Galil Motion Control DMC-14 5 Series User manual

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USER MANUAL
DMC-14x5/6
Manual Rev. 2.7
By Galil Motion Control, Inc.
Galil Motion Control, Inc.
270 Technology Way
Rocklin, California 95765
Phone: [phone]
Fax: [phone]
Internet Address: [email protected]
URL: www.galilmc.com
Rev 8/2011
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Using This Manual
This user manual provides information for proper operation of the DMC-1415, DMC-1416 and DMC-
1425 controllers. A separate supplemental manual, the Command Reference, contains a description of
the commands available for use with these controllers.
Your DMC-14XX 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.
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 machine. Galil shall not be liable or
responsible for any incidental or consequential damages.
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Contents
Using This Manual ....................................................................................................................ii
Chapter 1 Overview 1
Introduction ...............................................................................................................................1
Overview of Motor Types..........................................................................................................2
Standard Servo Motors with +/- 10 Volt Command Signal.........................................2
Brushless Servo Motor with Sinusoidal Commutation................................................2
Stepper Motor with Step and Direction Signals ..........................................................2
DMC-14XX Functional Elements .............................................................................................3
Microcomputer Section...............................................................................................3
Motor Interface............................................................................................................3
Communication...........................................................................................................3
General I/O..................................................................................................................4
System Elements .........................................................................................................4
Motor...........................................................................................................................4
Amplifier (Driver).......................................................................................................4
Encoder........................................................................................................................5
Watch Dog Timer........................................................................................................5
Chapter 2 Getting Started 7
The DMC-141X Motion Controller...........................................................................................7
Elements You Need...................................................................................................................8
Installing the DMC-14XX Controller........................................................................................9
Step 1. Determine Overall Motor Configuration........................................................9
Step 2. Configuring Jumpers on the DMC-14XX .....................................................10
Step 3. Connecting DC power and the Serial Cable to the DMC-14XX...................11
Step 4. Installing the Communications Software.......................................................12
Step 5. Establishing Communication between the DMC-14XX and the host PC .....12
Step 6. Set-up axis for sinusoidal commutation (DMC-1415 only) .........................18
Step 7. Make connections to amplifier and encoder..................................................18
Step 8a. Connect Standard Servo Motor...................................................................20
Step 8b. Connect brushless motor for sinusoidal commutation (DMC- 1415 only).23
Step 8c. Connect Step Motors ...................................................................................26
Step 8d. Connect brush or brushless servo motor to DMC-1416 .............................26
Step 9. Tune the Servo System..................................................................................27
Design Examples.....................................................................................................................28
Example 1 - System Set-up .......................................................................................28
Example 2 - Profiled Move .......................................................................................28
Example 3 - Position Interrogation............................................................................28
Example 4 - Absolute Position..................................................................................29
Example 5 - Velocity Control (Jogging) ...................................................................29
Example 6 - Operation Under Torque Limit .............................................................29
Example 7 - Interrogation..........................................................................................30
Example 8 - Operation in the Buffer Mode...............................................................30
Example 9 - Motion Programs...................................................................................30
DMC-14x5/6 Contents ●i
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Example 10 - Motion Programs with Loops..............................................................30
Example 11- Motion Programs with Trippoints........................................................31
Example 12 - Control Variables................................................................................31
Example 13 - Control Variables and Offset ..............................................................32
Chapter 3 Connecting Hardware 33
Overview .................................................................................................................................33
Using Inputs.............................................................................................................................33
Limit Switch Input.....................................................................................................33
Home Switch Input....................................................................................................34
Abort Input................................................................................................................34
Uncommitted Digital Inputs......................................................................................35
Amplifier Interface ..................................................................................................................35
TTL Inputs...............................................................................................................................36
Analog Inputs ..........................................................................................................................36
TTL Outputs............................................................................................................................36
Chapter 4 Communication 39
Introduction .............................................................................................................................39
RS232 Port...............................................................................................................................39
RS232 - Port 1 DATATERM ................................................................................39
RS-232 Configuration ...............................................................................................39
Ethernet Configuration ............................................................................................................40
Communication Protocols.........................................................................................40
Addressing.................................................................................................................40
Communicating with Multiple Devices.....................................................................42
Multicasting...............................................................................................................43
Using Third Party Software.......................................................................................43
Data Record.............................................................................................................................44
Data Record Map.......................................................................................................44
Explanation of Status Information and Axis Switch Information..............................45
Notes Regarding Velocity and Torque Information ..................................................46
QZ Command............................................................................................................47
Controller Response to Commands .........................................................................................47
Unsolicited Messages Generated by Controller.......................................................................47
Galil Software Tools and Libraries..........................................................................................48
Chapter 5 Command Basics 49
Introduction .............................................................................................................................49
Command Syntax - ASCII.......................................................................................................49
Coordinated Motion with more than 1 axis...............................................................50
Command Syntax - Binary ......................................................................................................50
Binary Command Format..........................................................................................51
Binary Command Table ............................................................................................52
Controller Response to DATA ................................................................................................53
Interrogating the Controller .....................................................................................................53
Interrogation Commands...........................................................................................53
Summary of Interrogation Commands......................................................................53
Interrogating Current Commanded Values................................................................54
Operands....................................................................................................................54
Command Summary..................................................................................................54
Chapter 6 Programming Motion 55
ii iContents DMC-14x5/6
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Overview .................................................................................................................................55
Independent Axis Positioning..................................................................................................56
Command Summary - Independent Axis ..................................................................57
Independent Jogging................................................................................................................59
Command Summary - Jogging..................................................................................59
Operand Summary - Independent Axis.....................................................................59
Linear Interpolation Mode.......................................................................................................60
Specifying Linear Segments......................................................................................60
Command Summary - Linear Interpolation...............................................................62
Operand Summary - Linear Interpolation..................................................................62
Example - Linear Move.............................................................................................63
Example - Multiple Moves........................................................................................65
Vector Mode: Linear and Circular Interpolation Motion.........................................................65
Specifying Vector Segments .....................................................................................65
Additional commands................................................................................................66
Command Summary - Coordinated Motion Sequence..............................................67
Operand Summary - Coordinated Motion Sequence.................................................67
Electronic Gearing...................................................................................................................68
Command Summary - Electronic Gearing ................................................................69
Electronic Cam ........................................................................................................................70
Contour Mode..........................................................................................................................75
Specifying Contour Segments...................................................................................75
Additional Commands...............................................................................................76
Command Summary - Contour Mode.......................................................................76
Operand Summary - Contour Mode..........................................................................77
Stepper Motor Operation.........................................................................................................80
Specifying Stepper Motor Operation.........................................................................81
Using an Encoder with Stepper Motors.....................................................................82
Command Summary - Stepper Motor Operation.......................................................82
Operand Summary - Stepper Motor Operation..........................................................82
Aux Encoder/ Dual Loop (DMC-1415 and DMC-1416 only).................................................83
Backlash Compensation ............................................................................................83
Motion Smoothing...................................................................................................................85
Using the IT and VT Commands...............................................................................85
Using the KS Command (Step Motor Smoothing)....................................................86
Homing....................................................................................................................................87
High Speed Position Capture...................................................................................................90
Chapter 7 Application Programming 91
Overview .................................................................................................................................91
Using the DMC-14XX Editor to Enter Programs....................................................................91
Edit Mode Commands...............................................................................................92
Program Format.......................................................................................................................92
Using Labels in Programs .........................................................................................92
Special Labels............................................................................................................93
Commenting Programs..............................................................................................94
Executing Programs - Multitasking.........................................................................................95
Debugging Programs ...............................................................................................................96
Program Flow Commands.......................................................................................................98
Event Triggers & Trippoints......................................................................................98
Event Trigger Examples:.........................................................................................100
Conditional Jumps...................................................................................................102
Using If, Else, and Endif Commands ......................................................................104
Subroutines..............................................................................................................106
Stack Manipulation..................................................................................................106
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Auto-Start Routine ..................................................................................................106
Automatic Subroutines for Monitoring Conditions.................................................107
Mathematical and Functional Expressions ............................................................................110
Mathematical Operators ..........................................................................................110
Bit-Wise Operators..................................................................................................111
Functions.................................................................................................................112
Variables................................................................................................................................112
Programmable Variables.........................................................................................113
Operands................................................................................................................................114
Special Operands (Keywords).................................................................................114
Arrays ....................................................................................................................................115
Defining Arrays.......................................................................................................115
Assignment of Array Entries...................................................................................115
Automatic Data Capture into Arrays.......................................................................116
Deallocating Array Space........................................................................................118
Input of Data (Numeric and String).......................................................................................118
Input of Data............................................................................................................118
Output of Data (Numeric and String) ....................................................................................119
Sending Messages ...................................................................................................119
Displaying Variables and Arrays.............................................................................120
Interrogation Commands.........................................................................................120
Formatting Variables and Array Elements..............................................................122
Converting to User Units.........................................................................................123
Programmable Hardware I/O.................................................................................................123
Digital Outputs........................................................................................................123
Digital Inputs...........................................................................................................124
Input Interrupt Function ..........................................................................................125
Example Applications............................................................................................................126
Wire Cutter..............................................................................................................126
X-Y Table Controller ..............................................................................................127
Chapter 8 Hardware & Software Protection 131
Introduction ...........................................................................................................................131
Hardware Protection..............................................................................................................131
Output Protection Lines...........................................................................................131
Input Protection Lines .............................................................................................132
Software Protection ...............................................................................................................132
Programmable Position Limits................................................................................132
Off-On-Error ...........................................................................................................133
Automatic Error Routine.........................................................................................133
Limit Switch Routine ..............................................................................................133
Chapter 9 Troubleshooting 135
Overview ...............................................................................................................................135
Installation.............................................................................................................................135
Communication......................................................................................................................136
Stability..................................................................................................................................136
Operation...............................................................................................................................136
Chapter 10 Theory of Operation 137
Overview ...............................................................................................................................137
Operation of Closed-Loop Systems.......................................................................................139
System Modeling...................................................................................................................140
Motor-Amplifier......................................................................................................141
iv iContents DMC-14x5/6
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Encoder....................................................................................................................143
DAC ........................................................................................................................144
Digital Filter............................................................................................................144
ZOH.........................................................................................................................144
System Analysis.....................................................................................................................145
System Design and Compensation.........................................................................................147
The Analytical Method............................................................................................147
Appendices 151
Electrical Specifications ........................................................................................................151
Servo Control ..........................................................................................................151
Stepper Control........................................................................................................151
Input/Output ............................................................................................................151
Power Requirements................................................................................................151
Performance Specifications ...................................................................................................152
Fast Update Rate Mode .........................................................................................................152
Connectors for DMC-14XX ..................................................................................................153
J3 DMC-1415 General I/O; 37- PIN D-type ...........................................................153
J3 DMC-1425 General I/O; 37- PIN D-type ...........................................................153
J3 DMC-1416 General I/O; 37- PIN D-type ...........................................................154
J4 DMC-1416 Encoders; 15-Pin D-type..................................................................155
J5 DMC-1416 Power; 5-Pin MOLEX; Brushless Config. (Standard Servo)...........155
J1 RS232 Main port: DB-9 Pin Male: .....................................................................155
Pin-Out Description...............................................................................................................156
ICM-1460 Interconnect Module............................................................................................157
Opto-Isolation Option for ICM-1460 (rev F and above) .......................................................159
64 Extended I/O of the DMC-1415/1416/1425 Controller....................................................160
Configuring the I/O of the DMC-1415/1416/1425 with DB-14064........................160
Connector Description:............................................................................................162
IOM-1964 Opto-Isolation Module for Extended I/O Controllers..........................................164
Description:.............................................................................................................164
Overview.................................................................................................................165
Configuring Hardware Banks..................................................................................166
Digital Inputs...........................................................................................................166
High Power Digital Outputs....................................................................................168
Standard Digital Outputs.........................................................................................169
Electrical Specifications..........................................................................................170
Relevant DMC Commands......................................................................................171
J5 80-pin Connector Pin out....................................................................................171
Screw Terminal Listing...........................................................................................173
CB-50-80 Adapter Board.......................................................................................................176
Connectors:..............................................................................................................176
CB-50-80 Drawing:.................................................................................................178
Coordinated Motion - Mathematical Analysis.......................................................................179
List of Other Publications......................................................................................................183
Training Seminars..................................................................................................................183
Contacting Us ........................................................................................................................184
WARRANTY........................................................................................................................185
Index 186
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Chapter 1 Overview
Introduction
The DMC-1400 series of motion controllers were developed specifically for one or two axis
applications, allowing it to be smaller in size (1/2 size card) and lower in cost than the Optima series
multi-axis controllers. This manual covers three Ethernet based stand-alone controllers in the DMC-
1400 Econo series. The DMC-1415 is a state-of-the-art single axis motion controller that
communicates via the Ethernet. The DMC-1425 is the identical controller configured for basic two
axis applications. The DMC-1416 is a single axis Ethernet controller integrated with an internal brush
or brushless power amplifier. Performance capability of these controllers includes: 12 MHz encoder
input frequency, 16-bit motor command output DAC, +/-2 billion counts total travel per move, 250
μsec minimum sample rate and non-volatile memory for program and parameter storage. Designed for
maximum flexibility, the DMC-14XX can be interfaced to a variety of motors and drives including
step motors, brush and brushless servo motors and hydraulics. The DMC-1415 can also be configured
to provide sinusoidal commutation for brushless motors.
The controller accepts feedback from a quadrature linear or rotary encoder with input frequencies up to
12 million quadrature counts per second. An additional encoder input is available on the DMC-1415
and DMC-1416 for gearing or cam applications, hand wheel inputs, or dual-loop operation. Modes of
motion include jogging, point-to-point positioning, electronic cam, electronic gearing and contouring.
Several motion parameters can be specified including acceleration and deceleration rates and slew
speed. The DMC-14XX also provides motion smoothing to eliminate jerk.
For synchronization with outside events, the DMC-14XX provides uncommitted I/O. The DMC-1415
and DMC-1416 provide 7 digital inputs, 3 digital outputs and 2 analog inputs. The DMC-1425
provides up to 3 digital inputs, 3 digital outputs and 2 analog inputs. Committed digital inputs are
provided for forward and reverse limits, abort, home, and definable input interrupts. Event triggers can
automatically check for elapsed time, distance and motion complete.
The DMC-14XX is easy to program. Instructions are represented by two letter commands such as BG
for Begin and SP for Speed. Conditional instructions, Jump statements and arithmetic functions are
included for writing self-contained applications programs. An internal editor allows programs to be
quickly entered and edited, and support software such as the WSDK allows quick system set-up and
tuning. Commands may also be sent in Binary to decrease processing time.
To prevent system damage during machine operation, the DMC-14XX provides many error handling
features. These include software and hardware limits, automatic shut-off on excessive error, abort
input and user-definable error and limit routines.
The DMC-1415 and DMC-1425 are designed for stand-alone applications and provide non-volatile
storage for programs, variables and array elements. The DMC-1416 provides an internal brush or
brushless power amplifier for a standard DC servo motor.
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Overview of Motor Types
The DMC-14XX can provide the following types of motor control:
1. Standard servo motors with +/- 10 volt command signals
2. Brushless servo motors with sinusoidal commutation
3. Step motors with step and direction signals
4. Other actuators such as hydraulics - For more information, contact Galil.
The user can configure each axis for any combination of motor types, providing maximum flexibility.
Standard Servo Motors with +/- 10 Volt Command Signal
The DMC-14XX achieves superior precision through use of a 16-bit motor command output DAC and
a sophisticated PID filter that features velocity and acceleration feedforward, an extra notch 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 (+/- 10Volt) to connect to a servo amplifier. This connection
is described in Chapter 2. In the case of the DMC-1416, a brush or brushless servo amplifier is
connected to the analog signal internally.
Brushless Servo Motor with Sinusoidal Commutation
The DMC-1415 can provide sinusoidal commutation for brushless motors (BLM). In this
configuration, the controller generates two sinusoidal signals for connection with amplifiers
specifically designed for this purpose.
Note: The task of generating sinusoidal commutation may be accomplished in the brushless motor
amplifier. If the amplifier generates the sinusoidal commutation signals, only a single command signal
is required and the controller should be configured for a standard servo motor (described above).
Sinusoidal commutation in the controller can be used with linear and rotary BLMs. However, the
motor velocity should be limited such that a magnetic cycle lasts at least 6 milliseconds*. For faster
motors, please contact the factory.
The controller provides a one-time, automatic set-up procedure. The parameters determined by this
procedure can then be saved in non-volatile memory to be used whenever the system is powered on.
The DMC-1415 can control BLMs equipped with Hall sensors as well as without Hall sensors. If hall
sensors are available, once the controller has been setup, the controller will estimate the commutation
phase upon reset. This allows the motor to function immediately upon power up. The Hall effect
sensors also provide a method for setting the precise commutation phase. Chapter 2 describes the
proper connection and procedure for using sinusoidal commutation of brushless motors.
* 6 Milliseconds per magnetic cycle assumes a servo update of 1 msec (default rate).
Stepper Motor with Step and Direction Signals
The DMC-14XX 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. Chapter 2 describes the proper
connection and procedure for using stepper motors.
NOTE: Hardware revisions A-D need factory reconfiguration in order to control steppers. Hardware
revisions E or newer have jumpers for stepper configuration.
2 iChapter 1 Overview DMC-14x5/6
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DMC-14XX Functional Elements
The DMC-14XX circuitry can be divided into the following functional groups as shown in Figure 1.1
and discussed below.
WATCHDOG TIMER
68331
MICROCOMPUTER
WITH
1 Meg RAM
2 Meg FLASH EEPROM
HIGH-SPEED
MOTOR/ENCODER
INTERFACE
FOR
X,Y,Z,W
I/O INTERFACE
ETHERNET
RS-232 /
2 UNCOMMITTED
ANALOG INPUTS
HIGH-SPEED LATCH FOR EACH AXIS
7 PROGRAMMABLE,
INPUTS
3 PROGRAMMABLE
OUTPUTS
ISOLATED LIMITS AND
HOME INPUTS
MAIN ENCODERS
AUXILIARY ENCODERS
+/- 10 VOLT OUTPUT FOR
SERVO MOTORS
PULSE/DIRECTION OUTPUT
FOR STEP MOTORS
HIGH SPEED ENCODER
COMPARE OUTPUT
Figure 1.1 - DMC-14XX Functional Elements
Microcomputer Section
The main processing unit of the DMC-14XX is a specialized 32-bit Motorola 68331 Series
Microcomputer with 1 Meg RAM and 2 Meg 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. It also contains the DMC-14XX firmware.
Motor Interface
Galil’s GL-1800 custom, sub-micron gate array performs quadrature decoding of each encoder at up to
12 MHz. For standard servo operation, the controller generates a +/-10 Volt analog signal (16 Bit
DAC). For sinusoidal commutation operation, the controller uses two DACs to generate two +/-10Volt
analog signals. For stepper motor operation, the controller generates a step and direction signal.
Communication
The communication interface with the DMC-14XX consists of one RS-232 port (19.2 kbaud) and one
10base-T Ethernet port.
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General I/O
The DMC-1415 and DMC-1416 provide interface circuitry for 7 TTL inputs and 3 TTL outputs. In
addition, the controller provides two 12-bit analog inputs. The general inputs can also be used for
triggering a high speed positional latch for each axis.
NOTE: In order to accommodate 2 axes on the DMC-1425, many of the general I/O features become
dedicated I/O for the second axis. The standard DMC-1425 will have 3 TTL inputs, 3 TTL outputs
and 2 analog inputs.
System Elements
As shown in Fig. 1.2, the DMC-14XX is part of a motion control system which includes amplifiers,
motors and encoders. These elements are described below.
Computer DMC-141X Controller
A
mplifier (Driver)
Power Supply
Encoder Motor
Figure 1.2 - Elements of Servo systems
Motor
A motor converts current into torque which produces motion. Each axis of motion requires a motor
sized properly to move the load at the required speed and acceleration. (Galil's "Motion Component
Selector" software can help you with motor sizing). Contact Galil for more information.
The motor may be a step or servo motor and can be brush-type or brushless, rotary or linear. For step
motors, the controller is capable of controlling full-step, half-step, or microstep drives. An encoder is
not required when step motors are used.
Amplifier (Driver)
For each axis, the power amplifier converts a +/-10 Volt signal from the controller into current to
drive the motor. For stepper motors, the amplifier converts step and direction signals into current.
The amplifier should be sized properly to meet the power requirements of the motor. For brushless
motors, an amplifier that provides electronic commutation is required or the controller must be
configured to provide sinusoidal commutation. The amplifiers may be either pulse-width-modulated
(PWM) or linear. They may also be configured for operation with or without a tachometer. For
current amplifiers, the amplifier gain should be set such that a 10 Volt command generates the
maximum required current. For example, if the peak motor current is 10A, the amplifier gain should
be 1 A/V. For velocity mode amplifiers, 10 Volts should run the motor at the maximum speed.
For step motors, the amplifiers should accept step and direction signals.
4 iChapter 1 Overview DMC-14x5/6
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For the DMC-1416, the power amplifier is internal to the unit. The controller may be purchased with
either a brush or brushless PWM amplifier. The amplifier requires a single external DC power supply
from 20 to 60 Volts. The amplifier provides 6 amps continuous at 12 amps peak.
Encoder
An encoder translates motion into electrical pulses which are fed back into the controller. The DMC-
14XX accepts feedback from either a rotary or linear encoder. Typical encoders provide two channels
in quadrature, known as CHA and CHB. This type of encoder is known as a quadrature encoder.
Quadrature encoders may be either single-ended (CHA and CHB) or differential (CHA,CHA-,
CHB,CHB-). The DMC-14XX decodes either type into quadrature states or four times the number of
cycles. Encoders may also have a third channel (or index) for synchronization.
For stepper motors, the DMC-14XX can also interface to encoders with pulse and direction signals.
There is no limit on encoder line density; however, the input frequency to the controller must not
exceed 3,000,000 full encoder cycles/second (12,000,000 quadrature counts/sec). For example, if the
encoder line density is 10000 cycles per inch, the maximum speed is 300 inches/second. If higher
encoder frequency is required, please consult the factory.
The standard voltage level is TTL (zero to five volts), however, voltage levels up to 12 Volts are
acceptable. (If using differential signals, 12 Volts can be input directly to the DMC-14XX. Single-
ended 12 Volt signals require a bias voltage input to the complementary inputs.)
The DMC-14XX can accept analog feedback instead of an encoder for any axis. For more information
see description of analog feedback in Chapter 2 under the section titled "Test the encoder operation".
To interface with other types of position sensors such as resolvers or absolute encoders, Galil can
customize the controller and command set. Please contact Galil to talk to one of our applications
engineers about your particular system requirements.
Watch Dog Timer
The DMC-14XX provides an internal watch dog timer which checks for proper microprocessor
operation. The timer toggles the Amplifier Enable Output (AEN) which can be used to switch the
amplifiers off in the event of a serious DMC-14XX failure. The AEN output is normally high. During
power-up and if the microprocessor ceases to function properly, the AEN output will go low. The
error light for each axis will also turn on at this stage. A reset is required to restore the DMC-14XX to
normal operation. Consult the factory for a Return Materials Authorization (RMA) Number if your
DMC-14XX is damaged.
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6 iChapter 1 Overview DMC-14x5/6
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Chapter 2 Getting Started
The DMC-141X Motion Controller
Figure 2.1 – Outline of the DMC-1415/DMC-1425
1
2
3
4
5
6
J5
J1 J4 J3
7
JP1
JP2
J2
Figure 2.2 – Outline of the DMC-1416
DMC-14x5/6 Chapter 2 Getting Started i7
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1 DMC-141X Flash EEPROM J2 10Base-T Ethernet connection
2 Motorola 68331 microprocessor J3 37 Pin-D connection for controller signal break-
out
3 GL-1800 custom gate array J4 15 Pin-D connection for controller main encoder
breakout (DMC-1416)
4 Reset switch J5 6 Pin power connector for +5V, +12V and –12V
input (DMC-1415/DMC-1425)
5 Pin connector for 20 – 60V DC supply and
motor connections (DMC-1416)
5 Error LED’s for active Ethernet
connection, transmit/receive on Ethernet,
error output and power.
JP1 Master reset , upgrade and baud rate selection
jumpers, Y step
6 Controller RAM JP2 Motor off as default jumper.
Stepper motor jumper (DMC-1415/DMC-1425)
7 Fuse for DC-to-DC converter. JP3 Jumper for selecting analog motor command or
step and direction pin-out configuration.
J1 RS232 Serial connection
Elements You Need
Before you start, you must get all the necessary system elements. These include:
1. DMC-1415, DMC-1425 or DMC-1416 Controller, and 37-pin cable (order Cable -37).
2. Servo motor(s) with Encoder or stepper motor.
3. Appropriate motor drive - servo amp (Power Amplifier or AMP-1460) or stepper drive.
4. Power Supply for Amplifier
5. +5V, ±12V supply for DMC-1415 or DMC-1425 card level
6. 20V to 60V DC supply for DMC-1416
7. Communication CD from Galil
8. WSDK Servo Design Software (not necessary, but strongly recommended)
9. Interface Module ICM-1460 with screw-type terminals or integrated Interface
Module/Amplifier, AMP-1460. (Note: An interconnect module is not necessary, but strongly
recommended.)
The motors may be servo (brush or brushless type) or steppers. The driver (amplifier) should be
suitable for the motor and may be linear or pulse-width-modulated and it may have current feedback or
voltage feedback.
For servo motors, the drivers should accept an analog signal in the +/-10 Volt range as a command.
The amplifier gain should be set so 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. For velocity mode
amplifiers, a command signal of 10 Volts should run the motor at the maximum required speed.
For step motors, the driver should accept step and direction signals. For start-up of a step motor
system refer to Step 8c “Connecting Step Motors”.
8 iChapter 2 Getting Started DMC-14x5/6
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For the DMC-1416, the internal amplifier is a 20V to 60V PWM amplifier in either a brush or
brushless configuration, so only a brush or brushless DC servo motor may be used.
The WSDK software is highly recommended for first time users of the DMC-14XX. It provides step-
by-step instructions for system connection, tuning and analysis.
Installing the DMC-14XX Controller
Installation of a complete, operational DMC-14XX system consists of 9 steps.
Step 1. Determine overall motor configuration.
Step 2. Configuring jumpers on the DMC-14XX.
Step 3. Connect the DC power supply and serial cable to the DMC-14XX.
Step 4. Install the communications software.
Step 5. Establish communications between the DMC-14XX and the host PC.
Step 6. Set-up axis for sinusoidal commutation (DMC-1415 only).
Step 7. Make connections to amplifier and encoder.
Step 8a. Connect standard servo motor.
Step 8b.Connect brushless motor for sinusoidal commutation. (DMC-1415 only)
Step 8c. Connect step motor.
Step 8d.Connect brush or brushless servo motor to DMC-1416
Step 9. Tune servo system.
Step 1. Determine Overall Motor Configuration
Before setting up the motion control system, the user must determine the desired motor configuration.
The DMC-141X can control standard brush or brushless servo motors, sinusoidally commutated
brushless motors or stepper motors. For control of other types of actuators, such as hydraulics, please
contact Galil. The following configuration information is necessary to determine the proper motor
configuration:
Standard Servo Motor Operation:
The DMC-141X has been setup by the factory for standard servo motor operation providing an analog
command signal of +/- 10 volt. The position of the jumpers at JP3 determines the type of output the
controllers will provide, analog motor command or PWM output. The installation of these jumpers is
discussed in the section “Configuring Jumpers on the DMC-14XX”. Figure 2.3 shows how the
jumpers are configured for the standard output mode.
The DMC-14XX controller will output the analog command signal to either brush or brushless servo
amplifiers. Please note that if the brushless amplifier provides the sinusoidal commutation, the
standard servo motor operation from the controller will be used. If the commutation is to be performed
by the controller, please see below.
The DMC-1416 provides an internal PWM amplifier for connection directly to a brush or brushless
motor. Either the brush or brushless amplifier must be specified at the time of purchase.
Sinusoidal Commutation:
Please consult the factory before operating with sinusoidal commutation.
Sinusoidal commutation is configured through a single software command, BA. This setting causes
the controller to reconfigure the control axis to output two commutated phases. The DMC-1415
requires two DAC outputs for a single axis of commutation. Therefore, sinusoidal commutation is not
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available on the DMC-1425. In standard servo operation, the DMC-1415 has one DAC for the single
axis. Issuing the BA command will enable the second DAC for commutation. Further instruction for
sinusoidal commutation connections are discussed in Step 6.
Stepper Motor Operation:
To configure the DMC-141X for stepper motor operation, the controller requires that the command,
MT, be given and jumpers placed to designate stepper motor. The installation of the stepper motor
jumper is discussed in the following section entitled “Configuring Jumpers on the DMC-14XX”.
Further instructions for stepper motor connections are discussed in Step 8c.
Step 2. Configuring Jumpers on the DMC-14XX
Master Reset and Upgrade Jumper
JP1 contains two jumpers, MR and UP. The MR jumper is the Master Reset jumper. When MR is
connected, the controller will perform a master reset upon PC power up or upon the reset input going
low. Whenever the controller has a master reset, all programs, arrays, variables, and motion control
parameters stored in EEPROM will be ERASED.
The UP jumper enables the user to unconditionally update the controller’s firmware. This jumper is
not necessary for firmware updates when the controller is operating normally, but may be necessary in
cases of corrupted EEPROM. EEPROM corruption should never occur, however, it is possible if there
is a power fault during a firmware update. If EEPROM corruption occurs, your controller may not
operate properly. In this case, install the UP Jumper and use the update firmware function on the Galil
Terminal to re-load the system firmware.
Stepper Motor Jumpers - Hardware Rev A-D
If the DMC-14XX will be driving a stepper motor, special stepper mode jumpers must be connected.
Location JP2 on the DMC-14XX contains the jumper SMX. If stepper motors are being used, this
j
umper must be installed.
In addition to the SMX jumper, the controller output must be configured for stepper output by the
placement of jumpers at location JP3. This jumper location controls whether the controller will output
the analog motor command signal (MC), or the step and direction signals (SD). Figure 2.3 shows how
these jumpers should be configured for stepper mode.
Please note, the standard DMC-1425 only provides access to one axis when in stepper mode. For both
axes as steppers order as DMC-1425-STEPPER.
Note: On the ICM-1460 the PULSE signal is output to pin 4 (ACMD) and the direction signal is
output to pin 38 (ACMD2).
Stepper Motor Jumper Selection - Rev E or newer
The newest version of the DMC-1425 the controller is configurable for stepper or servo through
jumpers instead of needing rework done by the factory. The configuration is as follows-
JP2
SMX JP2 SMY JP1 Y Step JP3 SD JP3 MC
X Servo , Y Servo Both
X Servo, Y Stepper X X Top Row Bottom Row
X Stepper, Y Stepper X X X Both
Note1: When the Y axis is set for stepper mode the pulse output for the Y axis is on the same pin as the
error output meaning that the red LED will be on. To permanently disable the red LED contact Galil.
Note2: When the controller is configured for X servo and Y stepper, the amp enable signal for the X
axis is no longer available as it is used for Y sign.
10 iChapter 2 Getting Started DMC-14x5/6
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MCSD
JP3
MCSD
JP3
Setting for analog motor command Setting for step/direction output
Figure 2.3 - Jumper settings for motor command output
Setting the Baud Rate on the DMC-14XX
The jumpers labeled “96” and “12” at JP1 allows the user to select the serial communication baud rate.
The baud rate can be set using the following table:
SWITCH SETTINGS BAUD RATE
96 12 --
OFF OFF 19200
ON OFF 9600
OFF ON 1200
The default baud rate for the controller is 19.2K.
Selecting MO as default on the DMC-14XX
The default condition for the motor on the DMC-14XX is in the servo on (SH) state. This will enable
the amplifiers upon power up of the controller. This state can be changed to the motor off (MO)
default by placing a jumper at JP2 across the MO terminals. This will power up the controller with the
amplifiers disabled and the motor command off. The SH command must then actively be given in
order for the servos or steppers to operate.
Step 3. Connecting DC power and the Serial Cable to the DMC-14XX
1. Insert 37-pin cable to J3.
2. If using serial communications, use the 9-pin RS232 ribbon cable to connect the SERIAL port
of the DMC-14XX to your computer or terminal communications port. The DMC-14XX
serial port is configured as DATASET. Your computer or terminal must be configured as a
DATATERM for full duplex, no parity, 8 bits data, one start bit and one stop bit.
Your computer needs to be configured as a "dumb" terminal which sends ASCII characters as
they are typed to the DMC-14XX.
Connections to the controller for Ethernet communication are covered in Step 5.
3. For the DMC-1415 and DMC-1425, apply ±12V, +5V power to the J5 connector. For the
DMC-1416, apply a single, external DC supply from 20 to 60 volts to the 5-pin box connector
at the locations V PWR+ and GND. This supply provides power for both the motion
controller and the internal PWM amplifier.
Warning: Damage to the DMC-1416 will occur if a supply larger than 60V is connected to
the controller.
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