Galil Motion Control DMC-1600 Series User manual

USER MANUAL
DMC-1600
Manual Rev. 1.0h
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

Using This Manual
Your DMC-1600 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.
Please note that many examples are written for the DMC-1640 four-axes controller or the
DMC-1680 eight axes controller. Users of the DMC-1630 3-axis controller, DMC-1620
2-axes controller or DMC-1610 1-axis controller should note that the DMC-1630 uses the
axes denoted as XYZ, the DMC-1620 uses the axes denoted as XY, and the DMC-1610 uses
the X-axis only.
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.

Contents
Contents i
Chapter 1 Overview 1
Introduction ............................................................................................................................... 1
Overview of Motor Types..........................................................................................................2
Standard Servo Motor with +/- 10 Volt Command Signal .......................................... 2
Brushless Servo Motor with Sinusoidal Commutation................................................2
Stepper Motor with Step and Direction Signals ..........................................................2
DMC-1600 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-1600 Motion Controller............................................................................................ 7
Elements You Need ................................................................................................................... 8
Installing the DMC-1600........................................................................................................... 9
Step 1. Determine Overall Motor Configuration .........................................................9
Step 2. Install Jumpers on the DMC-1600.................................................................10
Step 3. Install the Communications Software............................................................11
Step 4. Install the DMC-1600 in the PC.................................................................... 11
Step 5. Establish Communication using Galil Software............................................11
Step 6. Determine the Axes to be Used for Sinusoidal Commutation.......................12
Step 7. Make Connections to Amplifier and Encoder. ..............................................13
Step 8a. Connect Standard Servo Motors.................................................................. 15
Step 8b. Connect Sinusoidal Commutation Motors...................................................20
Step 8c. Connect Step Motors ...................................................................................23
Step 9. Tune the Servo System..................................................................................23
Design Examples .....................................................................................................................24
Example 1 - System Set-up ....................................................................................... 24
Example 2 - Profiled Move .......................................................................................24
DMC-1600 Contents •i

Example 3 - Multiple Axes........................................................................................25
Example 4 - Independent Moves............................................................................... 25
Example 5 - Position Interrogation............................................................................ 25
Example 6 - Absolute Position ..................................................................................26
Example 7 - Velocity Control....................................................................................26
Example 8 - Operation Under Torque Limit ............................................................. 26
Example 9 - Interrogation.......................................................................................... 27
Example 10 - Operation in the Buffer Mode.............................................................27
Example 11 - Using the On-Board Editor .................................................................27
Example 12 - Motion Programs with Loops.............................................................. 27
Example 13 - Motion Programs with Trippoints .......................................................28
Example 14 - Control Variables ................................................................................28
Example 15 - Linear Interpolation............................................................................. 29
Example 16 - Circular Interpolation..........................................................................29
Chapter 3 Connecting Hardware 32
Overview .................................................................................................................................32
Using Optoisolated Inputs .......................................................................................................32
Limit Switch Input.....................................................................................................32
Home Switch Input.................................................................................................... 33
Abort Input ................................................................................................................33
Uncommitted Digital Inputs ......................................................................................34
Wiring the Optoisolated Inputs................................................................................................ 34
Using an Isolated Power Supply................................................................................35
Bypassing the Opto-Isolation: ...................................................................................36
Analog Inputs ..........................................................................................................................36
Amplifier Interface .................................................................................................................. 36
TTL Outputs ............................................................................................................................ 37
Chapter 4 - Software Tools and Communications 38
Introduction ............................................................................................................................. 38
Galil SmartTERM....................................................................................................................39
Communication Settings..........................................................................................................44
Windows Servo Design Kit (WSDK) ......................................................................................48
Creating Custom Software Interfaces ...................................................................................... 49
DOS, Linux, and QNX tools.................................................................................................... 52
Command Format and Controller Response............................................................................53
Binary Command Format .......................................................................................... 53
Controller Event Interrupts and User Interrupts ......................................................................55
Hardware Level Communications ...........................................................................................57
Determining the Base Address .................................................................................. 57
Communication Registers..........................................................................................57
Secondary FIFO Memory Map................................................................................................ 59
Explanation of Status Information and Axis Switch Information..............................62
Chapter 5 Command Basics 64
Introduction ............................................................................................................................. 64
Command Syntax - ASCII....................................................................................................... 64
Coordinated Motion with more than 1 axis ...............................................................65
Command Syntax - Binary ...................................................................................................... 66
Binary Command Format .......................................................................................... 66
Binary command table...............................................................................................67
Controller Response to DATA ................................................................................................68
Interrogating the Controller .....................................................................................................68
ii •Contents DMC-1600

Interrogation Commands...........................................................................................68
Interrogating Current Commanded Values................................................................ 69
Operands.................................................................................................................... 69
Command Summary.................................................................................................. 70
Chapter 6 Programming Motion 72
Overview .................................................................................................................................72
Independent Axis Positioning.................................................................................................. 73
Command Summary - Independent Axis .................................................................. 74
Independent Jogging................................................................................................................ 76
Command Summary - Jogging.................................................................................. 76
Operand Summary - Independent Axis .....................................................................77
Linear Interpolation Mode.......................................................................................................77
Specifying Linear Segments...................................................................................... 78
Command Summary - Linear Interpolation............................................................... 80
Operand Summary - Linear Interpolation.................................................................. 80
Example - Linear Move............................................................................................. 80
Example - Multiple Moves........................................................................................82
Coordinated Motion Sequences ...............................................................................................83
Specifying the Coordinate Plane ...............................................................................83
Specifying Vector Segments .....................................................................................84
Additional commands................................................................................................ 84
Command Summary - Coordinated Motion Sequence .............................................. 86
Operand Summary - Coordinated Motion Sequence................................................. 86
Electronic Gearing ................................................................................................................... 88
Command Summary - Electronic Gearing ................................................................88
Electronic Cam ........................................................................................................................ 90
Command Summary – Electronic CAM....................................................................93
Contour Mode..........................................................................................................................95
Specifying Contour Segments ...................................................................................95
Additional Commands...............................................................................................97
Command Summary - Contour Mode .......................................................................97
Stepper Motor Operation ....................................................................................................... 101
Specifying Stepper Motor Operation....................................................................... 101
Using an Encoder with Stepper Motors................................................................... 102
Command Summary - Stepper Motor Operation..................................................... 102
Operand Summary - Stepper Motor Operation........................................................103
Stepper Position Maintenance Mode (SPM)..........................................................................103
Error Limit............................................................................................................... 104
Correction................................................................................................................ 104
Dual Loop (Auxiliary Encoder)............................................................................................. 107
Backlash Compensation ..........................................................................................108
Motion Smoothing................................................................................................................. 110
Using the IT and VT Commands (S curve profiling): ............................................. 110
Homing ..................................................................................................................................111
High Speed Position Capture (The Latch Function)..............................................................114
Fast Firmware Operation ....................................................................................................... 114
Chapter 7 Application Programming 116
Overview ...............................................................................................................................116
Using the DMC-1600 Editor to Enter Programs....................................................................116
Edit Mode Commands............................................................................................. 117
Program Format..................................................................................................................... 117
Using Labels in Programs .......................................................................................118
DMC-1600 Contents •iii

Special Labels..........................................................................................................118
Commenting Programs............................................................................................ 119
Executing Programs - Multitasking ....................................................................................... 120
Debugging Programs .............................................................................................................121
Program Flow Commands ..................................................................................................... 123
Event Triggers & Trippoints....................................................................................123
Event Trigger Examples:......................................................................................... 125
Conditional Jumps................................................................................................... 127
Using If, Else, and Endif Commands ......................................................................129
Subroutines..............................................................................................................131
Stack Manipulation.................................................................................................. 132
Auto-Start Routine .................................................................................................. 132
Automatic Subroutines for Monitoring Conditions ................................................. 132
Mathematical and Functional Expressions ............................................................................ 135
Mathematical Operators ..........................................................................................135
Bit-Wise Operators.................................................................................................. 136
Functions ................................................................................................................. 137
Variables................................................................................................................................138
Programmable Variables ......................................................................................... 138
Operands................................................................................................................................139
Special Operands (Keywords)................................................................................. 140
Arrays ....................................................................................................................................140
Defining Arrays....................................................................................................... 140
Assignment of Array Entries ...................................................................................141
Automatic Data Capture into Arrays....................................................................... 142
Deallocating Array Space........................................................................................ 143
Input of Data (Numeric and String)....................................................................................... 143
Input of Data............................................................................................................143
Output of Data (Numeric and String) ....................................................................................144
Sending Messages ................................................................................................... 144
Displaying Variables and Arrays............................................................................. 146
Interrogation Commands......................................................................................... 146
Formatting Variables and Array Elements ..............................................................148
Converting to User Units......................................................................................... 148
Programmable Hardware I/O................................................................................................. 149
Digital Outputs ........................................................................................................ 149
Digital Inputs........................................................................................................... 150
Input Interrupt Function .......................................................................................... 150
Analog Inputs ..........................................................................................................151
Example Applications............................................................................................................152
Wire Cutter.............................................................................................................. 152
X-Y Table Controller ..............................................................................................153
Speed Control by Joystick .......................................................................................155
Position Control by Joystick....................................................................................156
Backlash Compensation by Sampled Dual-Loop .................................................... 156
Chapter 8 Hardware & Software Protection 158
Introduction ........................................................................................................................... 158
Hardware Protection ..............................................................................................................158
Output Protection Lines........................................................................................... 158
Input Protection Lines .............................................................................................159
Software Protection ...............................................................................................................159
Programmable Position Limits ................................................................................ 159
Off-On-Error ...........................................................................................................160
Automatic Error Routine ......................................................................................... 160
iv •Contents DMC-1600

Limit Switch Routine .............................................................................................. 160
Chapter 9 Troubleshooting 162
Overview ...............................................................................................................................162
Installation ............................................................................................................................. 162
Communication......................................................................................................................163
Stability.................................................................................................................................. 163
Operation ............................................................................................................................... 163
Chapter 10 Theory of Operation 164
Overview ...............................................................................................................................164
Operation of Closed-Loop Systems....................................................................................... 166
System Modeling................................................................................................................... 167
Motor-Amplifier...................................................................................................... 168
Encoder....................................................................................................................170
DAC ........................................................................................................................171
Digital Filter ............................................................................................................ 171
ZOH.........................................................................................................................172
System Analysis.....................................................................................................................172
System Design and Compensation.........................................................................................174
The Analytical Method............................................................................................ 174
Appendices 178
Electrical Specifications ........................................................................................................178
Servo Control .......................................................................................................... 178
Stepper Control........................................................................................................178
Input/Output ............................................................................................................178
Power Requirement .................................................................................................179
Performance Specifications ................................................................................................... 179
Connectors for DMC-1600 Main Board ................................................................................180
Pin-Out Description for DMC-1600 ......................................................................................181
Extended I/O of the DMC-1600 Controller ........................................................................... 183
Configuring the I/O of the DMC-1600.................................................................... 183
Connector Description:............................................................................................ 184
Note for Interfacing to External I/O Racks.............................................................. 187
Jumper Description for DMC-1600 ....................................................................................... 188
Accessories and Options........................................................................................................189
PC/AT Interrupts and Their Vectors...................................................................................... 190
ICM-1900 Interconnect Module ............................................................................................ 190
ICM-1900 Drawing ............................................................................................................... 194
AMP-19X0 Mating Power Amplifiers................................................................................... 194
Coordinated Motion - Mathematical Analysis....................................................................... 195
DMC-1600/DMC-1000 Comparison..................................................................................... 198
List of Other Publications...................................................................................................... 199
Training Seminars.................................................................................................................. 199
Contacting Us ........................................................................................................................200
WARRANTY ........................................................................................................................201
Index 202
DMC-1600 Contents •v

Chapter 1 Overview
Introduction
The DMC-1600 series motion control cards install directly into a compact PCI bus. This
controller series offers many enhanced features including high speed communications, non-
volatile program memory, fast encoder speeds, and improved cabling for EMI reduction.
The DMC-1600 provides two communication channels: a high speed FIFO for sending and
receiving commands and a secondary channel which gives high speed access to status and
parameters. The DMC-1600 allows for high speed servo control up to 12 million encoder
counts/sec and step motor control up to 3 million steps per second. Sample rates as low as
62.5μsec per axis are available.
A 2 Meg Flash EEPROM provides non-volatile memory for storing application programs,
parameters, arrays and firmware. New firmware revisions are easily upgraded in the field without
removing the controller from the system.
The DMC-1600 can be used with step motors, servo motors, and hydraulics, on any combination
of axes. Each axis is configurable by the user for optimum flexibility.
The DMC-1600 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 pole
filter, and integration limits. Designed to solve complex motion problems, the DMC-1600 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-1600 provides continuous vector feed of an infinite number of linear
and arc segments. The DMC-1600 electronic gearing mode features operation for multiple
masters axes as well as gantry.
For synchronization with outside events, the DMC-1600 provides uncommitted I/O, including 8
general use digital inputs, 72 general use digital outputs, and 8 analog inputs for interface to
joysticks, sensors, and pressure transducers. Dedicated optoisolated inputs are provided for
forward and reverse limits, abort, home, and definable input interrupts. The DMC-1600 is a plug
and play device making it easy to set-up. Commands can be sent in either Binary or ASCII.
Additional software is available to autotune, view trajectories on a PC screen, translate CAD.DXF
files into motion, and create powerful, application-specific operator interfaces with Visual Basic.
Drivers for Dos, Windows 3.1, 95, 98, 2000, ME, XP and NT are available.
DMC-1600 Chapter 1 Overview •1

Overview of Motor Types
The DMC-1600 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 Motor with +/- 10 Volt Command Signal
The DMC-1600 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 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 (+/- 10Volt) to connect to a servo amplifier.
This connection is described in Chapter 2.
Brushless Servo Motor with Sinusoidal Commutation
The DMC-1600 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.
To simplify the wiring, 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-1600 can control BLMs equipped with or without Hall sensors. If hall sensors are
available, once the controller has been setup, the controller will automatically estimates 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-1600 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.
2 •Chapter 1 Overview DMC-1600

DMC-1600 Functional Elements
The DMC-1600 circuitry can be divided into the following functional groups as shown in Figure
1.1 and discussed below.
WATCHDOG TIMER
68331
MICROCOMPUTER
WITH
2 Meg RAM
2 Meg FLASH EEPROM
HIGH-SPEED
MOTOR/ENCODER
INTERFACE
FOR
X,Y,Z,W
I/O INTERFACE
2ND FIFO
Primary
FIFOS
PLUG & PLAY
INTERRUPTS
ISA BUS
DMA BUS 8 UNCOMMITTED
ANALOG INPUTS
HIGH-SPEED LATCH FOR EACH AXIS
8 PROGRAMMABLE,
OPTOISOLATED
INPUTS
8 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-1600 Functional Elements
Microcomputer Section
The main processing unit of the DMC-1600 is a specialized 32-bit Motorola 68331 Series
Microcomputer with 256K RAM and 256K 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-1600 firmware.
Motor Interface
Galil’s GL-1800 custom, sub-micron gate array performs quadrature decoding of each encoder at
up to 12 MHz, generates a +/-10 Volt analog signal (16 Bit D-to-A) for input to a servo amplifier,
and generates step and direction signal for step motor drivers.
Communication
The communication interface with the host PC contains a primary and secondary communication
channel. The primary channel uses a bi-directional FIFO (AM470) and includes PC interrupt
DMC-1600 Chapter 1 Overview •3

handling circuitry. The secondary channel can be enabled where data is placed into the DMC-
1600 FIFO buffer.
General I/O
The DMC-1600 provides interface circuitry for 8 bidirectional, optoisolated inputs, 8 TTL outputs
and 8 analog inputs with 12-Bit ADC (16-bit optional). The general inputs can also be used as
high speed latches for each axes. A high speed encoder compare output is also provided.
System Elements
As shown in Fig. 1.2, the DMC-1600 is part of a motion control system which includes amplifiers,
motors and encoders. These elements are described below.
Computer DMC-1600 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 at 800-377-6329 if
you would like this product.
The motor may be a step or servo motor and can be brush-type or brushless, rotary or linear. For
step motors, the controller can be configured to control 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 motor peak 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.
4 •Chapter 1 Overview DMC-1600

Encoder
An encoder translates motion into electrical pulses which are fed back into the controller. The
DMC-1600 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-1600 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-1600 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-1600. Single-
ended 12 Volt signals require a bias voltage input to the complementary inputs).
The DMC-1600 can accept analog feedback instead of an encoder for any axis. For more
information see description of analog feedback in Chapter 2 under section entitled "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-1600 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-1600 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-1600 to normal operation. Consult the factory for a Return Materials Authorization (RMA)
Number if your DMC-1600 is damaged.
DMC-1600 Chapter 1 Overview •5

THIS PAGE LEFT BLANK INTENTIONALLY
6 •Chapter 1 Overview DMC-1600

Chapter 2 Getting Started
The DMC-1600 Motion Controller
Figure 2-1 - Outline of the DMC-1600
DMC-1600 Chapter 2 Getting Started •7

U14 Flash EEPROM JP1 Master Reset & UPGRD jumpers
U9/U2
1
RAM JP3
INCOM & LSCOM jumpers. Used for bypassing
opto-isolation for the limit, home, and abort switches
and the digital inputs IN1 - IN8. See section
“Bypassing Opto-Isolation”, Chap3.
U30 Motorola 68331 microprocessor JP5
Jumpers used for configuring stepper motor operation
on axes X-W
U22 GL-1800 custom gate array JP6 ?
J1 100-pin high density connector (Axes X-W)
(Part number Amp #2-178238-9)
JP7 ?
J5 36-pin high density connector for the auxiliary
encoder signals.
J101 100-pin high density connector for extended I/O
(Part number Amp #2-178238-9)
Elements You Need
Before you start, you must get all the necessary system elements. These include:
1. DMC-1610, 1620, 1630, or DMC-1640 Motion Controller, (1) 100-pin cable, and (1)
ICM-1900 interconnect module.
2. Servo motors with Optical Encoder (one per axis) or step motors.
3. Power Amplifiers.
4. Power Supply for Amplifiers.
5. PC (Personal Computer - ISA bus).
6. Utilities Disk for DMC-1600 which contains Plug and Play drivers, and
communication utilities.
7. WSDK-16 or WSDK-32 is optional but recommend for first time users.
The motors may be servo (brush type or brushless) or steppers. 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.
For servo motors in current mode, the amplifiers 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. Set the velocity gain so that an input signal of 10V, runs the motor at the maximum
required speed.
For step motors, the amplifiers should accept step and direction signals. For start-up of a step motor
system refer to “Connecting Step Motors” on page 20.
The WSDK software is highly recommended for first time users of the DMC-1600. It provides
step-by-step instructions for system connection, tuning and analysis.
8 •Chapter 2 Getting Started DMC-1600

Installing the DMC-1600
Installation of a complete, operational DMC-1600 system consists of 9 steps.
Step 1. Determine overall motor configuration.
Step 2. Install Jumpers on the DMC-1600.
Step 3. Install the communications software.
Step 4. Install the DMC-1600 in the PC.
Step 5. Establish communications with the Galil Communication Software.
Step 6. Determine the Axes to be used for sinusoidal commutation.
Step 7. Make connections to amplifier and encoder.
Step 8a. Connect standard servo motors.
Step 8b. Connect sinusoidal commutation motors
Step 8c. Connect step motors.
Step 9. Tune the 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-1600 can control any combination of standard servo motors, sinusoidally
commutated brushless motors, and stepper motors. Other types of actuators, such as hydraulics
can also be controlled, please consult Galil.
The following configuration information is necessary to determine the proper motor configuration:
Standard Servo Motor Operation:
The DMC-1600 has been setup by the factory for standard servo motor operation providing an
analog command signal of +/- 10V. No hardware or software configuration is required for
standard servo motor operation.
Sinusoidal Commutation:
Sinusoidal commutation is configured through a single software command, BA. This
configuration causes the controller to reconfigure the number of available control axes.
Each sinusoidally commutated motor requires two DAC's. In standard servo operation, the DMC-
1600 has one DAC per axis. In order to have the additional DAC for sinusoidal commutation, the
controller must be designated as having one additional axis for each sinusoidal commutation axis.
For example, to control two standard servo axes and one axis of sinusoidal commutation, the
controller will require a total of four DAC's and the controller must be a DMC-1640.
Sinusoidal commutation is configured with the command, BA. For example, BAX sets the X axis
to be sinusoidally commutated. The second DAC for the sinusoidal signal will be the highest
available DAC on the controller. For example: Using a DMC-1640, the command BAX will
configure the X axis to be the main sinusoidal signal and the 'W' axis to be the second sinusoidal
signal.
The BA command also reconfigures the controller to indicate that the controller has one less axis
of 'standard' control for each axis of sinusoidal commutation. For example, if the command BAX
is given to a DMC-1640 controller, the controller will be re-configured to a DMC-1630 controller.
By definition, a DMC-1630 controls 3 axes: X,Y and Z. The 'W' axis is no longer available since
the output DAC is being used for sinusoidal commutation.
DMC-1600 Chapter 2 Getting Started •9

Further instruction for sinusoidal commutation connections are discussed in Step 6.
Stepper Motor Operation:
To configure the DMC-1600 for stepper motor operation, the controller requires a jumper for each
stepper motor and the command, MT, must be given. The installation of the stepper motor jumper
is discussed in the following section entitled "Installing Jumpers on the DMC-1600". Further
instructions for stepper motor connections are discussed in Step 8c.
Step 2. Install Jumpers on the DMC-1600
Master Reset and Upgrade Jumpers
JP1 contains two jumpers, MRST and UPGRD. The MRST jumper is the Master Reset jumper.
With MRST 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 UPGRD 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 UPGRD Jumper and use the
update firmware function on the Galil Terminal to re-load the system firmware.
Opto-Isolation Jumpers
The inputs and limit switches are optoisolated. If you are not using an isolated power supply, the
internal +5V supply from the PC may be used to power the optoisolators. This is done by
installing the jumpers on JP3. LSCOM to VCC will power the limit switch optoisolators, and
INCOM to VCC will power the general input optoisolators.
Note: Using the PC’s internal +5V supply to power the optoisolators will effectively bypass the
optoisolation and fail to provide any isolation for the inputs and limit switches.
Stepper Motor Jumpers
For each axis that will be used for stepper motor operation, the corresponding stepper mode (SM)
jumper must be connected. The stepper motor jumpers, labeled JP5 for axes X through W are
located directly beside the GL-1800 IC’s on the main board (see the diagram for the DMC-1600).
The individual jumpers are labeled SMX, SMY, SMZ and SMW for axes 1 through 4.
(Optional) Motor Off Jumper
The state of the motor upon power up may be selected with the placement of a hardware jumper
on the controller. With a jumper installed at the OPT location (next to the stepper motor
jumpers), the controller will be powered up in the ‘motor off’ state. The SH command will then
need to be issued in order for the motor(s) to be enabled. With no jumper installed, the controller
will immediately enable the motor(s) upon power up.
10 •Chapter 2 Getting Started DMC-1600

Step 3. Install the Communications Software
After applying power to the computer, you should install the Galil software that enables
communication between the controller and PC.
Using Dos:
Using the Galil Software CD-ROM, go to the directory DMCDOS. Type “INSTALL” at the DOS
prompt and follow the directions.
Using Windows SE, 98, NT, ME, XP or 2000 (32 bit versions):
The Galil Software CD-ROM will automatically begin the installation procedure when the CD-
ROM is installed. After installing the Galil CD-ROM software on your computer, you can easily
install other software components as desired. To install the basic communications software, run
the Galil Software CD-ROM and choose “DMCWIN32 – Windows Utilities and Programming
Libraries, WIN95, 98, NT”. This will install the Galil Terminal that can be used for
communication.
Step 4. Install the DMC-1600 in the PC
The DMC-1600 is installed directly into the Compact PCI bus. The procedure is outlined below.
1. Make sure the host computer is in the power-off condition.
2. Remove unit cover.
3. Remove the metal plate covering the expansion bus slot where the DMC-1600 will be
inserted.
4. Insert DMC-1600 card in the expansion bus and secure with screw.
5. Attach 100-pin cable to your controller card. If you are using a Galil ICM-1900 or
AMP-19X0, this cable connects into the J2 connection on the interconnect module. If
you are not using a Galil interconnect module, you will need to appropriately
terminate the cable to your system components, see the appendix for cable pin outs.
The auxiliary encoder connections are accessed through the 36-pin connector, J5.
Note: The part number for the 100-pin connector is #2-178238-9 from AMP.
6. Turn power on to computer.
7. The operating system should recognize the DMC-1600 as a new device.
8. The Plug and Play feature will automatically configure the controller for your
computers available resources. The installation will also automatically add this
information to the Galil Registry.
Step 5. Establish Communication using Galil Software
DMC-1600 DOS Users
All that is required for installation of the DMC-1600 in DOS is the DMCTERM software. Within
DMCTERM, the DMC-1600 should be selected from the card options, and the DOS drivers will
automatically register the card with a correct address and IRQ.
DMC-1600 Chapter 2 Getting Started •11

After providing the setup information, the terminal should indicate, “Attempting to connect to
controller”, followed by the colon “:” being sent. This indicates a successful connection. Note:
The BIOS for your PC when using DOS should be set for Non-Plug and Play OS for successful
communication.
Using Windows98SE, ME, NT, 2000, XP:
In order for the windows software to communicate with a Galil controller, the controller must be
registered in the Galil Registry, listing the controller information and address. Under Windows
NT/2000, the DMC-1600 controller is registered by initializing the Galil Driver. To do this,
install the DTERM32 software program (DMCWIN32.exe) or the Galil Servo Design Kit
Software (WSDK32.exe). Begin the software and add the DMC-1600 controller to the registry.
The registry is available from the pull down menu, Registry, from DTERM32 and from the pull
down menu, File, from the WSDK software. After registering the controller, re-boot the system.
Under the Options Menu, select, Start Device Driver. Then select the terminal to begin
communicating directly with the controller.
Dterm32 will find the DMC-1600 controller and automatically insert the controller information
into the registry. The registry entry also displays timeout and delay information. These are
advanced parameters that should only be modified by advanced users (see software documentation
for more information).
Communication is established by selecting the Terminal Menu. Select the controller by
highlighting it. Once the entry has been selected, click on the OK button. If communication is
established, the terminal window will open and a colon prompt will be displayed. From the top
line of the terminal, commands can be sent to the controller. Command syntax is described in the
Command Reference and later sections.
If you are not properly communicating with the controller, the program will pause for 3-15
seconds. The top of the screen will display the message “Status: not connected with Galil motion
controller” and the following error will appear: “STOP - Unable to establish communication with
the Galil controller. A time-out occurred while waiting for a response from the Galil controller.”
If this message appears, you must click OK. Contact Galil if you are unable to communicate with
your controller.
Step 6. Determine the Axes to be Used for Sinusoidal
Commutation
* This step is only required when the controller will be used to control a brushless motor(s) with
sinusoidal commutation.
The command, BA is used to select the axes of sinusoidal commutation. For example, BAXZ sets
X and Z as axes with sinusoidal commutation.
Notes on Configuring Sinusoidal Commutation:
The command, BA, reconfigures the controller such that it has one less axis of 'standard' control
for each axis of sinusoidal commutation. For example, if the command BAX is given to a DMC-
1640 controller, the controller will be re-configured to be a DMC-1630 controller. In this case the
highest axis is no longer available except to be used for the 2nd phase of the sinusoidal
commutation. Note that the highest axis on a controller can never be configured for sinusoidal
commutation.
The first phase signal is the motor command signal. The second phase is derived from the highest
DACX on the controller. When more than one axis is configured for sinusoidal commutation, the
highest sinusoidal commutation axis will be assigned to the highest DAC and the lowest
sinusoidal commutation axis will be assigned to the lowest available DAC. Note the lowest axis is
the X axis.
12 •Chapter 2 Getting Started DMC-1600