2), hardware timer and
precision output in motion.
◆Support pulse closed loop, pitch compensation and other functions.
◆Multi-file and multi-task programming in ZBasic.
◆A variety of procedure encryption methods to protect the intellectual property rights
of customers.
◆Support power failure detection and power failure storage.

ZMC408SCAN Motion Controller Hardware Manual V1.5
1.3. System Frame
1.4. Hardware Installment
The ZMC408SCAN motion controller is installed horizontally with screws, and each
controller should be fastened with 4 screws.
→Unit: mm →Mounting Hole Diameter 4.5mm

ZMC408SCAN 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

ZMC408SCAN Motion Controller Hardware Manual V1.5
Chapter II Product Specification
2.1. Basic Specification
Item
Description
Model
ZMC408SCAN
Axes
8 (4 motion axes + 4 galvanometer axes / 6 motion axes +
2 galvanometer axes)
Max Extended Axes
16 (the number of axes relates to system period and
galvanometer period)
Type of basic axes
EtherCAT/local pulse axes, galvanometer axes
Internal IO
24 inputs and 20 outputs, there are another 2 general
inputs and 2 general outputs on each axis terminal, which
can do alarm, enable, on-position, clear error, etc.
Max extended IOs
Up to 4096 inputs and 4096 outputs
PWM
8 (general digital outputs OUT0~OUT7) + 2 (specialized
laser interface, OUT8 and OUT9)
Internal AD/DA
2 general ADs and 2 general DAs, for special modes,
custom 1 specialized laser AD and 1 specialized laser DA.
Max extended AD/DA
1024
Pulse Bits
64
Encoder Bits
64
Speed/Acceleration bits
64
Max pulse frequency
10MHz
Axis motion buffer
4096 (the number of buffers is relative to system cycle)
Array Size
2560000
Procedure space
128MByte
Flash Space
256MByte
Power Input
24V DC input
Communication
RS232, RS485, Ethernet, USB drive, CAN, EtherCAT
Size
235mm*149mm*50mm

ZMC408SCAN Motion Controller Hardware Manual V1.5
2.2. 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.
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

ZMC408SCAN Motion Controller Hardware Manual V1.5
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 10 high-
speed inputs, and IN0-3 have the latch
function.
OUT
Digital IO output port
20
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 functions.
AD
Analog input port
2
12-bit resolution, 0-10V.
DA
Analog output port
2
12-bit resolution, 0-10V.
AXIS
Pulse axis interface
4
It includes differential pulse output and
differential encoder input.
MPG
Handwheel interface
1
5-24V handwheel signal input
SCAN
Laser galvanometer
2
Laser galvanometer interface is with
feedback, use XY2-100 protocol.
LASER
Laser
1
OUT8-9 support PWM function, and precision
output and PSO function are valid in OUT8-9.
Laser power control interface support IPG,
YLR, YLS and other types of laser powers.
EXIO
Expansion IO
1
Flexibly custom adapter board, FIBER, YAG
and other kinds of laser power control
interfaces are supported.

ZMC408SCAN Motion Controller Hardware Manual V1.5
2.3. 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

ZMC408SCAN Motion Controller Hardware Manual V1.5
Chapter III Wiring, Communication
Configuration &
3.1. Power Input
The power supply input adopts a 5Pin (there are all 3 terminals) screw-type pluggable
wiring terminal, and the interval (means the gap distance between two ports) should be
3.81mm. This 5Pin terminal is shared by controller power and CAN communication.
→Terminal Definition:
Terminal
Name
Type
Function
EGND
Input
Negative (-) terminal of DC power
input (connect negative of power to
negative of controller)
CHNL
Input/output
CAN communication L
FG
Earthing
Protect
CHNH
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

ZMC408SCAN Motion Controller Hardware Manual V1.5
Overcurrent Protection
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
Description
Maximum Communication Rate (bps)
1Mbps
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 controller, and connect the public ends “EGND”of the CAN bus communication parties
together, and connect a 120Ωresistor between CANH and CANL. (Both left and right two
CANH and CANL need one resistor respectively, please see below graphic).

ZMC408SCAN Motion Controller Hardware Manual V1.5
→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.
→Cable Requirements:
Shielded Twisted Pair, and the shielded cable is grounded.

ZMC408SCAN Motion Controller Hardware Manual V1.5
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 "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.
(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

ZMC408SCAN Motion Controller Hardware Manual V1.5
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 8Pin (there are 3 groups of 8 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.
→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
/