Galil Motion Control DMC-42 0 Series User manual

USER MANUAL
DMC-42x0
Manual Rev. 1.0
Galil Motion Control, Inc.
270 Technology ay
Rocklin, California
916.626.0101
[email protected]m
galil.com
8/2015

Using This Manual
This user manual provides information for proper operation of the DMC-42x0 controller. A separate supplemental
manual, the Command Reference, contains a description of the commands available for use with this controller. It
is recommended that the user download the latest version of the Command Reference and User Manual from the
Galil ebsite.
http://www.galilmc.com/support/manuals.php
Your DMC-42x0 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.
4280
Attention: Pertains to controllers with more than 4 axes.
Please note that many examples are written for the DMC-4240 four-axes controller or the DMC-4280 eight axes
controller. Users of the DMC-4230 3-axis controller, DMC-4220 2-axes controller or DMC-4210 1-axis controller
should note that the DMC-4230 uses the axes denoted as ABC, the DMC-4220 uses the axes denoted as AB, and the
DMC-4210 uses the A-axis only.
Examples for the DMC-4280 denote the axes as A,B,C,D,E,F,G,H. Users of the DMC-4250 5-axes controller. DMC-
4260 6-axes controller or DMC-4270, 7-axes controller should note that the DMC-4250 denotes the axes as
A,B,C,D,E, the DMC-4260 denotes the axes as A,B,C,D,E,F and the DMC-4270 denotes the axes as A,B,C,D,E,F,G. The
axes A,B,C,D may be used interchangeably with X, Y, Z, .
WARNING
Machinery in motion can be dangerous!
It is the responsibility of the user to design effective error handling and safety protection as
part of the machinery. Galil shall not be liable or responsible for any incidental or
consequential damages
DMC-42x0 Contents ▫ i

Contents
Contents iii
Chapter 1 Overview 1
Introduction.................................................................................................................................. 1
Part Numbers
...................................................................................................................................................... 2
Electrical Specifications................................................................................................................. 2
Mechanical Specifications............................................................................................................. 3
Environmental Specifications........................................................................................................ 3
Equipment Maintenance............................................................................................................... 3
Overview of Motor Types.............................................................................................................. 3
Overview of External Amplifiers.................................................................................................... 4
Functional Elements..................................................................................................................... 5
Chapter 2 Getting Started 8
Layout........................................................................................................................................... 8
Dimensions................................................................................................................................... 9
Elements You Need....................................................................................................................... 10
Installing the DMC, Amplifiers, and Motors.................................................................................. 11
Chapter 3 Connecting Hardware 24
Overview....................................................................................................................................... 24
Overview of Optoisolated Inputs.................................................................................................. 24
Optoisolated Input Electrical Information..................................................................................... 27
TTL Inputs and Outputs................................................................................................................. 30
Analog Inputs................................................................................................................................ 32
Extended I/O................................................................................................................................. 33
External Amplifier Interface.......................................................................................................... 33
Chapter 4 Software Tools and Communication 41
Introduction.................................................................................................................................. 41
Controller Response to Commands............................................................................................... 41
Unsolicited Messages Generated by Controller............................................................................. 42
Serial Communication Ports.......................................................................................................... 42
Ethernet Configuration................................................................................................................. 44
Modbus........................................................................................................................................ 46
Data Record.................................................................................................................................. 49
GalilSuite ( indows and Linux)..................................................................................................... 53
Creating Custom Software Interfaces............................................................................................ 54
Chapter 5 Command Basics 56
Introduction.................................................................................................................................. 56
Command Syntax - ASCII............................................................................................................... 56
Controller Response to DATA........................................................................................................ 57
Interrogating the Controller.......................................................................................................... 58
Chapter 6 Programming Motion 60
Overview....................................................................................................................................... 60
Independent Axis Positioning........................................................................................................ 61
Independent Jogging..................................................................................................................... 63
Position Tracking........................................................................................................................... 64
Linear Interpolation Mode............................................................................................................ 68
Vector Mode: Linear and Circular Interpolation Motion................................................................71
Electronic Gearing......................................................................................................................... 78
Electronic Cam.............................................................................................................................. 81
PVT Mode..................................................................................................................................... 86
Contour Mode.............................................................................................................................. 89
Virtual Axis.................................................................................................................................... 93
DMC-42x0 Contents ▫ ii

Stepper Motor Operation............................................................................................................. 94
Stepper Position Maintenance Mode (SPM).................................................................................96
Dual Loop (Auxiliary Encoder)....................................................................................................... 99
Motion Smoothing ....................................................................................................................... 101
Homing......................................................................................................................................... 103
High Speed Position Capture (The Latch Function) .......................................................................105
Chapter 7 Application Programming 106
Overview....................................................................................................................................... 106
Program Format............................................................................................................................ 106
Executing Programs - Multitasking................................................................................................ 108
Debugging Programs..................................................................................................................... 109
Program Flow Commands............................................................................................................. 110
Mathematical and Functional Expressions....................................................................................125
Variables....................................................................................................................................... 128
Operands...................................................................................................................................... 129
Arrays............................................................................................................................................ 130
Input of Data (Numeric and String)............................................................................................... 133
Output of Data (Numeric and String)............................................................................................ 135
Hardware I/O................................................................................................................................ 139
Extended I/O of the DMC-42x0 Controller ................................................................................... 143
Example Applications.................................................................................................................... 145
Using the DMC Editor to Enter Programs...................................................................................... 149
Chapter 8 Hardware & Software Protection 151
Introduction.................................................................................................................................. 151
Hardware Protection..................................................................................................................... 151
Software Protection...................................................................................................................... 152
Chapter 9 Troubleshooting 156
Overview....................................................................................................................................... 156
Chapter 10 Theory of Operation 159
Overview....................................................................................................................................... 159
Operation of Closed-Loop Systems............................................................................................... 161
System Modeling.......................................................................................................................... 162
System Analysis............................................................................................................................. 166
System Design and Compensation................................................................................................ 168
Appendices 171
Electrical Specifications................................................................................................................. 171
Performance Specifications........................................................................................................... 173
Ordering Options.......................................................................................................................... 174
Accessories................................................................................................................................... 178
Input Current Limitations.............................................................................................................. 179
Serial Cable Connections............................................................................................................... 180
Opto-Isolated Outputs for ICM-2900/ICM-1900/AMP-19520/40..................................................182
Configuring the Amplifier Enable Circuit....................................................................................... 183
Signal Descriptions........................................................................................................................ 184
Connectors for DMC-42x0 Main Board......................................................................................... 185
A1. ICM-2900 Interconnect Module.............................................................................................. 192
A2. ICM-2908 Interconnect Module.............................................................................................. 197
A3. ICM-1900 Interconnect Module.............................................................................................. 198
A4. AMP-19520/40 ...................................................................................................................... 202
A5. CB-50-100 Adapter Board....................................................................................................... 203
A6. CB-50-80 Adapter Board......................................................................................................... 208
List of Other Publications.............................................................................................................. 212
Training Seminars.......................................................................................................................... 212
Contacting Us................................................................................................................................ 213
ARRANTY................................................................................................................................... 214
Integrated Components 215
Overview....................................................................................................................................... 215
DMC-42x0 Contents ▫ iii

Chapter 1 Overview
Intro uction
The DMC-42x0 Series are Galil’s highest performance stand-alone controller. The controller series offers many
enhanced features including high speed communications, non-volatile program memory, faster encoder speeds,
and improved cabling for EMI reduction.
Each DMC-42x0 provides two communication channels: high speed RS-232 (2 channels up to 115K Baud) and 100
BaseT Ethernet. The controllers allow for high-speed servo control up to 22 million encoder counts/sec and step
motor control up to 6 million steps per second. Sample rates as low as 31.25 µsec per axis are available.
A Flash EEPROM provides non-volatile memory for storing application programs, parameters, arrays and firmware.
New firmware revisions are easily upgraded in the field.
The DMC-42x0 is available with up to eight axes in a single stand alone unit. The DMC-4210, 4020, 4030, 4040 are
one thru four axes controllers and the DMC-4250, 4060, 4070, 4080 are five thru eight axes controllers. All eight
axes have the ability to use Galil’s integrated amplifiers or drivers and connections for integrating external devices.
Designed to solve complex motion problems, the DMC-42x0 can be used for applications involving jogging, point-
to-point positioning, vector positioning, electronic gearing, multiple move sequences, contouring and a PVT Mode.
The controller eliminates jerk by programmable acceleration and deceleration with profile smoothing. For smooth
following of complex contours, the DMC-42x0 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-42x0 provides uncommitted I/O, including 8 optoisolated digital
inputs (16 inputs for DMC-4250 thru DMC-4280), 8 high power optically isolated outputs (16 outputs for DMC-4250
thru DMC-4280), and 8 analog inputs for interface to joysticks, sensors, and pressure transducers. The DMC-42x0
also has an additional 32 I/O at 3.3V logic. Further I/O is available if the auxiliary encoders are not being used (2
inputs / each axis). Dedicated optoisolated inputs are provided for forward and reverse limits, abort, home, and
definable input interrupts.
Commands are sent in ASCII. Additional software is available for automatic-tuning, trajectory viewing on a PC
screen, and program development using many environments such as Visual Basic, C, C++ etc. Drivers for indows
XP, Vista and 7 (32 & 64 bit) as well as Linux are available.
Chapter 1 Overview ▫ 1 DMC-42x0 User Manual

Part Numbers
DMC, “DMC-42X0(Y)” Options
Option Type Options Brief Description Documentation
X 1,2,3,4,5,6,7, and 8 Number of control axes N/A
Y -16bit 16-bit analog inputs DMC, “DMC-42x0(Y)” Controller Board Options
, starting on pg 170.
4-20mA 4-20mA analog inputs
TRES Encoder terminating resistors
SSI SSI feedback
BiSS BiSS feedback
Electrical Specifications
Description Specification
AC Input Voltage 100-240 VAC
AC Input Line Frequency 50-60 Hz
Power Dissipation 12
Chapter 1 Overview ▫ 2 DMC-42x0 User Manual
Figure 1.1: Layout of a complete DMC-42x0 part number

Mechanical Specifications
Description Specification
eight 5.2 lb
Length 12.25 in.
idth 5.49 in.
Height 2.37 in.
Environmental Specifications
Description Specification
Storage Temperature -25° to +70 ° C
Operating Temperature 0° to +70 ° C
Operating Altitude 10,000 feet
Equipment Maintenance
The DMC-42x0 does not require maintenance.
Overview of Motor Types
The DMC-42x0 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 and ceramic motors - For more information, contact Galil.
The user can configure each axis for any combination of motor types, providing maximum flexibility.
Stan ar Servo Motor with ±10 Volt Comman Signal
The DMC-42x0 achieves superior precision through use of a 16-Bit motor command output DAC and a sophisticated
PID filter that features velocity and acceleration feed-forward, an extra pole filter and integration limits.
The controller is configured by the factory for standard servo motor operation. In this configuration, the controller
provides an analog signal (±10 volts) to connect to a servo amplifier. This connection is described in Chapter 2.
Brushless Servo Motor with Sinusoi al Commutation
The DMC-42x0 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.
Chapter 1 Overview ▫ 3 DMC-42x0 User Manual

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 with a standard update rate of 1
millisecond. For faster motors, please contact the factory.
To simplify the wiring, the controller provides a one-time, automatic set-up procedure. hen the controller has
been properly configured, the brushless motor parameters may be saved in non-volatile memory.
The DMC-42x0 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 brushless motor parameters may be saved in non-volatile
memory. In this case, the controller will automatically 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.
Stepper Motor with Step an Direction Signals
The DMC-42x0 can control stepper motors. In this mode, the controller provides two signals to connect
to the stepper motor: Step and Direction. For stepper motor operation, the controller does not require
an encoder and operates the stepper motor in an open loop fashion. Chapter 2 describes the proper
connection and procedure for using stepper motors.
If encoders are available on the stepper motor, Galil’s Stepper Position Maintenance Mode may be used
for automatic monitoring and correction of the stepper position. See Stepper Position Maintenance
Mode (SPM) in Chapter 6 for more information.
Overview of External Amplifiers
The amplifiers should be suitable for the motor and may be linear or pulse-width-modulated. An amplifier may
have current feedback, voltage feedback or velocity feedback.
Amplifiers in Current Mo e
Amplifiers in current mode should accept an analog command signal in the ±10 volt range. The amplifier gain
should be set such that a +10V command will generate the maximum required current. For example, if the motor
peak current is 10A, the amplifier gain should be 1 A/V.
Amplifiers in Velocity Mo e
For velocity mode amplifiers, a command signal of 10 volts should run the motor at the maximum required speed.
The velocity gain should be set such that an input signal of 10V runs the motor at the maximum required speed.
Stepper Motor Amplifiers
For step motors, the amplifiers should accept step and direction signals.
Chapter 1 Overview ▫ 4 DMC-42x0 User Manual

Functional Elements
The DMC-42x0 circuitry can be divided into the following functional groups as shown in Figure 1.2 and discussed
below.
Figure 1.2: DMC-42x0 Functional Element
Microcomputer Section
The main processing unit of the controller is a specialized Microcomputer with RAM and Flash EEPROM. The RAM
provides memory for variables, array elements, and application programs. The flash EEPROM provides non-volatile
storage of variables, programs, and arrays. The Flash also contains the firmware of the controller, which is field
upgradeable.
Motor Interface
Galil’s GL-1800 custom, sub-micron gate array performs quadrature decoding of each encoder at up to 22 MHz. For
standard servo operation, the controller generates a ±10 volt analog signal (16-bit DAC). For sinusoidal
commutation operation, the controller uses two DACs to generate two ±10 volt analog signals. For stepper motor
operation, the controller generates a step and direction signal.
Communication
The communication interface with the DMC-42x0 consists of high speed RS-232 and Ethernet. The Ethernet is
10/100Bt and the two RS-232 channels can generate up to 115K.
Chapter 1 Overview ▫ 5 DMC-42x0 User Manual
WATCHDOG TIMER
RISC BASED
MICROCOMPUTER
HIGH-SPEED
MOTOR/ENCODER
INTERFACE
FOR
A,B,C,D
I/O INTERFACE
ETHERNET
RS-232 /
RS-422
8 UNCOMMITTED
ANALOG INPUTS
HIGH-SPEED LATCH FOR EACH AXIS
ISOLATED LIMITS AND
HOME INPUTS
MAIN ENCODERS
AUXILIARY ENCODERS
+/- 1 VOLT OUTPUT FOR
SERVO MOTORS
PULSE/DIRECTION OUTPUT
FOR STEP MOTORS
HIGH SPEED ENCODER
COMPARE OUTPUT
8 PROGRAMMABLE,
OPTOISOLATED
INPUTS
8 PROGRAMMABLE
HIGH POWER OPTOISOLATED
OUTPUTS
32 Configurable I/O

General I/O
The DMC-42x0 provides interface circuitry for 8 bi-directional, optoisolated inputs, 8 high power optoisolated
outputs and 8 analog inputs with 12-Bit ADC (16-Bit optional). The DMC-42x0 also has an additional 32 I/O (3.3V
logic) and unused auxiliary encoder inputs may also be used as additional inputs (2 inputs / each axis). The general
inputs as well as the index pulse can also be used as high speed latches for each axis. A high speed encoder
compare output is also provided.
4280
The DMC-4250 through DMC-4280 controller provides an additional 8 optoisolated inputs and 8 high
power optoisolated outputs.
System Elements
As shown in Figure 1.3, the DMC-42x0 is part of a motion control system which includes amplifiers, motors and
encoders. These elements are described below.
Figure 1.3: Element of Servo y tem
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 MotorSizer eb tool can help you with motor
sizing: www.galilmc.com/support/motorsizer)
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.
Other motors and devices such as Ultrasonic Ceramic motors and voice coils can be controlled with the DMC-42x0.
Chapter 1 Overview ▫ 6 DMC-42x0 User Manual
Computer DMC-42x0 Controller Amplifier (Driver)
Power Supply
Encoder Motor

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 (P M) 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.
Galil offers amplifiers that are integrated into the same enclosure as the DMC-42x0. See the section in the
Appendices or http://galilmc.com/products/accelera/dmc42x0.html for more information.
Enco er
An encoder translates motion into electrical pulses which are fed back into the controller. The DMC-42x0 accepts
feedback from either a rotary or linear encoder. Typical encoders provide two channels in quadrature, known as
MA and MB. This type of encoder is known as a quadrature encoder. Quadrature encoders may be either single-
ended (MA+ and MB+) or differential (MA+, MA-, MB+, and MB-). The DMC-42x0 decodes either type into
quadrature states or four times the number of cycles. Encoders may also have a third channel (or index) for
synchronization.
The DMC-42x0 can be ordered with 120 Ω termination resistors installed on the encoder inputs. See the Ordering
Options in the Appendix for more information.
The DMC-42x0 can also interface to encoders with pulse and direction signals. Refer to the “CE” command in the
command reference for details.
There is no limit on encoder line density; however, the input frequency to the controller must not exceed 5,500,000
full encoder cycles/second (22,000,000 quadrature counts/sec). For example, if the encoder line density is 10,000
cycles per inch, the maximum speed is 300 inches/second. If higher encoder frequency is required, please consult
the factory.
The standard encoder voltage level is TTL (0-5v), however, voltage levels up to 12 Volts are acceptable. (If using
differential signals, 12 Volts can be input directly to the DMC-42x0. Single-ended 12 Volt signals require a bias
voltage input to the complementary inputs).
The DMC-42x0 can accept analog feedback (±10v) instead of an encoder for any axis. For more information see the
command AF in the command reference.
To interface with other types of position sensors such as 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-42x0 provides an internal watch dog timer which checks for proper microprocessor operation. The timer
toggles the Amplifier Enable Output (AMPEN) which can be used to switch the amplifiers off in the event of a
serious DMC-42x0 failure. The AMPEN output is normally high. During power-up and if the microprocessor ceases
to function properly, the AMPEN output will go low. The error light will also turn on at this stage. A reset is
required to restore the DMC-42x0 to normal operation. Consult the factory for a Return Materials Authorization
(RMA) Number if your DMC-42x0 is damaged.
Chapter 1 Overview ▫ 7 DMC-42x0 User Manual

Chapter 2 Getting Starte
Layout
DMC-42x0
Figure 2.1: Outline of the of the DMC-4280 1-8 axe model
Chapter 2 Getting Started ▫ 8 DMC-42x0 User Manual

Dimensions
DMC-4240
Figure 2.3: Dimen ion (in inche ) of the DMC-42x0 (Where x= 1-8 )
Chapter 2 Getting Started ▫ 9 DMC-42x0 User Manual

Elements You Nee
For a complete system, Galil recommends the following elements:
1. DMC-42x0, motion controller where the x designates number of axis, 1-8.
2. Interconnect.
3. a. (1) ICM-2900 and (1) CABLE-100 for a 1-4 axis DMC-42x0.
b. (2) ICM-2900s and (2) CABLE-100s for a 5-8 axis DMC-42x0.
c. An interconnect board provided by the user.
4. Motor Amplifiers.
5. Power Supply for Motor Amplifiers.
6. AC Power source for DMC-42x0 controller.
7. Brush or Brushless Servo motors with Optical Encoders or stepper motors.
a. Cables for connecting to the DMC-42x0.
8. PC (Personal Computer - RS232 or Ethernet for DMC-42x0)
9. GalilSuite or GalilSuite Lite (Free) software package.
GalilSuite is highly recommended for first time users of the DMC-42x0. It provides step-by-step instructions for
system connection, tuning, and analysis.
Figure 2.4: Recommended Sy tem Element of DMC-42x0
Chapter 2 Getting Started ▫ 10 DMC-42x0 User Manual

Installing the DMC, Amplifiers, an Motors
Installation of a complete, operational motion control system consists of the following steps:
Step 1. Determine Overall System Configuration, pg 11
Step 2. Install Jumpers, pg 12
Step 3. Configure Dip Switches ,pg 12
Step 4. Install the Communications Software, pg 13
Step 5. Connect AC Power to the Controller, pg 13
Step 6. Establish Communications with Galil Software, pg 13
Step 7. Connecting Encoder Feedback, pg 13 Optional for tepper
Step 8. Setting Safety Features before iring Motors, pg 15 Servo motor only
Step 9. iring Motors to Galil's AMP-19540., pg 17 Galil amplifier only
Step 9a. Commutation of 3-phased Brushless Motors, pg 18 Bru hle motor only
Step 10. Connecting External Amplifiers and Motors, pg 21 External amplifier only
Step 11. Tune the Servo System, pg 23 Servo motor only
WARNING
Electronics are dangerous!
Only a certified electrical technician, electrical engineer, or electrical professional should wire
the DMC product and related components. Galil shall not be liable or responsible for any
incidental or consequential damages.
All wiring procedures and suggestions mentioned in the following sections should be done
with the controller in a powered-off state. Failing to do so can cause harm to the user or to
the controller.
NOTE
The following instructions are given for Galil products only. If wiring an non-Galil device,
follow the instructions provided with that product. Galil shall not be liable or responsible for
any incidental or consequential damages that occur to a 3rd party device.
Step 1. Determine Overall System Configuration
Before setting up the motion control system, the user must determine the desired motor configuration. The DMC-
42x0 can control any combination of brushless motors, brushed motors, and stepper motors. Galil has amplifier
options that can drive motors directly but can also control external amplifiers using either a ±10V motor command
line or P M/Step and direction lines. There are also several feedback options that the DMC can accept.
See Part Numbers , pg 2 for understanding your complete DMC unit and part number before continuing.
Chapter 2 Getting Started ▫ 11 DMC-42x0 User Manual

Step 2. Install Jumpers
Master Reset an Upgra e Jumpers
Jumpers labeled MRST and UPGD are the Master Reset and Upgrade jumpers, respectively.
JP1 on the main board contains two jumpers, MRST and UPGRD. The MRST jumper is the Master Reset jumper.
hen MRST is connected, the controller will perform a master reset upon PC power up or upon the reset input
going low. The MRST can also be set with the DIP switches on the outside of the controller. henever the
controller has a master reset, all programs, arrays, variables, and motion control parameters stored in EEPROMwill
be ERASED.
The UPGD jumper enables the user to unconditionally update the controller’s firmware. This jumper should not be
used without first consulting Galil.
Step 3. Configure Dip Switches
Located on the outside of the controller box is a set of 8 DIP switches. hent eh controller is powered on or reset,
the state of the DIP switches are read.
Switch 1 – Master Reset
hen this switch is on, the controller will perform a master reset upon PC power up. henever the controller has
a master reset, all programs and motion control parameters stored in EEPROM will be ERASED. During normal
operation, this switch should be off.
Switches 2,3, and 4 are non-functional and reserved
Switches 5 and 6 Main Serial Port Baud Rate
If using the RS232 port for communication, the baud rate is set via switches 5 and 6. To set the baud rate, configure
switches 5 and 6as follows:
Switch 5 -19.2 Switch 6 – 38.4 BAUD RATE
ON OFF 19200
OFF ON 38400
ON ON 115200
Switch – Option
hen OFF, the controller will use the auto-negotiate function to set the Ethernet connection speed. hen the DIP
switch is ON, the controller defaults to 10BaseT.
Switch 8 – Motor Off
It is recommended to use the MO switch when connecting motors for the first time. ith the MO switch ON, the
controller will boot-up in the “motor off” state. In this state the amplifier enable signals are toggled to
“inhibit/disable”. ith this switch OFF
Chapter 2 Getting Started ▫ 12 DMC-42x0 User Manual

Step 4. Install the Communications Software
After applying power to the controller, a PC is used for programming. Galil's development software enables
communication between the controller and the host device. The most recent copy of Galil's development software
can be found here:
http://www.galilmc.com/support/software-downloads.php
Step 5. Connect AC Power to the Controller
WARNING
Dangerous voltages, current, temperatures and energy levels exist in this product and the
associated amplifiers and servo motor(s). Extreme caution should be exercised in the
application of this equipment. Only qualified individuals should attempt to install, set up
and operate this equipment. Never open the controller box when DC power is applied
Before applying power, connect the 100-pin cable between the DMC-42x0 and ICM-2900 interconnect module. The
DMC-42x0 requires a single AC supply voltage, single phase, 50 Hz or 60 Hz. From 90 VAC to 260 VAC.
The green power light indicator should go on when power is applied.
Step 6. Establish Communications with Galil Software
See Ethernet Configuration, pg 39 for details on using Ethernet with the DMC-42x0. To configure your NIC card
using indows to connect to a DMC controller, see this two-minute video:
http://www.galilmc.com/learning/two-minute-display.php?video=connecting-to-ethernet-controller
For connecting using serial, see RS-232 Configuration, pg 37 for proper configuration of the Main DMC-42x0 serial
port.
See the GalilSuite manual for using the software to communicate:
http://www.galilmc.com/support/manuals/galilsuite/index.html
Step 7. Connecting Enco er Fee back
4280
DMC-42x0 controllers with more than 4 axes require a second ICM-2900 and 100-pin cable.
The motion control system typically consists of an ICM-2900 Interface Module, an amplifier for each axis of motion,
and a motor to transform the current from the amplifier into torque for motion.
If you are using an ICM-2900, connect it to the DMC-42x0 via the 100-pin high density cable. The ICM-2900
provides screw terminals for access to the connections described in the following discussion.
System connection procedures will depend on system components and motor types. Any combination of motor
types can be used with the DMC-42x0. If sinusoidal commutation is to be used, special attention must be paid to
the reconfiguration of axes.
The type of feedback the unit is capable of depends on the additional options ordered. Table 2.1 shows the
different Encoder feedback types available for the DMC-42x0 including additional options are required. Note that
each feedback type has a different configuration command. See the Command Reference for full details on how to
properly configure each axis.
Chapter 2 Getting Started ▫ 13 DMC-42x0 User Manual

Different feedback types can be used on the same controller. For instance, one axis could be using Standard
quadrature and the next could be using SSI. By default, all axis are configured for Standard quadrature.
Fee back Type Configuration
Comman Connection Location
Standard quadrature CE Standard on all units Encoder
Step/Dir CE Standard on all units Encoder
Analog1AF Standard on all units
(12-bit Standard. 16-bit optional) Analog
SSI SI Requires the SSI Option, see page(172) Encoder
BiSS SS Requires the BiSS Option, see page(172) Encoder
None2– – --
Other Contact Galil at 1.800.377.6329
Table 2.1: Configuration command , ICM/Part number required for a given feedback type
1 All wiring/electrical information regarding using analog inputs can be found in the Analog Inputs, pg 33.
2 Although stepper systems do not require feedback, Galil supports a feedback sensor on each stepper axis. Servo motors require a
position sensor.
A note about using enco ers an steppers:
hen a stepper is used, the auxiliary encoder for the corresponding axis is unavailable for an external
connection. If an encoder is used for position feedback, connect the encoder to the main encoder input
corresponding to that axis. The commanded position of the stepper can be interrogated with TD and the
encoder position can be interrogated with TP.
The following steps provide a general guide for connecting encoders to the DMC unit:
Step A. ire the encoder
The pinouts for the DMC-42x0 Main Board connectors can be found in the Appendix:
Connectors for DMC-42x0 Main Board
The pin-outs and electrical information for SSI and BiSS options can be found here:
DMC-42x0 (BiSS or SSI Option) Pinout, pg. 172.
The encoder pin-outs for Galil Interconnect Modules are listed below.
ICM-2900
A1. ICM-2900 Interconnect Module
ICM-1900
A3. ICM-1900 Interconnect Module
For AMP-19520/40 encoder connections, please refer to the amplifier's User Manual:
http://galilmc.com/download/manual/man_195x .pdf
Step B. Issue the appropriate configuration commands
Find the appropriate configuration commands for your feedback type as shown in Table 2.1, pg 14.
Step C. Verify proper encoder operation
1. Ensure the motor is off my issuing an MO.
2. Check the current position by issuing TP, the value reported back is in the units of counts.
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3. Move the motor by hand and re-issue TP. The returned value should have been incremented or
decremented from the first TP. If there is no change, check the encoder wiring and settings and
retest starting at Step 1.
4. Using the encoder specification sheet, translate a physical distance of the motor into counts read
by the controller. For example, a 2000 line encoder means that the controller reads 2000*4=
8000 counts/revolution and a half turn of the motor would be 4000 counts.
5. Issue TP to determine the current motor position, record this value.
6. Move the motor by hand some measured physical distance.
7. Query TP again. Take the absolute difference from the current TP and the TP recorded from
Step 5.
8. Determine if the physical distance moved is equal to the expected amount of counts calculated in
Step 4, move on to Step 9. Otherwise, check the encoder wiring and settings and retest starting
at Step 1.
9. Perform Step 5-8 again, instead moving a physical distance in the opposite direction. If the
physical distance correctly translates to the expected amount of counts, the encoder is wired
correctly.
Step D. Reverse encoder direction, if necessary
Table 2.2 below provides instructions for how to reverse the direction of feedback by rewiring the encoder to the
DMC controller. The direction of standard, quadrature encoders can be be reversed using the CE command.
NOTE Reversing direction of the feedback may cause a servo motor to runaway, see Step 8. Setting
Safety Features before iring Motors, pg 15 regarding Runaway Motors.
Fee back Type Directions
Standard Quadrature
Differential Swap channels A+ and A-
Single-ended Swap channels A+ and B+
SSI or BiSS Follow encoder manufacturer's instructions.
Analog feedback Cannot change the direction of feedback without external hardware to invert
analog signal.1
Table 2.2: Direction for rever ing feedback direction ba ed upon feedback type
1 The polarity of the control loop may still be inverted by either re-wiring the motor or using the MT command, see Step 8.
Setting Safety Features before iring Motors, pg 15 regarding positive feedback loops.
Step 8. Setting Safety Features before Wiring Motors
Thi ection applie to ervo motor only.
Step A. Set Torque Limit
TL will limit the output voltage of the ±10V motor command line. This output voltage is either translated into
torque or velocity by the amplifier (Galil's internal amplifiers are in torque mode). This command should be used to
avoid excessive torque or speed when initially setting up a servo system. The user is responsible for determining
the relationship between the motor command line and the amplifier torque/velocity using the documentation of
the motor and/or amplifier.
See the TL setting in the Command Reference for more details.
See the AG command in the command reference for current gains of Galil's internal amplifiers. The amplifier gain
can also be used to change the ratio of outputting amps of the amplifier per commanded volts of the controller.
Chapter 2 Getting Started ▫ 15 DMC-42x0 User Manual

This is another way to limit the amount of current but can also maintain the resolution of the ±10V motor
command line.
Step B. Set the Error Limit
hen ER (error limit) and OE (off-on-error) is set, the controller will automatically shut down the motors when
excess error (|TE| > ER) has occurred. This is an important safety feature during set up as wrong polarity can cause
the motor to run away, see Step C below for more information regarding runaway motors.
NOTE: Off-on-error (OE) requires the amplifier enable signal to be connected from the controller to the amplifier.
This is automatic when using Galil's internal amplifiers, see Step 10. Connecting External Amplifiers and Motors, pg
21 for external amplifiers
Step C. Understanding and Correcting for Runaway Motors
A runaway motor is a condition for which the motor is rotating uncontrollably near it's maximum speed in a single
direction. This is often caused by one of two conditions:
1. The amplifier enable signal is the incorrect logic required by the amplifier
This is only applicable to external amplifiers only.
If the motor is in a MO state when the motor runs away, the MO command is toggling your amplifier
“on/enabled” and needs to be reconfigured. The motor is running away because the controller is registering
the axis is in an “inactive” and is not attempting to control it's movement. See Step 10. Connecting External
Amplifiers and Motors, pg 21 for configuring the amplifier enable signal.
2. The motor and encoder are in opposite polarity causing a positive feedback loop
Reversed polarity is when a positive voltage on the motor command line results in negative movement of the
motor. This will result in a po itive feedback loop and a runaway motor.
The following steps can be taken to detect reverse polarity, the A-axis is used as an example:
1. After connecting your servo motor using either Step 9. iring Motors to Galil's AMP-19540., pg 17 or
Step 10. Connecting External Amplifiers and Motors, pg 21 issue the following commands:
MO A
KIA= 0
KPA= 0
KDA= 0
SH A
2. Check your current position by issuing TP A.
3. Set a small, positive voltage on your motor command line using the OF command; use a high enough
voltage to get the motor to move. This will cause a runaway-like condition so have an appropriate OE
set, see Step B. Example:
OFA= 0.5
4. If the motor has not been disabled by OE, disable it by issuing MO A.
5. Check the position again by using TP A.
6. If TP has increased, than the motor command line and encoder are in correct polarity. If TP has
decreased than the motor command line is in opposite polarity with the encoder.
If the system has reverse polarity, take the following steps to correct for it:
Brushe Motor
Choose one of the following:
1. Reverse the direction of the motor leads by swapping phase A and phase B
Chapter 2 Getting Started ▫ 16 DMC-42x0 User Manual