ZMC408CE Hardware Introduction
The ZMC408CE is a multi-axis, high-performance EtherCAT bus motion controller launched by Zheng Motion. It has communication interfaces such as EtherCAT, EtherNET, RS232, CAN and USB flash drive. The ZMC series motion controllers can be used in various occasions that require offline or online operation.
The ZMC408CE supports 8-axis motion control, expandable to a maximum of 32 axes, and supports linear interpolation, arbitrary circular interpolation, spatial circular interpolation, helical interpolation, electronic cam, electronic gear, synchronous following and other functions.
The ZMC408CE supports three programming methods: PLC, Basic, and HMI configuration. PC-based API programming supports interfaces such as C#, C++, LabVIEW, Matlab, Qt, Linux, VB.Net, and Python.
The ZMC408CE supports 8-axis motion control and can use pulse axes (with encoder feedback) or EtherCAT bus axes. The general-purpose I/O includes 24 input ports and 16 output ports. Some I/O are high-speed I/O, with two analog AD/DA channels and an EtherCAT refresh cycle of up to 125us.
The ZMC408CE supports 8 channels of hardware compare output, hardware timer, precise output during motion, and also supports 8 channels of PWM output, with corresponding output ports OUT0-7, supporting simultaneous triggering of hardware compare output on all 8 channels.
ZMC408CE Video Introduction
01. ZCAN Expansion Module The ZCAN bus expansion module includes two series: ZCAN expansion module and ZMIO310-CAN expansion module. Today we will mainly introduce the ZCAN expansion module.
ZCAN offers a wide variety of expansion modules, including the following models.
02. Wiring of the ZCAN expansion module
1. When multiple CAN communication modules are connected to the CAN bus, connect all the CANL and CANH ports together (CANL to CANL, CANH to CANH).
2. Connect a 120-ohm terminating resistor in parallel at each of the two ends of the CAN bus interface to match the circuit impedance and ensure communication stability. (On the controller/control card side, a 120-ohm resistor needs to be connected between CANL and CANH, and a 120-ohm resistor needs to be connected in parallel through the DIP switch of the last CAN expansion module).
3. Ensure that the common terminal of the controller's main power supply and the common terminal of the CAN expansion module's main power supply are connected together (commonly known as "common neutral") to prevent the CAN chip from burning out.
4. In cases of severe interference (the ALM light on the ZCAN expansion board remains on after a normal wiring restart), the communication cable should be replaced with a twisted-pair shielded cable, and the shielding layer should be reliably grounded.
5. All ZIO series expansion modules use dual power supplies. The main power supply of the expansion board and the individual power supply of the I/O are powered by two separate power supplies. This prevents interference from the I/O from affecting the main power supply of the ZCAN expansion module and thus communication. The ZAIO analog expansion module uses a single power supply; it only requires the main power supply, and the I/O does not need a separate power supply.
6. When wiring, pay attention to keeping the distance between high-voltage and low-voltage wiring, and it is recommended to keep a distance of more than 20cm.
Wiring reference for single power supply controller and expansion module
Wiring reference for dual power controller and expansion module
03. ZCAN Expansion Module DIP Switch Settings
Speaking of the DIP switch settings for the ZCAN expansion module, let's first understand the DIP switch. Each ZCAN expansion board has a red DIP switch, and the specific meaning of the DIP switch is as follows.
1. DIP switches 1-4
The 4-bit CAN ID (CAN DIP address) is used for ZCAN expansion module IO address mapping. The 4-bit binary combination value corresponds to a value range of 0-15. The controller sets the IO start address of the corresponding expansion module and the start address of AD and DA according to the CAN DIP address.
The following table shows the allocation of the starting numbers of digital I/O corresponding to different binary bit combinations.
Note: I/O numbers for the entire control system must not be duplicated, and existing numbers must be avoided when mapping resources.
The following table shows the starting address allocation for AD and DA corresponding to different binary bit combinations. The 1-4 bit DIP switch states and their corresponding address IDs can be found in the table above.
2. DIP switch 5-6
CAN communication speed, the combined value ranges from 0 to 3, and four different speeds can be selected. Generally, the default CAN communication speed is sufficient. Severe interference can reduce the CAN communication speed. At the same time, the CAN communication speed on the controller side (master side) needs to be modified to match the ZCAN expansion module through the CANIO_ADDRESS command for normal communication.
3. DIP switch 7
Special function reserved (the 7th bit of the ZIO3232MT enables the first 6 bits of the DIP switch; when ON, the settings of the first 6 bits of the DIP switch take effect, and when OFF, the settings do not take effect);
4. DIP switch 8120 ohm resistor. Setting it to ON means that a 120 ohm resistor is connected in parallel between CANL and CANH. When multiple CAN communication modules are connected, only the 8th bit of the last CAN communication module needs to be set to ON. (1) Setting the CAN DIP switch address requires that the IO numbers of the entire control system must not be repeated. The range of local IO addresses on the controller can be viewed by clicking [Controller] - [Controller Status] - [Zcan Node] in the RTSys software.
The above diagram shows the distribution of local digital I/O and analog I/O of the ZMC432 controller. For the ZCAN expansion module that expands digital I/O, we need to ensure that the starting address of the I/O of the ZCAN expansion board is greater than the maximum value of the input port number (29) and the maximum value of the output port number (17). By referring to the digital I/O combination value lookup table, we can find that the combination value of the CAN address DIP switch must be greater than or equal to 1. (2) CAN communication speed. Generally, the default setting is sufficient, and all switches are set to OFF. At this time, the default baud rate is 500kbps. (3) Special function reservation, generally set to OFF (the 7th bit of ZIO3232MT should be set to ON). (4) The 8th bit of the last CAN expansion module should be set to ON, and the 120-ohm matching resistor at the end should be added to the CAN network. After completing the wiring of the CAN expansion module and the setting of the DIP switches, the controller and expansion module need to be powered off and restarted for the changes to take effect.
04. ZCAN Extension Module Function Verification 1. After power failure and restart, observe whether the ALM of the ZCAN extension module is off. If the extension module is communicating normally with the master controller, the lights of the ZCAN extension module should be Power [on], Run [on], and Alarm/ALM [off] (the ALM light in the picture below indicates an abnormality).
Is the power supply to the I/O pins normal? (In the image below, a lit POW indicator light on the I/O pins indicates that the power supply is normal.)
2. By clicking on [Controller] - [Controller Status] - [Zcan Node] in the RTSys software, you can view information such as the IO start number of each ZCAN extension module.
3. ZCAN Expansion Board I/O Port Monitoring. In the RTSys software, click 【Tools】-【Input Port/Output Port】-【IO Selection】 to monitor the I/O information of the corresponding I/O port.
4. Analog signal monitoring on the ZCAN expansion board. In the RTSys software, click 【Tools】-【AD/DA】; you can then monitor the relevant information of the corresponding analog input/output ports. The ZAIO0802 expansion module has 12-bit analog inputs and outputs, so the maximum scale value range must be manually selected as 4095.
5. Testing ZCAN Extended Axes. When extending pulse axes via the CAN bus, the ZIO16082 can be selected to extend two pulse axes. Axis extension requires axis mapping, using the AXIS_ADDRESS command. The mapping rules are as follows.
·
AXIS_ADDRESS(axis number) = (32*0) + ID 'Local axis interface 0 of the expansion board AXIS_ADDRESS(axis number) = (32*1) + ID 'Local axis interface 1 of the expansion board
The ID is a combination of the 1-4 bit address DIP switches on the expansion board. After mapping, the ATYPE isoaxial parameter can be set, and then the expansion axis can be used.
·
ATYPE(6)=0 'Set as virtual axis' Axis 6 is mapped to axis interface 1 of the expansion board with ZCAN expansion module ID 2. AXIS_ADDRESS(6)=2+(32*1) ATYPE(6)=8 'Pulse axis of ZCAN expansion axis type' Generally, the pulse equivalent is set to the number of pulses required for the motor to move 1mm or 1 degree. UNITS(6)=100 'Pulse equivalent 100 SPEED(6)=100 'Speed 100 units/s ACCEL(6)=1000 'Acceleration 1000 units/s^2 DECEL(6)=1000 'Deceleration 1000 units/s^2
After mapping the ZCAN extended axis numbers according to the above example, you can click on 【Tools】-【Manual Motion】to select the corresponding axis number and perform left and right jogging tests. If the motor movement is too slow to notice, you can gradually increase the pulse equivalent value in multiples of 10 to test the effect.
05. Analysis of Common Problems with ZCAN Extension Modules
Common problem 1: The Power, Run, and Alarm indicators of the CAN expansion module cannot communicate with the controller, and the expansion module information cannot be seen in the RTSys software in the interface of [Controller] - [Controller Status] - [Zcan Node].
The following solutions are suggested:
A. Refer to the wiring instructions in Section 2 to check if the power supply of the wiring is normal (whether the main power supply of the ZIO module is 24V and the power supply of the IO terminals is 24V). Use a multimeter to check whether the wires are properly connected and whether there are any poor contacts. Check whether the CAN communication cable uses twisted-pair shielded wire, whether the shielding layer is reliably grounded, and whether the expansion board is powered by dual power supplies.
B. Check if a 120-ohm resistor is connected to the controller, and whether the DIP switch 8 of the last expansion module is turned ON. The CAN grounds at both ends must be on the same ground: ensure that the common terminal of the controller's main power supply and the GND of the ZCAN expansion module's main power supply are connected to the same terminal (commonly known as "common neutral"), sharing the same ground potential to prevent the CAN chip from burning out.
C. Some expansion modules (such as ZIO3232MT) require DIP switch 7 to be switched on to be enabled. You can switch DIP switch 7 to ON, then power off and restart to check.
D. Check if the DIP switches are set correctly and if there are any I/O address conflicts with the main unit or other expansion modules. You can view the I/O start number and other information for each ZCAN expansion module by clicking on [Controller] - [Controller Status] - [Zcan Node] in the RTSys software.
E. Check for interference sources. Disconnect all I/O terminals and other terminal blocks of the controller and expansion module, as well as shaft interfaces. Power off other unrelated devices, then power off and restart to see if communication is possible.
F. Check if the controller's CAN is in master mode (if bit 5 of CANIO_ADDRESS is set to 1, e.g., CANIO_ADDRESS=32), and whether the CAN communication baud rate is consistent with the expansion module. Detailed information such as the settings for each CAN master station can be viewed by clicking 【Controller】-【Controller Status】-【Communication Configuration】 in the RTSys software.
G. Check if the hardware is burnt out. You can replace the controller and expansion module to test and check.
Common problem 2: Some IO responses from the extension module are normal, while others are abnormal.
Solution suggestion: You can check for conflicts in the IO number range of each ZCAN extension module by clicking [Controller] - [Controller Status] - [Zcan Node] in the RTSys software.
06. Instructions related to the ZCAN extension module
1. CANIO_ADDRESS -- CAN communication settings
2. CANIO_ENABLE -- Enable CAN
3. CANIO_STATUS -- CAN expansion board communication status query
That concludes our sharing on the use of the ZCAN bus ZIO module with the ZhengMotion Technology motion controller/motion control card.
For more exciting content, please follow the "Zheng Motion Assistant" WeChat official account. For related development environment and example code, please contact Zheng Motion's technical sales engineer: 400-089-8936.
This article is original content from Zheng Motion Technology. We welcome everyone to reprint it for mutual learning and to jointly improve China's intelligent manufacturing level. Copyright belongs to Zheng Motion Technology. Please indicate the source if you reprint this article.
