Galil Motion Control DMC-21 5 Series User manual

USER MANUAL
DMC-21x5
Manual Rev. 1.0a1
Galil Motion Control, Inc.
270 Technology ay
Rocklin, California
916.626.0101
[email protected]
galil.com
12/2020

Using This Manual
This user manual provides information for proper operation of the DMC-21x5 controller. A separate supplemental
manual, the Command Reference, contains a description of the commands available for use with this controller. It
is recommended that the user download the latest version of the Command Reference and User Manual from the
Galil ebsite.
https://galil.com/downloads/manuals-and-data-sheets
The DMC-21x5 motion controller has been designed to work with both servo and stepper type motors. Installation
and system setup will vary depending upon whether the controller will be used with stepper motors or servo
motors. To make finding the appropriate instructions faster and easier, icons will be next to any information that
applies exclusively to one type of system. Otherwise, assume that the instructions apply to all types of systems.
The icon legend is shown below.
Attention: Pertains to servo motor use.
Attention: Pertains to stepper motor use.
Attention: Pertains to controllers with more than 4 axes.
Please note that many examples are written for the DMC-2145 four-axes controller or the DMC-2185 eight axes
controller. Users of the DMC-2135 3-axis controller, DMC-2125 2-axes controller or DMC-2115 1-axis controller
should note that the DMC-2135 uses the axes denoted as ABC, the DMC-2125 uses the axes denoted as AB, and
the DMC-2115 uses the A-axis only.
Examples for the DMC-2185 denote the axes as A,B,C,D,E,F,G,H. Users of the DMC-2155 5-axes controller, DMC-
2165 6-axes controller, or DMC-2175 7-axes controller should note that the DMC-2155 denotes the axes as
A,B,C,D,E, the DMC-2165 denotes the axes as A,B,C,D,E,F and the DMC-2175 denotes the axes as A,B,C,D,E,F,G. The
axes A,B,C,D may be used interchangeably with X, Y, Z, .
WARNING
Machinery in motion can be dangerous!
It is the responsibility of the user to design effective error handling and safety protection as part of
the machinery. Galil shall not be liable or responsible for any incidental or consequential damages.
Contents ▫ i DMC-21x5 User Manual 1.0a1

Contents
Contents iii
Chapter 1 Overview 1
Introduction ................................................................................................................... 1
Part Numbers ................................................................................................................ 2
Overview of Motor Types ............................................................................................. 3
Overview of Externa Amp ifiers .................................................................................. 4
Overview of Ga i Amp ifiers and Drivers ................................................................... 4
DMC-21x5 Functiona E ements .................................................................................. 5
Chapter 2 Getting Started 8
E ements Needed .......................................................................................................... 8
Layout ........................................................................................................................... 9
Insta ing the DMC, Amp ifiers, and Motors ................................................................ 10
Chapter 3 Connecting Hardware 18
Overview ....................................................................................................................... 18
Overview of Inputs ....................................................................................................... 19
Overview of Outputs ..................................................................................................... 22
Externa Amp ifier Interface ......................................................................................... 23
Chapter 4 Software Tools and Communication 24
Introduction ................................................................................................................... 24
Contro er Response to Commands .............................................................................. 24
Unso icited Messages Generated by Contro er ............................................................ 25
RS-232 Port ................................................................................................................... 25
Ethernet Configuration .................................................................................................. 26
Data Record .................................................................................................................. 28
Ga i Software ............................................................................................................... 31
Creating Custom Software Interfaces ........................................................................... 31
Chapter Command Basics 32
Introduction ................................................................................................................... 32
Command Syntax - ASCII ............................................................................................ 32
Contro er Response to DATA ...................................................................................... 34
Interrogating the Contro er .......................................................................................... 34
Chapter 6 Programming Motion 36
Overview ....................................................................................................................... 36
Independent Axis Positioning ....................................................................................... 37
Independent Jogging ..................................................................................................... 39
Position Tracking .......................................................................................................... 40
Linear Interpo ation Mode ............................................................................................ 44
Vector Mode: Linear and Circu ar Interpo ation Motion ............................................. 49
E ectronic Gearing ........................................................................................................ 55
E ectronic Cam .............................................................................................................. 58
Contour Mode ............................................................................................................... 63
Virtua Axis ................................................................................................................... 66
Stepper Motor Operation .............................................................................................. 67
Stepper Position Maintenance Mode (SPM) ................................................................. 69
Dua Loop (Auxi iary Encoder) .................................................................................... 72
Motion Smoothing ....................................................................................................... 74
Homing ......................................................................................................................... 75
Contents ▫ ii DMC-21x5 User Manual 1.0a1

High Speed Position Capture (The Latch Function) .................................................... 77
Chapter 7 Application Programming 78
Overview ....................................................................................................................... 78
Program Format ............................................................................................................ 78
Executing Programs - Mu titasking .............................................................................. 80
Debugging Programs .................................................................................................... 81
Program F ow Commands ............................................................................................ 82
Mathematica and Functiona Expressions ................................................................... 96
Variab es ....................................................................................................................... 98
Operands ....................................................................................................................... 100
Arrays ............................................................................................................................ 101
Input of Data (Numeric and String) .............................................................................. 103
Output of Data (Numeric and String) ........................................................................... 105
Hardware I/O ................................................................................................................ 109
Examp e App ications ................................................................................................... 113
Using the DMC Editor to Enter Programs (Advanced) ................................................ 117
Chapter 8 Hardware & Software Protection 118
Introduction ................................................................................................................... 118
Hardware Protection ..................................................................................................... 118
Software Protection ....................................................................................................... 119
Chapter 9 Troubleshooting 122
Overview ....................................................................................................................... 122
Chapter 10 Theory of Operation 124
Overview ....................................................................................................................... 124
Operation of C osed-Loop Systems .............................................................................. 125
System Mode ing .......................................................................................................... 126
System Ana ysis ............................................................................................................ 130
System Design and Compensation ................................................................................ 132
Appendices 13
E ectrica Specifications ................................................................................................ 135
Performance Specifications .......................................................................................... 137
Ordering Options .......................................................................................................... 138
Power Connector Part Numbers .................................................................................... 141
Pin-outs ......................................................................................................................... 142
Signa Descriptions ....................................................................................................... 145
List of Other Pub ications ............................................................................................. 147
Training Seminars ......................................................................................................... 147
Contacting Us ................................................................................................................ 148
WARRANTY ............................................................................................................... 148
Accessory Components 149
Overview ....................................................................................................................... 149
A1 – AMP-20341 1 1
Description .................................................................................................................... 151
E ectrica Specifications ................................................................................................ 152
Pin-outs ......................................................................................................................... 153
Servo Motor Operation ................................................................................................. 154
A2 – AMP-20440 1
Description .................................................................................................................... 155
E ectrica Specifications ................................................................................................ 156
Pin-outs ......................................................................................................................... 157
Servo Motor Operation ................................................................................................. 158
Error Monitoring and Protection ................................................................................... 159
A3 – AMP-20 4 /20 2 161
Contents ▫ iii DMC-21x5 User Manual 1.0a1

Description .................................................................................................................... 161
E ectrica Specifications ................................................................................................ 162
Pin-outs ......................................................................................................................... 163
Servo Motor Operation ................................................................................................. 164
Error Monitoring and Protection ................................................................................... 166
Externa Amp ifier Interface ......................................................................................... 167
Ana og Inputs ................................................................................................................ 168
A4 – SDM-20242 169
Description .................................................................................................................... 169
E ectrica Specifications ................................................................................................ 170
Pin-outs ......................................................................................................................... 171
Stepper Motor Operation .............................................................................................. 172
Error Monitoring and Protection ................................................................................... 173
A – SDM-2064 17
Description .................................................................................................................... 175
E ectrica Specifications ................................................................................................ 176
Pin-outs ......................................................................................................................... 177
Stepper Motor Operation .............................................................................................. 178
Error Monitoring and Protection ................................................................................... 179
Ana og Inputs ................................................................................................................ 180
A6 – ICM-20100 181
Description .................................................................................................................... 181
Pin-outs ......................................................................................................................... 182
A7 – ICM-2010 183
Description .................................................................................................................... 183
Pin-outs ......................................................................................................................... 184
Optoiso ated Inputs ....................................................................................................... 185
Optoiso ated Outputs .................................................................................................... 187
Amp ifier Enab e Circuit ............................................................................................... 188
A8 – DB-2804 190
Description .................................................................................................................... 190
Pin-outs ......................................................................................................................... 191
Extended I/O ................................................................................................................ 192
Ana og Inputs ................................................................................................................ 193
A9 – SR-19900 194
Description .................................................................................................................... 194
Layout ........................................................................................................................... 195
E ectrica Specifications ................................................................................................ 196
Contents ▫ iv DMC-21x5 User Manual 1.0a1

Chapter 1 Overview
Intro uction
The DMC-21x5 series is the latest in Galil's Econo line of motion controllers and is an upgraded version of the
popular DMC-21x3 series controller. The controller series offers many enhanced features compared to prior
generation controllers including high speed communications, non-volatile program memory, faster encoder
speeds, and improved command processing.
The DMC-21x5 is available with up to eight axes in a single stand alone unit. The DMC-2115, 2125, 2135, 2145 are
one thru four axes controllers and the DMC-2155, 2165, 2175, 2185 are five thru eight axes controllers. All eight
axes have the ability to use Galil's integrated amplifiers or drivers and connections for integrating external devices.
Designed to solve complex motion problems, the DMC-21x5 can be used for applications involving jogging, point-
to-point positioning, vector positioning, electronic gearing, multiple move sequences, and contouring. The
controller eliminates jerk by programmable acceleration and deceleration with profile smoothing. For smooth
following of complex contours, the DMC-21x5 provides continuous vector feed of an infinite number of linear and
arc segments. The controller also features electronic gearing with multiple master axes as well as gantry mode
operation.
For synchronization with outside events, the DMC-21x5 provides uncommitted I/O, including 8 digital inputs (16
inputs for DMC-2155 thru DMC-2185), 8 outputs (16 outputs for DMC-2155 thru DMC-2185), and 8 analog inputs
for interface to joysticks, sensors, and pressure transducers. Further I/O is available if the auxiliary encoders are
not being used (2 inputs / each axis). Dedicated inputs are provided for forward and reverse limits, Abort, home,
and definable input interrupts.
A Flash EEPROM provides non-volatile memory for storing application programs, parameters, arrays and firmware.
New firmware revisions are easily upgraded in the field.
Commands are sent in ASCII. Additional software is available for automatic-tuning, trajectory viewing on a PC
screen, and program development using many environments such as Visual Basic, C, C++ etc.
Chapter 1 Overview ▫ 1 DMC-21x5 User Manual 1.0a1

Part Numbers
The DMC controller board comes in two sizes, 1-4 axis models (labeled A-D) and 5-8 axis models (labeled E-H). The
number of axis is designated by x in the part number DMC-21x5.
The full DMC-21x5 part number is a combination of the DMC controller part number (DMC-21x5), controller board
options, and optional accessory types, where Y is option for the controller or accessory.
The placement of the AMP/SDM options is extremely important for 5-8 axis models. The first AMP/SDM (Axis A-D)
will be placed for the first bank of axes and the second AMP/SDM (Axis E-H) will be placed for the second bank.
Please use the DMC-21x5 part number generator to check the validity of all part numbers before ordering:
https://galil.com/order/part-number-generator/dmc-21x5
DMC, "DMC-21x5(Y)" Options
Option Type Options Brief Description Documentation
x 1, 2, 3, 4, 5, 6, 7, and 8 Number of controller axis N/A
Y
DIN DIN Rail Mounting DMC, "DMC-21x5(Y)" Options starting on
pg 138
UP Upward Facing 96 Pin DIN Connector
DO N Downward Facing 96 Pin DIN Connector
VVertical RS232, Status Lights, and
Ethernet
HHorizontal RS232, Status Lights, and
Ethernet
VP Vertical Power Connector
HP Horizontal Power Connector
RA Right Angle 96 Pin Connector
MO Motor Off Jumper Installed
TRES Termination Resistors
DC24, DC48 DC to DC Converter
Table 1.1: List of DMC options
Chapter 1 Overview ▫ 2 DMC-21x5 User Manual 1.0a1
Figure 1.1: Layout of DMC-21x5 with one ban of axes and layout of DMC-21x5 with two ban s of axes

Accessory Options
Option Type Options Brief Description Documentation
AMP
20341 20 brush-type only drive A1 – AMP-20341, pg 151
20440 200 brush-type only drive A2 – AMP-20440, pg 155
20540/20520 500 trapazoidal servo drive
2 and 4-axis models A3 – AMP-20545/20525, pg 161
SDM
20242 Configurable microstepping drive A4 – SDM-20242, pg 169
20640 1/64 microstepping drive A5 – SDM-20645, pg 175
ICM
20100 I/O module A6 – ICM-20100, pg 181
20105 Optoisolated I/O module A7 – ICM-20105, pg 183
DB 28040 Extended I/O daughter board A8 – DB-28045, pg 190
Y
ISCNTL Isolated controller power Accessory Specific Options, starting on pg
139
Not available for all accessory options, see the
proper documentation.
SSR Solid State Relay
LAEN Low Amplifier Enable Configuration
24V 24V Amplifier Enable Configuration
BOX Metal Enclosure
5V 5V Logic for Extended I/O
16BIT 16Bit Resolution on Analog Inputs
SHUNT Shunt Regulator A9 – SR-19900, pg 194
Table 1.2: List of accessories and options
Overview of Motor Types
The DMC-21x5 can provide the following types of motor control:
1. Standard servo motors with ±10 volt command signals
2. Step motors with step and direction signals
3. Other actuators such as hydraulics and ceramic motors - For more information, contact Galil.
The user can configure each axis for any combination of motor types, providing maximum flexibility.
Stan ar Servo Motor with ±10 Volt Comman Signal
The DMC-21x5 achieves superior precision through use of a 16-Bit motor command output DAC and a
sophisticated PID filter that features velocity and acceleration feed-forward, an extra pole filter and integration
limits.
The controller is configured by the factory for standard servo motor operation. In this configuration, the controller
provides an analog signal (±10 volts) to connect to a servo amplifier. This connection is described in Chapter 2.
Chapter 1 Overview ▫ 3 DMC-21x5 User Manual 1.0a1

Stepper Motor with Step an Direction Signals
The DMC-21x5 can control stepper motors. In this mode, the controller provides two signals to
connect to the stepper motor: Step and Direction. For stepper motor operation, the controller does
not require an encoder and operates the stepper motor in an open loop fashion. Chapter 2 describes
the proper connection and procedure for using stepper motors.
If encoders are available on the stepper motor, Galil's Stepper Position Maintenance Mode may be
used for automatic monitoring and correction of the stepper position. See Stepper Position
Maintenance Mode (SPM) in Chapter 6 for more information.
Overview of External Amplifiers
The amplifiers should be suitable for the motor and may be linear or pulse-width-modulated. An amplifier may
have current feedback, voltage feedback or velocity feedback.
Amplifiers in Current Mo e
Amplifiers in current mode should accept an analog command signal in the ±10 volt range. The amplifier gain
should be set such that a +10V command will generate the maximum required current. For example, if the motor
peak current is 10A, the amplifier gain should be 1 A/V.
Amplifiers in Velocity Mo e
For velocity mode amplifiers, a command signal of 10 volts should run the motor at the maximum required speed.
The velocity gain should be set such that an input signal of 10V runs the motor at the maximum required speed.
Stepper Motor Amplifiers
For step motors, the amplifiers should accept step and direction signals.
Overview of Galil Amplifiers an Drivers
ith the DMC-21x5 Galil offers a variety of Servo Amplifiers and Stepper Drivers that are integrated with the
controller. Using the Galil Amplifiers and Drivers provides a simple straightforward motion control solution .
Instead of having to route a +/-10V motor command signal or STEP/DIR to some external box, all the wiring is
taken care of. In addition, Galil's amplifiers reside on top of the controller, saving real estate space and the hassle
of configuring a separate device.
A full list of amplifier specifications and details can be found in the Accessory Components, pg 149.
Chapter 1 Overview ▫ 4 DMC-21x5 User Manual 1.0a1

DMC-21x5 Functional Elements
The DMC-21x5 circuitry can be divided into the following functional groups as shown in Figure 1.2 and discussed
below.
DMC-21x5
The main processing unit of the controller is a specialized Microcomputer with RAM and Flash EEPROM. The RAM
provides memory for variables, array elements, and application programs. The flash EEPROM provides non-volatile
storage of variables, programs, and arrays. The Flash also contains the firmware of the controller, which is field
upgradeable.
Motor/Enco er Interface
The controller provides an interface for quadrature decoding of each encoder at up to 15 MHz. For standard servo
operation, the controller generates a ±10 volt analog signal (16 Bit DAC). For stepper motor operation, the
controller generates a step and direction signal.
Axis I/O
The controller provided dedicated I/O for each axis such as forward and reverse limit switches, home switches, and
a high speed latch.
Communication
The communication interface with the DMC-21x5 consists of high speed 100bT Ethernet and an RS232 serial port.
General Purpose an Committe I/O
The DMC-21x5 provides interface circuitry for 8 TTL inputs, 8 TTL outputs, as well as 40 extended IO bits and 8
analog inputs with 12-Bit or 16-Bit ADC with certain accessories. Unused auxiliary encoder inputs may also be used
Chapter 1 Overview ▫ 5 DMC-21x5 User Manual 1.0a1
Figure 1.2: DMC-21x5 Functional Elements