Galil Motion Control DMC-500 Series User manual

USER MANUAL
DMC-500x0
Manual Rev. 1.0d
Galil Motion Control, Inc.
270 Technolog Wa
Rocklin, California
916.626.0101
[e-mail]
galil.com
01/2015

Using This Manual
This user manual provides information for proper operation of the DMC-500x0 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 Website.
http://www.galil.com/downloads/manuals-and-data-sheets
Your DMC-500x0 motion controller has been designed to work with both servo and stepper t pe motors.
Installation and s stem setup will var 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 an information
that applies exclusivel to one t pe of s stem. Otherwise, assume that the instructions appl to all t pes of
s stems. The icon legend is shown below.
Attention: Pertains to servo motor use.
Attention: Pertains to stepper motor use.
Please note that man examples are written for the DMC-50040 four-axes controller or the DMC-50080 eight axes
controller. Users of the DMC-50030 3-axis controller, DMC-50020 2-axes controller or DMC-50010 1-axis controller
should note that the DMC-50030 uses the axes denoted as ABC, the DMC-50020 uses the axes denoted as AB, and
the DMC-50010 uses the A-axis onl .
Examples for the DMC-50080 denote the axes as A,B,C,D,E,F,G,H. Users of the DMC-50050 5-axes controller. DMC-
50060 6-axes controller or DMC-50070, 7-axes controller should note that the DMC-50050 denotes the axes as
A,B,C,D,E, the DMC-50060 denotes the axes as A,B,C,D,E,F and the DMC-50070 denotes the axes as A,B,C,D,E,F,G.
The axes A,B,C,D ma be used interchangeabl with X, Y, Z, W.
WARNING
Machiner in motion can be dangerous!
It is the responsibilit of the user to design effective error handling and safet protection as
part of the machiner . Galil shall not be liable or responsible for an incidental or
consequential damages
DMC-500x0 Contents ▫ i

Contents
Contents iii
Chapter 1 Overview 1
Introduction ................................................................................................................... 1
Part Numbers ................................................................................................................ 2
Overview of Motor Types ............................................................................................. 5
Overview of xternal Amplifiers .................................................................................. 6
Galil Internal Amplifiers and Drivers ........................................................................... 7
Functional lements ...................................................................................................... 8
Chapter 2 Getting Started 11
Layout ........................................................................................................................... 11
Power Connections ....................................................................................................... 12
Dimensions ................................................................................................................... 13
lements You Need ....................................................................................................... 14
Installing the DMC, Amplifiers, and Motors ................................................................ 15
Chapter 3 Connecting Hardware 32
Overview ....................................................................................................................... 32
Overview of Optoisolated Inputs .................................................................................. 32
Optoisolated Input lectrical Information .................................................................... 35
High Power Optoisolated Outputs ................................................................................ 38
TTL Inputs and Outputs ................................................................................................ 39
Analog Inputs ................................................................................................................ 41
xtended I/O ................................................................................................................. 41
xternal Amplifier Interface ......................................................................................... 42
Chapter 4 Software Tools and Communication 49
Introduction ................................................................................................................... 49
Controller Response to Commands .............................................................................. 49
Unsolicited Messages Generated by Controller ............................................................ 50
Serial Communication Ports ......................................................................................... 50
thernet Configuration .................................................................................................. 52
Modbus ......................................................................................................................... 54
Data Record .................................................................................................................. 57
GalilSuite (Windows and Linux) .................................................................................. 61
Creating Custom Software Interfaces ........................................................................... 62
Chapter 5 Command Basics 64
Introduction ................................................................................................................... 64
Command Syntax - ASCII ............................................................................................ 64
Controller Response to DATA ...................................................................................... 65
Interrogating the Controller .......................................................................................... 66
Chapter 6 Programming Motion 68
Overview ....................................................................................................................... 68
Independent Axis Positioning ....................................................................................... 69
Independent Jogging ..................................................................................................... 71
Position Tracking .......................................................................................................... 73
Linear Interpolation Mode ............................................................................................ 76
Vector Mode: Linear and Circular Interpolation Motion .............................................. 80
lectronic Gearing ........................................................................................................ 86
lectronic Cam .............................................................................................................. 89
PVT Mode ..................................................................................................................... 94
Contour Mode ............................................................................................................... 97
DMC-500x0 Contents ▫ ii

Virtual Axis ................................................................................................................... 101
Stepper Motor Operation .............................................................................................. 102
Stepper Position Maintenance Mode (SPM) ................................................................. 104
Dual Loop (Auxiliary ncoder) .................................................................................... 107
Motion Smoothing ....................................................................................................... 109
Homing ......................................................................................................................... 111
High Speed Position Capture (The Latch Function) .................................................... 113
Chapter 7 Application Programming 114
Overview ....................................................................................................................... 114
Program Format ............................................................................................................ 114
xecuting Programs - Multitasking .............................................................................. 116
Debugging Programs .................................................................................................... 117
Program Flow Commands ............................................................................................ 118
Mathematical and Functional xpressions ................................................................... 134
Variables ........................................................................................................................ 136
Operands ....................................................................................................................... 138
Arrays ............................................................................................................................ 138
Input of Data (Numeric and String) .............................................................................. 141
Output of Data (Numeric and String) ........................................................................... 143
Hardware I/O ................................................................................................................ 148
xtended I/O of the DMC-500x0 Controller ............................................................... 151
xample Applications ................................................................................................... 153
Using the DMC ditor to nter Programs .................................................................... 157
Chapter 8 Hardware & Software Protection 159
Introduction ................................................................................................................... 159
Hardware Protection ..................................................................................................... 159
Software Protection ....................................................................................................... 160
Chapter 9 Troubleshooting 164
Overview ....................................................................................................................... 164
Chapter 10 Theory of Operation 167
Overview ....................................................................................................................... 167
Operation of Closed-Loop Systems .............................................................................. 169
System Modeling .......................................................................................................... 170
System Analysis ............................................................................................................ 174
System Design and Compensation ................................................................................ 176
Appendices 179
lectrical Specifications ................................................................................................ 179
Performance Specifications .......................................................................................... 181
Ordering Options .......................................................................................................... 182
Power Connector Part Numbers .................................................................................... 188
Input Current Limitations ............................................................................................. 189
Serial Cable Connections .............................................................................................. 190
Configuring the Amplifier nable Circuit .................................................................... 192
Signal Descriptions ....................................................................................................... 201
List of Other Publications ............................................................................................. 203
Training Seminars ......................................................................................................... 203
Contacting Us ................................................................................................................ 204
WARRANTY ................................................................................................................ 205
Integrated Components 206
Overview ....................................................................................................................... 206
A1 – AMP-430x0 (-D3040,-D3020) 208
Description .................................................................................................................... 208
lectrical Specifications ................................................................................................ 209
Operation ....................................................................................................................... 210
rror Monitoring and Protection ................................................................................... 212
DMC-500x0 Contents ▫ iii

A2 – AMP-43140 (-D3140) 214
Description .................................................................................................................... 214
lectrical Specifications ................................................................................................ 214
Operation ....................................................................................................................... 215
A3 – AMP-43240 (-D3240) 217
Description .................................................................................................................... 217
lectrical Specifications ................................................................................................ 218
Operation ....................................................................................................................... 219
rror Monitoring and Protection ................................................................................... 221
A4 – AMP-435x0 (-D3540,-D3520) 223
Description .................................................................................................................... 223
lectrical Specifications ................................................................................................ 224
Operation ....................................................................................................................... 225
rror Monitoring and Protection ................................................................................... 228
A5 – AMP-43640 (-D3640) 230
Introduction ................................................................................................................... 230
lectrical Specifications ................................................................................................ 231
Operation ....................................................................................................................... 233
A6 – AMP-43740 (-D3740) 236
Description .................................................................................................................... 236
lectrical Specifications ................................................................................................ 237
Operation ....................................................................................................................... 238
rror Monitoring and Protection ................................................................................... 241
A7 – SDM-440x0 (-D4040,-D4020) 242
Description .................................................................................................................... 242
lectrical Specifications ................................................................................................ 243
Operation ....................................................................................................................... 244
A8 – SDM-44140 (-D4140) 246
Description .................................................................................................................... 246
lectrical Specifications ................................................................................................ 247
Operation ....................................................................................................................... 248
rror Monitoring and Protection ................................................................................... 249
A9 – CMB-41023 (-C023) 250
Description .................................................................................................................... 250
Connectors for CMB-41023 Interconnect Board ......................................................... 251
A10 – ICM-42000 (-I000) 255
Description .................................................................................................................... 255
Connectors for ICM-42000 Interconnect Board ........................................................... 256
A11 – ICM-42200 (-I200) 258
Description .................................................................................................................... 258
Connectors for ICM-42200 Interconnect Board ........................................................... 259
DMC-500x0 Contents ▫ iv

Chapter 1 Overview
Intro uction
The DMC-500x0 Series are Galil’s highest performance stand-alone controller with EtherCAT Master capabilit . The
EtherCAT Master operates in c clic s nchronous torque or c clic s nchronous position mode and is configurable for
up to 8 axes of EtherCAT slaves. The controller series offers man enhanced features including high speed
communications, non-volatile program memor , faster encoder speeds, and improved cabling for EMI reduction.
Each DMC-500x0 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.
A Flash EEPROM provides non-volatile memor for storing application programs, parameters, arra s and firmware.
New firmware revisions are easil upgraded in the field.
The DMC-500x0 is available with up to eight control axes in a single stand alone unit. The DMC-50010, 50020,
50030, 50040 are one thru four axis controllers, and the DMC-50050, 50060, 50070, 50080 are five thru eight axis
controllers. The DMC-500x0 allows for an combination of local and EtherCAT axes, with a maximum of four local
axes. The Four local axes have the abilit to use Galil’s integrated amplifiers or drivers and connections for
integrating external devices.
Designed to solve complex motion problems, the DMC-500x0 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 b programmable acceleration and deceleration with profile smoothing. For smooth
following of complex contours, the DMC-500x0 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 gantr mode
operation.
For s nchronization with outside events, the DMC-500x0 provides uncommitted I/O, including 8 optoisolated digital
inputs, 8 high power opticall isolated outputs, and 8 analog inputs for interface to jo sticks, sensors, and pressure
transducers. The DMC-500x0 also has an additional 32 I/O at 3.3V logic. Further I/O is available if the auxiliar
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, trajector viewing on a PC
screen, and program development using man environments such as Visual Basic, C, C++ etc. Drivers for Windows
XP, Vista and 7 (32 & 64 bit) as well as Linux are available.
Chapter 1 Overview ▫ 1 DMC-500x0 User Manual

Part Numbers
The DMC-500x0 is modular b nature, meaning that a customer must specif several components in order to create
a full part number. The user must specif the main control board (DMC), the communication board (CMB), and the
interconnect module (ICM) to have a complete unit. The user can also specif an optional internal amplifier (AMP
or SDM). How these models stack up internall is shown in Figure 1.1.
Each module has it's own set of part numbers and configuration options that make the full part number of a DMC-
500x0 unit. The DMC has the part number format “DMC-500x0(Y),” the CMB is “-CXXX(Y),” the ICM is “-IXXX(Y),”
and the AMP/SDM is “-DXXX(Y),” where X designates different module options and Y designates different
configuration options for these modules. The full DMC-500x0 part number would be the full string of individual
module part numbers combined as shown in Figure 1.2.
DMC-500x0 User Manual Chapter 1 Overview ▫ 2
Figure 1.1: Abstract internal layout of the DMC-500x0

Reading left to right each of the controller's components, CMB, ICM, and AMP/SDM have a designated space in the
part number.
If the part number is not readil available, ou can determine the information b using the 'ID' command. Issuing
an 'ID' command when connected to the controller will return our controller's internal hardware configuration.
WARNING
The CMB an ICM mo ule options effect the pin-outs of the DMC-500x0.
Use Table 1.2 and Table 1.3 below to determine our CMB and ICM part numbers then refer to the
appropriate documentation for our pin-outs before connecting an hardware.
DMC, “DMC-500x0(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 DIN DIN Rail Mount DMC, “DMC-500x0(Y)” Controller Board
Options, starting on pg 182.
12V Power Controller with 12 VDC
-16bit 16-bit analog inputs
4-20mA 4-20mA analog inputs
ISCNTL Isolate Controller Power
TRES Encoder terminating resistors
ETL ETL certification
MO Motor off jumper installed
Table 1.1: Controller board DMC “DMC-500x0(Y)” options
Chapter 1 Overview ▫ 3 DMC-500x0 User Manual
Figure 1.2: Layout of a complete DMC-500x0 part number

CMB, “-CXXX(Y)” Options
Option Type Options Brief Description Documentation
XXX 023 Dual-Ethernet communication board A9 – CMB-41023 (-C023), pg 250
Y 5V Configures extended I/O for 5V logic 5V – Configure Extended I/O for 5V logic, pg
184
P422 RS-422 on Main and Aux serial port RS-422 – Serial Port Serial Communication, pg
184
P1422 RS-422 on Main serial port onl
P2422 RS-422 on Aux serial port onl
Table 1.2: Communication board CMB “-CXXX(Y)” options
ICM, “-IXXX(Y)” Options
Option Type Options Brief Description Documentation
XXX 000 Default interconnect board A10 – ICM-42000 (-I000), pg 255
200 26-pin encoder connecter interconnect board A11 – ICM-42200 (-I200),pg 258
Y DIFF Differential ±10 motor command outputs ICM, “-IXXX(Y)” Interconnect Board Options,
starting on pg 185
STEP Differential STEP/DIR outputs
Table 1.3: Interconnect module ICM “-IXXX(Y)” options
AMP/SDM, “-DXXXX(Y)” Options
Option Type Options Brief Description Documentation
XXXX 3020/3040 500 W trapazoidal servo drive
2 and 4-axis models A1 – AMP-430x0 (-D3040,-D3020), pg 208
3140 20 W brush-t pe onl drive A2 – AMP-43140 (-D3140), pg 214
3240 750 W trapazoidal servo drive A3 – AMP-43240 (-D3240), pg 217
3520/3540 600 W sinusoidal servo drive
2 and 4-axis models A4 – AMP-435x0 (-D3540,-D3520), pg 223
3640 20 W sinusoidal servo drive A5 – AMP-43640 (-D3640), pg 230
4040/4020 1.4 A with 1/16 microstepping drive A7 – SDM-440x0 (-D4040,-D4020), pg 242
4140 3 A with 1/64 microstepping drive A8 – SDM-44140 (-D4140), pg 246
Y 100mA 100mA current
-D3140 option onl
AMP/SDM, “-DXXXX(Y)” Internal Amplifier Options,
starting on pg 187
1 Not available for all amplifier options see the
proper documentation.
SSR Solid state rela 1
HALLF Filtered hall sensors1
Table 1.4: Amplifier options AMP/SDM “-DXXXX(Y)”
DMC-500x0 User Manual Chapter 1 Overview ▫ 4

Overview of Motor Types
The DMC-500x0 can provide the following t pes 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 h draulics and ceramic motors - For more information, contact Galil.
5. C clic S nchronous Torque
6. C clic S nchronous Position
The user can configure each axis for an combination of motor t pes, providing maximum flexibilit .
Stan ar Servo Motor with ±10 Volt Comman Signal
The DMC-500x0 achieves superior precision through use of a 16-Bit motor command output DAC and a
sophisticated PID filter that features velocit and acceleration feed-forward, an extra pole filter and integration
limits.
The controller is configured b the factor 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-500x0 can provide sinusoidal commutation for brushless motors (BLM). In this configuration, the
controller generates two sinusoidal signals for connection with amplifiers specificall designed for this purpose.
Note: The task of generating sinusoidal commutation ma be accomplished in the brushless motor amplifier. If the
amplifier generates the sinusoidal commutation signals, onl 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 rotar BLMs. However, the motor velocit
should be limited such that a magnetic c cle lasts at least 6 milliseconds with a standard update rate of 1
millisecond. For faster motors, please contact the factor .
To simplif the wiring, the controller provides a one-time, automatic set-up procedure. When the controller has
been properl configured, the brushless motor parameters ma be saved in non-volatile memor .
The DMC-500x0 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 ma be saved in non-volatile
memor . In this case, the controller will automaticall estimate the commutation phase upon reset. This allows
the motor to function immediatel 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.
Chapter 1 Overview ▫ 5 DMC-500x0 User Manual

Stepper Motor with Step an Direction Signals
The DMC-500x0 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 ma be used for
automatic monitoring and correction of the stepper position. See Stepper Position Maintenance Mode (SPM) in
Chapter 6 for more information.
Cyclic Synchronous Torque
For this motor t pe the DMC-500x0 closes the position loop, and outputs a commanded torque value to a
connected EtherCAT drive.
Cyclic Synchronous Position
For this motor t pe a connected EtherCAT drive closes the position loop. The DMC-500x0 outputs a commanded
position based on its internall generated motion profile.
Overview of External Amplifiers
The amplifiers should be suitable for the motor and ma be linear or pulse-width-modulated. An amplifier ma
have current feedback, voltage feedback or velocit 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 velocit mode amplifiers, a command signal of 10 volts should run the motor at the maximum required speed.
The velocit 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
EtherCAT Amplifiers
Supported EtherCAT amplifiers should support either C clic S nchronous Torque or C clic S nchronous Position
modes of operation. The amplifiers should accept either a commanded torque or a commanded position value
from the DMC-500x0.
DMC-500x0 User Manual Chapter 1 Overview ▫ 6

Galil Internal Amplifiers an Drivers
With the DMC-500x0 Galil offers a variet of Servo Amplifiers and Stepper Drivers that are integrated into the same
enclosure as the controller. Using the Galil Amplifiers and Drivers provides a simple straightforward motion control
solution in one box. Instead of having to route a +/-10V motor command signal, or STEP/DIR to some external box,
all the wiring is taken care of internall . In addition, Galil's internal amplifiers reside inside the same box as the
controller, ICM, and communication board (see Part Numbers, pg 2) saving real estate space and the hassle of
configuring a separate device.
A full list of amplifier specifications and details can be found in the Integrated Components, starting on pg 206.
Chapter 1 Overview ▫ 7 DMC-500x0 User Manual

Functional Elements
The DMC-500x0 circuitr can be divided into the following functional groups as shown in Figure 1.3 and discussed
below.
Figure 1.3: DMC-500x0 Functional Elements
Microcomputer Section
The main processing unit of the controller is a specialized Microcomputer with RAM and Flash EEPROM. The RAM
provides memor for variables, arra elements, and application programs. The flash EEPROM provides non-volatile
storage of variables, programs, and arra s. The Flash also contains the firmware of the controller, which is field
upgradeable.
Motor Interface
Galil’s GL-1800 custom, sub-micron gate arra 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-500x0 consists of high speed RS-232 and Ethernet. The Ethernet is
10/100Bt and the two RS-232 channels can generate up to 115K, see A9 – CMB-41023 (-C023), pg 250 for details.
General I/O
The DMC-500x0 provides interface circuitr for 8 bi-directional, optoisolated inputs, 8 high power optoisolated
outputs and 8 analog inputs with 12-Bit ADC (16-Bit optional). The DMC-500x0 also has an additional 32 I/O (3.3V
logic) and unused auxiliar encoder inputs ma also be used as additional inputs (2 inputs / each axis). The general
DMC-500x0 User Manual Chapter 1 Overview ▫ 8
WATCHDOG TIM R
RISC BAS D
MICROCOMPUT R
HIGH-SP D
MOTOR/ NCOD R
INT RFAC
FOR
A,B,C,D
I/O INT RFAC
TH RN T
RS-232 /
RS-422
8 UNCOMMITT D
ANALOG INPUTS
HIGH-SP D LATCH FOR ACH AXIS
ISOLAT D LIMITS AND
HOM INPUTS
MAIN NCOD RS
AUXILIARY NCOD RS
+/- 10 VOLT OUTPUT FOR
S RVO MOTORS
PULS /DIR CTION OUTPUT
FOR ST P MOTORS
HIGH SP D NCOD R
COMPAR OUTPUT
8 PROGRAMMABL ,
OPTOISOLAT D
INPUTS
8 PROGRAMMABL
HIGH POW R OPTOISOLAT D
OUTPUTS
32 Configurable I/O

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.
System Elements
As shown in Figure 1.4, the DMC-500x0 is part of a motion control s stem which includes amplifiers, motors and
encoders. These elements are described below.
Figure 1.4: Elements of Servo systems
Motor
A motor converts current into torque which produces motion. Each axis of motion requires a motor sized properl
to move the load at the required speed and acceleration. (Galil’s MotorSizer Web tool can help ou with motor
sizing: http://www.galil.com/learn/motorsizer)
The motor ma be a step or servo motor and can be brush-t pe or brushless, rotar 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-
500x0.
Conventional 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
properl 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
ma be either pulse-width-modulated (PWM) or linear. The ma 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
velocit 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-500x0. See the Integrated section in
the Appendices or http://www.galil.com/motion-controllers/multi-axis/dmc-500x0 for more information.
Chapter 1 Overview ▫ 9 DMC-500x0 User Manual
Computer DMC-500x0 Controller Amplifier (Driver)
Power Supply
Encoder Motor

EtherCAT Amplifier (Driver)
An EtherCAT amplifier supports the EtherCAT digital communication bus. This allows an EtherCAT master device to
control the amplifier in different modes of operation. Each manufacturer's EtherCAT drive has different features
and capabilities. Refer to the manufacturer's documentation to see which motors, position feedback options and
modes of operation are supported. The DMC-500x0 supports the C clic S nchronous Position and C clic
S nchronous Torque modes1 of operation for EtherCAT amplifiers. When operating in these respective modes the
DMC-500x0 will function as the EtherCAT master and provide either a commanded position or commanded torque
value to the EtherCAT drive. To disable a previousl enabled EtherCAT axis, issue an MTm=0 for axes E-H, and
MTm=1 axes A-D, where m is the axis to be disabled.
1 Supported on select EtherCAT drives.
Enco er
An encoder translates motion into electrical pulses which are fed back into the controller. The DMC-500x0 accepts
feedback from either a rotar or linear encoder. T pical encoders provide two channels in quadrature, known as
MA and MB. This t pe of encoder is known as a quadrature encoder. Quadrature encoders ma be either single-
ended (MA+ and MB+) or differential (MA+, MA-, MB+, and MB-). The DMC-500x0 decodes either t pe into
quadrature states or four times the number of c cles. Encoders ma also have a third channel (or index) for
s nchronization.
The DMC-500x0 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-500x0 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 densit ; however, the input frequenc to the controller must not exceed 5,500,000
full encoder c cles/second (22,000,000 quadrature counts/sec). For example, if the encoder line densit is 10,000
c cles per inch, the maximum speed is 300 inches/second. If higher encoder frequenc is required, please consult
the factor .
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 directl to the DMC-500x0. Single-ended 12 Volt signals require a bias
voltage input to the complementar inputs).
The DMC-500x0 can accept analog feedback (±10v) instead of an encoder for an axis. For more information see
the command AF in the command reference.
To interface with other t pes 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 our particular s stem
requirements.
Watch Dog Timer
The DMC-500x0 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-500x0 failure. The AMPEN output is normall high. During power-up and if the microprocessor
ceases to function properl , the AMPEN output will go low. The error light will also turn on at this stage. A reset is
required to restore the DMC-500x0 to normal operation. Consult the factor for a Return Materials Authorization
(RMA) Number if our DMC-500x0 is damaged.
DMC-500x0 User Manual Chapter 1 Overview ▫ 10

Chapter 2 Getting Starte
Layout
The following la outs assume either an ICM-42000(I000) interconnect module is installed. For la outs of s stems
with ICM-42200’s(I200) installed please contact Galil. Overall dimensions and footprint are identical, the onl
differences are in connector t pe and location.
DMC-500x0
Figure 2.1: Outline of the of the DMC-500x0
Chapter 2 Getting Started ▫ 11 DMC-500x0 User Manual

Power Connections
Figure 2.2: Power Connector locations for the DMC-500x0
Figure 2.3: Power Connector used when controller is ordered without Galil Amplifiers
For more information on powering our controller see Step 4. Power the Controller, pg 16. For more information
regarding connector t pe and part numbers see Power Connector Part Numbers, pg 188. The power specifications
for the controller are provided in Power Requirements, pg 180. and the power specifications for each amplifier are
found under their specific section in the appendix, see Integrated Components, pg 206.
DMC-500x0 User Manual Chapter 2 Getting Started ▫ 12
2-pin Molex controller power connector.
SDM/AMP Power
Axis A-D

Dimensions
DMC-500x0
Figure 2.4: Dimensions (in inches) of DMC-500x0 (where x= 1 2 3 or 4 axis)
Chapter 2 Getting Started ▫ 13 DMC-500x0 User Manual

Elements You Nee
For a complete s stem, Galil recommends the following elements:
1. DMC-500x0, motion controller where the x designates number of axis, 1-8.
2. Motor Amplifiers (Integrated when using Galil amplifiers and drivers)
3. Power Suppl for Amplifiers and controller
4. Brush or Brushless Servo motors with Optical Encoders or stepper motors.
a. Cables for connecting to the DMC-500x0’s integrated ICM’s.
5. PC (Personal Computer - RS232 or Ethernet for DMC-500x0)
6. GalilSuite or GalilSuite Lite (Free) software package
GalilSuite is highl recommended for first time users of the DMC-500x0. It provides step-b -step instructions for
s stem connection, tuning, and anal sis.
DMC-500x0 User Manual Chapter 2 Getting Started ▫ 14

Installing the DMC, Amplifiers, an Motors
Installation of a complete, operational motion control s stem consists of the following steps:
Step 1. Determine Overall S stem Configuration, pg 15
Step 2. Install Jumpers on the DMC-500x0, pg 16
Step 3. Install the Communications Software, pg 16
Step 4. Power the Controller, pg 16
Step 5. Establish Communications with Galil Software, pg 17
Step 6. Connecting Encoder Feedback, pg 17 Optional for steppers
Step 7. Setting Safet Features before Wiring Motors, pg 19 Servo motors only
Step 8. Wiring Motors to Galil's Internal Amps, pg 21 Internal amplifiers only
Step 8a. Commutation of 3-phased Brushless Motors, pg 23 Brushless motors only
Step 9. Connecting External Amplifiers and Motors, pg 28 External amplifiers only
Step 10. Tune the Servo S stem, pg 31 Servo motors only
WARNING
Electronics are dangerous!
Onl 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 an
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 onl . If wiring an non-Galil device,
follow the instructions provided with that product. Galil shall not be liable or responsible for
an incidental or consequential damages that occur to a 3rd part device.
Step 1. Determine Overall System Configuration
Before setting up the motion control s stem, the user must determine the desired motor configuration. The DMC-
500x0 can control an combination of brushless motors, brushed motors, and stepper motors. Galil has several
internal amplifier options that can drive motors directl . The DMC-500x0 can also control external amplifiers using
either a ±10V motor command line, PWM/Step and direction lines, or field bus communications with EtherCAT.
There are also several feedback options that the DMC can accept.
See Part Numbers, pg 2 for understanding our complete DMC unit and part number before continuing.
Chapter 2 Getting Started ▫ 15 DMC-500x0 User Manual