Galil Motion Control DMC-18 2 Series User manual

Artisan Technology Group is your source for quality
new and certied-used/pre-owned equipment
• FAST SHIPPING AND
DELIVERY
• TENS OF THOUSANDS OF
IN-STOCK ITEMS
• EQUIPMENT DEMOS
• HUNDREDS OF
MANUFACTURERS
SUPPORTED
• LEASING/MONTHLY
RENTALS
• ITAR CERTIFIED
SECURE ASSET SOLUTIONS
SERVICE CENTER REPAIRS
Experienced engineers and technicians on staff
at our full-service, in-house repair center
WE BUY USED EQUIPMENT
Sell your excess, underutilized, and idle used equipment
We also offer credit for buy-backs and trade-ins
www.artisantg.com/WeBuyEquipment
REMOTE INSPECTION
Remotely inspect equipment before purchasing with
our interactive website at www.instraview.com
LOOKING FOR MORE INFORMATION?
Visit us on the web at www.artisantg.com for more
information on price quotations, drivers, technical
specications, manuals, and documentation
Contact us: (888) 88-SOURCE | [e-mail] | www.artisantg.com
SM
View
Instra

USER MANUAL
DMC-18x2
Manual Rev. 1.0i
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 3/08
Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

Using This Manual
This user manual provides information for proper operation of the DMC-18x2 controller. A separate
supplemental manual, the Command Reference, contains a description of the commands available for
use with this controller.
Your DMC-18x2 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-1842 four-axes controller. Users of the
DMC-1832 3-axis controller, DMC-1822 2-axes controller or DMC-1812 1-axis controller should note
that the DMC-1832 uses the axes denoted as XYZ, the DMC-1822 uses the axes denoted as XY, and
the DMC-1812 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.
Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

DMC-18x2 ●i
Contents
CONTENTS ........................................................................................................................................................................ I
CHAPTER 1 OVERVIEW ................................................................................................................................................1
INTRODUCTION.................................................................................................................................................................1
OVERVIEW OF MOTOR TYPES...........................................................................................................................................1
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-18X2FUNCTIONAL ELEMENTS ...............................................................................................................................2
Microcomputer Section...............................................................................................................................................3
Motor Interface ...........................................................................................................................................................3
Communication...........................................................................................................................................................3
General I/O..................................................................................................................................................................3
System Elements.........................................................................................................................................................3
Motor ..........................................................................................................................................................................4
Amplifier (Driver).......................................................................................................................................................4
Encoder.......................................................................................................................................................................4
Watch Dog Timer........................................................................................................................................................5
CHAPTER 2 GETTING STARTED ................................................................................................................................7
THE DMC-18X2MOTION CONTROLLER...........................................................................................................................7
ELEMENTS YOU NEED ......................................................................................................................................................8
INSTALLING THE DMC-18X2............................................................................................................................................8
Step 1. Determine Overall Motor Configuration.........................................................................................................9
Step 2. Install Jumpers on the DMC-18x2................................................................................................................10
Step 3. Install the Communications Software...........................................................................................................10
Step 4. Install the DMC-18x2 in the PC....................................................................................................................10
Step 5. Establish Communication using Galil Software ...........................................................................................11
Step 6. Determine the Axes to be Used for Sinusoidal Commutation.......................................................................11
Step 7. Make Connections to Amplifier and Encoder...............................................................................................12
Step 8a. Connect Standard Servo Motors..................................................................................................................14
Step 8b. Connect Sinusoidal Commutation Motors..................................................................................................18
Step 8C. Connect Step Motors..................................................................................................................................20
Step 9. Tune the Servo System .................................................................................................................................21
DESIGN EXAMPLES.........................................................................................................................................................22
Example 1 - System Set-up.......................................................................................................................................22
Example 2 – Profiled Move ......................................................................................................................................22
Example 3 – Multiple Axes.......................................................................................................................................22
Example 4 - Independent Moves...............................................................................................................................23
Example 5 - Position Interrogation ...........................................................................................................................23
Example 6 - Absolute Position..................................................................................................................................23
Example 7 - Velocity Control ...................................................................................................................................24
Example 8 - Operation Under Torque Limit.............................................................................................................24
Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

ii ●DMC-18x2
Example 9 - Interrogation .........................................................................................................................................25
Example 10 - Operation in the Buffer Mode.............................................................................................................25
Example 11 - Using the On-Board Editor.................................................................................................................25
Example 12 - Motion Programs with Loops.............................................................................................................26
Example 13 - Motion Programs with Trippoints.......................................................................................................26
Example 14 - Control Variables................................................................................................................................26
Example 15 - Linear Interpolation............................................................................................................................27
Example 16 - Circular Interpolation..........................................................................................................................27
CHAPTER 3 CONNECTING HARDWARE ................................................................................................................29
OVERVIEW......................................................................................................................................................................29
USING INPUTS.................................................................................................................................................................29
Limit Switch Input....................................................................................................................................................29
Home Switch Input ...................................................................................................................................................30
Abort Input................................................................................................................................................................30
Uncommitted Digital Inputs......................................................................................................................................31
AMPLIFIER INTERFACE ...................................................................................................................................................31
TTL INPUTS....................................................................................................................................................................32
TTL OUTPUTS ................................................................................................................................................................32
CHAPTER 4 - SOFTWARE TOOLS AND COMMUNICATIONS............................................................................35
INTRODUCTION...............................................................................................................................................................35
GALIL SMARTTERM......................................................................................................................................................37
COMMUNICATION SETTINGS FOR ISA AND PCI..............................................................................................................41
WINDOWS SERVO DESIGN KIT (WSDK) ........................................................................................................................44
CREATING CUSTOM SOFTWARE INTERFACES .................................................................................................................45
Galil Communications API with Visual Basic..........................................................................................................47
DOS, LINUX,AND QNX TOOLS......................................................................................................................................48
COMMAND FORMAT AND CONTROLLER RESPONSE ........................................................................................................49
CONTROLLER EVENT INTERRUPTS AND USER INTERRUPTS ............................................................................................51
HARDWARE LEVEL COMMUNICATIONS FOR PCI ............................................................................................................53
Communication Registers.........................................................................................................................................54
Simplified Communication Procedure......................................................................................................................54
Advanced Communication Techniques ....................................................................................................................55
DATA RECORD................................................................................................................................................................55
Explanation of Status Information and Axis Switch Information.............................................................................58
CHAPTER 5 COMMAND BASICS ...............................................................................................................................61
INTRODUCTION...............................................................................................................................................................61
COMMAND SYNTAX -ASCII ..........................................................................................................................................61
Coordinated Motion with more than 1 axis...............................................................................................................62
COMMAND SYNTAX -BINARY........................................................................................................................................63
Binary Command Format..........................................................................................................................................63
Binary command table ..............................................................................................................................................64
CONTROLLER RESPONSE TO DATA................................................................................................................................65
INTERROGATING THE CONTROLLER................................................................................................................................65
Interrogation Commands...........................................................................................................................................65
Summary of Interrogation Commands......................................................................................................................65
Interrogating Current Commanded Values. ..............................................................................................................66
Operands...................................................................................................................................................................66
Command Summary .................................................................................................................................................66
CHAPTER 6 PROGRAMMING MOTION ..................................................................................................................67
OVERVIEW......................................................................................................................................................................67
INDEPENDENT AXIS POSITIONING...................................................................................................................................68
Command Summary - Independent Axis..................................................................................................................69
Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

DMC-18x2 • iii
Operand Summary - Independent Axis.....................................................................................................................69
INDEPENDENT JOGGING ..................................................................................................................................................71
Command Summary - Jogging..................................................................................................................................71
Operand Summary - Independent Axis.....................................................................................................................72
LINEAR INTERPOLATION MODE......................................................................................................................................72
Specifying Linear Segments .....................................................................................................................................72
Command Summary - Linear Interpolation..............................................................................................................74
Operand Summary - Linear Interpolation.................................................................................................................75
Example - Linear Move ............................................................................................................................................75
Example - Multiple Moves........................................................................................................................................77
VECTOR MODE:LINEAR AND CIRCULAR INTERPOLATION MOTION................................................................................77
Specifying Vector Segments.....................................................................................................................................77
Additional commands ...............................................................................................................................................78
Command Summary - Coordinated Motion Sequence..............................................................................................80
Operand Summary - Coordinated Motion Sequence.................................................................................................80
ELECTRONIC GEARING ...................................................................................................................................................82
Command Summary - Electronic Gearing................................................................................................................82
ELECTRONIC CAM ..........................................................................................................................................................84
Command Summary – Electronic CAM...................................................................................................................88
CONTOUR MODE ............................................................................................................................................................89
Specifying Contour Segments...................................................................................................................................89
Additional Commands ..............................................................................................................................................91
Command Summary - Contour Mode.......................................................................................................................91
STEPPER MOTOR OPERATION .........................................................................................................................................94
Specifying Stepper Motor Operation ........................................................................................................................94
Using an Encoder with Stepper Motors ....................................................................................................................95
Command Summary - Stepper Motor Operation......................................................................................................96
Operand Summary - Stepper Motor Operation.........................................................................................................96
STEPPER POSITION MAINTENANCE MODE (SPM)...........................................................................................................96
Error Limit................................................................................................................................................................97
Correction .................................................................................................................................................................97
MOTION SMOOTHING ...................................................................................................................................................101
Using the IT and VT Commands (S curve profiling):.............................................................................................101
Using the KS Command (Step Motor Smoothing): ................................................................................................102
HOMING........................................................................................................................................................................103
HIGH SPEED POSITION CAPTURE (THE LATCH FUNCTION)...........................................................................................106
FAST UPDATE RATE MODE...........................................................................................................................................106
CHAPTER 7 APPLICATION PROGRAMMING......................................................................................................109
OVERVIEW....................................................................................................................................................................109
USING THE DMC-18X2EDITOR TO ENTER PROGRAMS ................................................................................................109
Edit Mode Commands ............................................................................................................................................110
PROGRAM FORMAT.......................................................................................................................................................110
Using Labels in Programs.......................................................................................................................................111
Special Labels.........................................................................................................................................................111
Commenting Programs ...........................................................................................................................................112
EXECUTING PROGRAMS -MULTITASKING ....................................................................................................................113
DEBUGGING PROGRAMS...............................................................................................................................................114
PROGRAM FLOW COMMANDS.......................................................................................................................................116
Event Triggers & Trippoints...................................................................................................................................116
Event Trigger Examples:.........................................................................................................................................118
Conditional Jumps...................................................................................................................................................120
Using If, Else, and Endif Commands......................................................................................................................122
Subroutines .............................................................................................................................................................123
Stack Manipulation.................................................................................................................................................124
Auto-Start Routine..................................................................................................................................................124
Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

iv ●DMC-18x2
Automatic Subroutines for Monitoring Conditions.................................................................................................124
MATHEMATICAL AND FUNCTIONAL EXPRESSIONS .......................................................................................................127
Mathematical Operators..........................................................................................................................................127
Bit-Wise Operators .................................................................................................................................................128
Functions.................................................................................................................................................................129
VARIABLES...................................................................................................................................................................130
Programmable Variables.........................................................................................................................................130
OPERANDS....................................................................................................................................................................131
Special Operands (Keywords).................................................................................................................................131
ARRAYS........................................................................................................................................................................132
Defining Arrays.......................................................................................................................................................132
Assignment of Array Entries...................................................................................................................................132
Automatic Data Capture into Arrays.......................................................................................................................133
Deallocating Array Space .......................................................................................................................................135
INPUT OF DATA (NUMERIC AND STRING)......................................................................................................................135
Input of Data ...........................................................................................................................................................135
OUTPUT OF DATA (NUMERIC AND STRING)..................................................................................................................136
Sending Messages...................................................................................................................................................136
Displaying Variables and Arrays ............................................................................................................................137
Interrogation Commands.........................................................................................................................................137
Formatting Variables and Array Elements..............................................................................................................139
Fast Firmware Mode...............................................................................................................................................140
Converting to User Units ........................................................................................................................................140
PROGRAMMABLE HARDWARE I/O................................................................................................................................141
Digital Outputs........................................................................................................................................................141
Digital Inputs ..........................................................................................................................................................142
Input Interrupt Function..........................................................................................................................................143
EXAMPLE APPLICATIONS..............................................................................................................................................143
Wire Cutter..............................................................................................................................................................143
X-Y Table Controller..............................................................................................................................................144
CHAPTER 8 HARDWARE & SOFTWARE PROTECTION...................................................................................149
INTRODUCTION.............................................................................................................................................................149
HARDWARE PROTECTION .............................................................................................................................................149
Output Protection Lines ..........................................................................................................................................149
Input Protection Lines.............................................................................................................................................150
SOFTWARE PROTECTION...............................................................................................................................................150
Programmable Position Limits................................................................................................................................150
Off-On-Error...........................................................................................................................................................151
Automatic Error Routine.........................................................................................................................................151
Limit Switch Routine..............................................................................................................................................152
CHAPTER 9 TROUBLESHOOTING..........................................................................................................................153
OVERVIEW....................................................................................................................................................................153
INSTALLATION..............................................................................................................................................................153
COMMUNICATION.........................................................................................................................................................153
STABILITY ....................................................................................................................................................................154
OPERATION...................................................................................................................................................................154
CHAPTER 10 THEORY OF OPERATION................................................................................................................155
OVERVIEW....................................................................................................................................................................155
OPERATION OF CLOSED-LOOP SYSTEMS ......................................................................................................................157
SYSTEM MODELING......................................................................................................................................................158
Motor-Amplifier......................................................................................................................................................159
SYSTEM ANALYSIS .......................................................................................................................................................163
SYSTEM DESIGN AND COMPENSATION .........................................................................................................................165
Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

DMC-18x2 • v
The Analytical Method ...........................................................................................................................................165
APPENDICES.................................................................................................................................................................169
ELECTRICAL SPECIFICATIONS.......................................................................................................................................169
Servo Control..........................................................................................................................................................169
Stepper Control.......................................................................................................................................................169
Input/Output............................................................................................................................................................169
Power ......................................................................................................................................................................169
PERFORMANCE SPECIFICATIONS...................................................................................................................................170
CONNECTORS FOR DMC-18X2MAIN BOARD...............................................................................................................170
PIN-OUT DESCRIPTION FOR DMC-18X2.......................................................................................................................171
JUMPER DESCRIPTION FOR DMC-18X2 ........................................................................................................................173
ACCESSORIES AND OPTIONS.........................................................................................................................................173
ICM-1900 INTERCONNECT MODULE............................................................................................................................174
ICM-1900 DRAWING....................................................................................................................................................177
AMP-19X0 MATING POWER AMPLIFIERS....................................................................................................................177
ICM-2900 INTERCONNECT MODULE............................................................................................................................178
OPTO-ISOLATED OUTPUTS ON ICM-1900/ICM-2900 (-OPTO OPTION).........................................................................181
Standard Opto-Isolation and High Current Opto-isolation: ....................................................................................181
64 EXTENDED I/O OF THE DMC-18X2CONTROLLER ...................................................................................................181
Configuring the I/O of the DMC-18x2 with DB-14064..........................................................................................182
Connector Description: ...........................................................................................................................................183
IOM-1964 OPTO-ISOLATION MODULE FOR EXTENDED I/O CONTROLLERS..................................................................186
Description:.............................................................................................................................................................186
Overview.................................................................................................................................................................187
Configuring Hardware Banks .................................................................................................................................188
Digital Inputs ..........................................................................................................................................................189
High Power Digital Outputs....................................................................................................................................191
Standard Digital Outputs.........................................................................................................................................192
Electrical Specifications..........................................................................................................................................193
COORDINATED MOTION -MATHEMATICAL ANALYSIS .................................................................................................196
LIST OF OTHER PUBLICATIONS .....................................................................................................................................201
TRAINING SEMINARS ....................................................................................................................................................201
CONTACTING US...........................................................................................................................................................202
WARRANTY..............................................................................................................................................................203
INDEX .............................................................................................................................................................................204
Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

DMC-18x2 Chapter 1 Overview ●1
Chapter 1 Overview
Introduction
The DMC-18x2 series motion control cards install directly into the PCI bus. This controller series
offers many enhanced features including high speed communications, non-volatile program memory,
faster encoder speeds, and improved cabling for EMI reduction.
The DMC-18x2 provides a high speed FIFO for sending and receiving commands. This PCI bus
motion controller 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 PC.
The DMC-18x2 is available with up to four axes on a single PCI card. The DMC-1812, 1822, 1832,
and 1842, one thru four axes controllers, are on a single 4.23” x 9” card.
Designed to solve complex motion problems, the DMC-18x2 can be used for applications involving
jogging, point-to-point positioning, vector positioning, electronic gearing, multiple move sequences,
and contouring. The controller eliminates jerk with programmable acceleration, deceleration, and
profile smoothing. For seamless following of complex contours, the DMC-18x2 provides continuous
vector feed of an infinite number of linear and arc segments. The controller also features electronic
gearing with multiple master axes as well as gantry mode operation.
For synchronization with outside events, the DMC-18x2 provides uncommitted I/O, including 8 digital
inputs, and 8 digital outputs. Committed digital inputs are provided for forward and reverse limits,
abort, home, and definable input interrupts. 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, Labview
and others. Drivers for DOS, Windows 3.1, 95, 98, 98SE, ME, NT4.0, 2000, XP, QNX, and Linux are
available.
Overview of Motor Types
The DMC-18x2 can provide the following types of motor control:
1. Standard servo motors with +/- 10 volt or PWM 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.
Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

2 ●Chapter 1 Overview DMC-18x2
Standard Servo Motors with +/- 10 Volt Command Signal
The DMC-18x2 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-18x2 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-18x2 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-18x2 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.
DMC-18x2 Functional Elements
The DMC-18x2 circuitry can be divided into the following functional groups as shown in Figure 1.1
and discussed below.
Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

DMC-18x2 Chapter 1 Overview • 3
WATCHDOG TIMER
68331
MICROCOMPUTER
WITH
2 Meg RAM
2 MegFLASH EEPROM
HIGH-SPEED
MOTOR/ENCODER
INTERFACE
FOR
X,Y,Z,W
I/O INTERFACE
Primary
FIFOS
PLUG & PLAY
INTERRUPTS
PCI BUS
HIGH-SPEED
LATCH FOR EACH
AXIS
8 PROGRAMMABLE,
TTL
INPUTS
8 PROGRAMMABLE
OUTPUTS
TTL LIMITS AND
HOME INPUTS
MAIN ENCODERS
+/- 10 VOLT OUTPUT FOR
SERVO MOTORS
PULSE/DIRECTION OUTPUT
FOR STEP MOTORS
HIGH SPEED ENCODER
COMPARE OUTPUT
Figure 1.1 - DMC-18x2 Functional Elements
Microcomputer Section
The main processing unit of the DMC-18x2 is a specialized 32-bit Motorola 68331 Series
Microcomputer with 2 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-18x2 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 2 DACs to generate 2 +/-10Volt
analog signals. For stepper motor operation, the controller generates a step and direction signal.
Communication
The communication interface with the host PC contains a bi-directional FIFO (AM4701) and includes
PC interrupt handling circuitry.
General I/O
The DMC-18x2 provides interface circuitry for 8 TTL inputs and 8 TTL outputs. The general inputs
can also be used for triggering a high speed positional latch for each axis.
System Elements
As shown in Fig. 1.2, the DMC-18x2 is part of a motion control system which includes amplifiers,
motors and encoders. These elements are described below.
Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

4 ●Chapter 1 Overview DMC-18x2
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, a 10 volt command should run the motor at the maximum
speed.
Encoder
An encoder translates motion into electrical pulses which are fed back into the controller. The DMC-
18x2 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-18x2 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-18x2 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.
Computer DMC-18x2 Controller
A
mplifier (Driver)
Power Supply
Encoder Motor
Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

DMC-18x2 Chapter 1 Overview • 5
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-18x2. Single-
ended 12 Volt signals require a 5-7V bias voltage input to the complementary inputs.)
The DMC-18x2 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-18x2 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-18x2 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 will also turn on at this stage. A reset is required to restore the DMC-18x2 to normal
operation. Consult the factory for a Return Materials Authorization (RMA) Number if your DMC-
18x2 is damaged.
Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

6 ●Chapter 1 Overview DMC-18x2
THIS PAGE LEFT BLANK INTENTIONALLY
Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

DMC-18x2 Chapter 2 Getting Started • 7
Chapter 2 Getting Started
The DMC-18x2 Motion Controller
2A
J2
2B
1
3
4
5
JP6
JP2
DMC-18x2
Figure 2-1 - Outline of the DMC-1812 thru DMC-1842
1 Flash EEPROM
2A/2B RAM
3 Motorola 68331 microprocessor
4 GL-1800 custom gate array
5 Error LED
J2 100-pin high density connector (part number Amp#2-178238-9)
JP2 Jumpers used for configuring stepper motor operation *
JP6 Master Reset & UPGRD jumpers
*Install JP2 OPT jumper for default MO (Motor Off), firmware 1.0e and higher
Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

8 ●Chapter 2 Getting Started DMC-18x2
Elements You Need
Before you start, you must get all the necessary system elements. These include:
1. DMC-1812, 1822, 1832, or DMC-1842 Motion Controller, (1) 100-pin cable, and (1)
interconnect module (either ICM/AMP-1900 or ICM-2900).
2. Servo Motors with Optical Encoder (one per axis) or Stepper Motors.
3. Power Amplifiers.
4. Power Supply for Amplifiers.
5. PC (Personal Computer - PCI bus).
6. Communications Software – DMCTERM, DMCWIN32, or WSDK32 (On Galil Software
CD, or download at http://www.galilmc.com/support/download.html).
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 such that a +10V command will generate 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, 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-18x2. It provides step-
by-step instructions for system setup, tuning and analysis.
Installing the DMC-18x2
Installation of a complete, operational DMC-18x2 system consists of 9 steps.
Step 1. Determine overall motor configuration.
Step 2. Install Jumpers on the DMC-18x2.
Step 3. Install the communications software.
Step 4. Install the DMC-18x2 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.
Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

DMC-18x2 Chapter 2 Getting Started • 9
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-18x2 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-18x2 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-18x2
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-1842.
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-1842, 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-1842 controller, the controller will be re-configured to a DMC-1832 controller. By
definition, a DMC-1832 controls 3 axes: X, Y and Z. The 'W' axis is no longer available since the
output DAC is being used for sinusoidal commutation.
Further instruction for sinusoidal commutation connections are discussed in Step 6.
Stepper Motor Operation:
To configure the DMC-18x2 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-18x2". Further
instructions for stepper motor connections are discussed in Step 8c.
Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com