Zmotion ZMC460 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.

ZMC460 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........................................................................................5
Chapter II Product Specification .........................................................................................7
2.1. Basic Specification............................................................................................7
2.2. Order Information..............................................................................................8
2.3. Interface Definition............................................................................................8
2.4. Work Environment ...........................................................................................10
Chapter III Wiring and Communication Configuration......................................................11
3.1. Power Input .....................................................................................................11
3.1.1. Power Specification..............................................................................11
3.2. RS485, CAN Communication Interface ...........................................................12
3.2.1. RS485, CAN Communication Specification & Wiring...........................12
3.2.2. Basic Usage Method ............................................................................14
3.3. RS232 Serial Port ............................................................................................16
3.3.1. RS232 Communication Interface Specification & Wiring ....................16
3.3.2. Basic Usage Method ............................................................................18
3.4. IN Digital Input & High-Speed Latch Port & Single-ended Encoder ...............19
3.4.1. Digital Input Specification & Wiring .....................................................20
3.4.2. Basic Usage Method ............................................................................21
3.5. OUT: Digital Output, PWM Terminal, Hardware Comparison Output, Single-
ended Pulse................................................................................................................22
3.5.1. Digital Output Specification & Wiring...................................................23
3.5.2. Basic Usage Method ............................................................................25

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3.6. AD / DA: Analog Input / Output .......................................................................25
3.6.1. Analog Output Specification & Wiring..................................................26
3.6.2. Basic Usage Method ............................................................................27
3.7. U Disk ..............................................................................................................28
3.8. ETHERNET .......................................................................................................28
3.9. EtherCAT Bus Interface ...................................................................................29
3.10. AXIS Differential Pulse Axis Interface .........................................................31
3.10.1. AXIS Interface Signal Specification & Wiring.......................................33
3.10.2. Basic Usage Method ............................................................................35
Chapter IV Expansion Module ...........................................................................................38
4.1. CAN Bus Expansion.........................................................................................38
4.1.1. CAN Bus Expansion Wiring...................................................................38
4.1.2. CAN Bus Expansion Resource Mapping ..............................................40
4.2. EtherCAT Bus Expansion.................................................................................44
4.2.1. EtherCAT Bus Expansion Wiring...........................................................44
4.2.2. EtherCAT Bus Expansion Resource Mapping ......................................45
Chapter V Program & Application......................................................................................48
5.1. ZDevelop Software Usage...............................................................................48
5.2. PC Upper-Computer Program Application .....................................................53
Chapter VI Run and Maintain ............................................................................................56
6.1. Regular Inspection and Maintenance .............................................................56
6.2. Common Problems..........................................................................................57

ZMC460 Motion Controller User 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.
ZMC4 series supports Zmotion XPLC function, and can be configured and displayed
through the network.
ZMC460 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 complex continuous trajectory control requirements of up to 60 axes.
ZMC4 series high-performance multi-axis motion controller 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
◆Motion control of up to 60 axes.
◆Pulse output mode: pulse / direction or dual pulses or quadrature pulse.
◆Maximum pulse frequency output of each axis: 10MHZ.
◆IO can be expanded through CAN and EtherCAT, and 4096 isolated inputs and 4096
isolated 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

ZMC460 Motion Controller User Manual V1.5
directly drive some kinds of solenoid valves.
◆Interfaces: EtherCAT, RS232, RS485, U Disk, Ethernet.
◆Support linear interpolation, any circular interpolation, helical interpolation and spline
interpolation of 60 axes at most.
◆Support electronic cam, electronic gear, position latch, synchronous follow, virtual
axis, etc.
◆Support hardware comparison output (HW_PSWITCH2), hardware timer, precision
output in motion.
◆Support pulse closed loop, pitch compensation and other functions.
◆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

ZMC460 Motion Controller User Manual V1.5
1.4. Hardware Installment
The ZMC460 motion controller adopts the horizontal installation method of screw
fixing, and each controller should be installed with 4 screws for fastening.
→Unit: mm →Installment 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.

ZMC460 Motion Controller User Manual V1.5
⚫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

ZMC460 Motion Controller User Manual V1.5
Chapter II Product Specification
2.1. Basic Specification
Item
Description
Model
ZMC460
ZMC430
Basic Axes
60
30
Max Extended Axes
60
60
Basic Axes Type
EtherCAT/ Local pulse axes
Digital IO
24 inputs, 12 outputs, each pulse axis has 1 input and 1
output
Max Extended IO
4096 inputs, 4096 outputs
PWM
12
AD/DA
2 general ADs and 2 general DAs, 0-10V
Max Extended AD/DA
1000 ADs, 1000 DAs
Pulse Bit
64
Encoder Bit
64
Speed Acceleration Bit
64
Pulse Max Frequency
10MHz
Motion Axis Buffer
4096
Array Space
320000
Program Space
32MByte
Flash Space
256MByte
Power Supply Input
24V DC input
Communication
Interfaces
RS232, RS485, Ethernet, U disk, CAN, EtherCAT
Dimensions
216mm*144mm

ZMC460 Motion Controller User Manual V1.5
2.2. Order Information
Model
Description
ZMC460
60 axes, point to point, linear, circular, electronic cam, continuous
trajectory motion, robotic car instructions.
ZMC430
30 axes, point to point, linear, circular, electronic cam, continuous
trajectory motion, robotic car instructions.
➢Except for the axis resources in the function description in the form above, the above
models have the same resources, so you can refer to this manual.
2.3. Interface Definition

ZMC460 Motion Controller User Manual V1.5
→Interface Description
Mark
Interface
Number
Description
POW
Status Indication Light
1
Power indicator: it lights when power is
conducted.
RUN
1
Run indicator: it lights when runs normally
ALM
1
Error indicator: it lights when runs
abnormally
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
Ethernet
1
Use MODBUS_TCP protocol, expand
Ethernet through interchanger, the number
of net port channels can be checked
through “?*port”, default IP address id
192.168.0.11
UDISK
U disk interface
1
Insert U disk equipment
E+24V
Main power
1
24V DC power supplies for controller
CAN
CAN bus interface
1
Connect CAN expansion module and CAN
equipment of other standards
IN
Digital IO input
24
Leakage type, internal 24V supply power, 12
high-speed inputs, IN0-3 have latch
function, IN0-11 have single-ended
encoder function.
OUT
Digital IO output
12
Leakage type, internal 24V supply power, 12
high-speed outputs, OUT0-11 have PWM,
single-ended pulse and hardware
comparison output function.
AD
Analog input
2
Resolution: 12 bits, 0-10V
DA
Analog output
2
Resolution: 12 bits, 0-10V
AXIS
Pulse axis
6
It includes differential pulse output and
differential encoder input

ZMC460 Motion Controller User Manual V1.5
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

ZMC460 Motion Controller User Manual V1.5
Chapter III Wiring and Communication
Configuration
3.1. Power Input
The power supply input adopts a 3Pin (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 3Pin terminal is the power supply of the controller.
→Terminal Definition:
Terminal
Name
Type
Function
EARTH
Connect to ground
Case Protection
EGND
Input
Negative (-) of DC input
E+24V
Input
Positive (+) of DC 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

ZMC460 Motion Controller User Manual V1.5
3.2. RS485, CAN Communication Interface
The communication interface adopts a 5Pin screw-type pluggable wiring terminal and the
gap spacing between 2 terminals should be 3.81mm. For both RS485 communication and
CAN communication, they can be used by connecting the corresponding interface.
→Terminal Definition:
Terminal
Name
Function
485B
485-
485A
485+
EGND
External power supply ground
CANL
CAN differential data -
CANH
CAN differential data +
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.
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
RS485
CAN
Maximum Communication Rate (bps)
115200
1M
Terminal Resistor
No
120Ω
Topological Structure
Daisy Chain Topology
The number of nodes can be extended
Up to 127
Up to 16
Communication Distance
The longer communication distance is, the

ZMC460 Motion Controller User Manual V1.5
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.
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,

ZMC460 Motion Controller User 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.
3.2.2. 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;

ZMC460 Motion Controller User Manual V1.5
(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
“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.
(8) 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

ZMC460 Motion Controller User Manual V1.5
disordered.
3.3. RS232 Serial Port
RS232 is in a 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
RXD
Input
RS232 signal, receive data
3
TXD
Output
RS232 signal, send data
5
EGND
Output
Negative pole output of 5V power,
and output for the public end
9
E5V
Output
Positive pole output of 5V power,
maximum is 300mA
3.3.1.RS232 Communication Interface Specification &
Wiring
→Specification:
Item
RS232
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,