Galil DMC-41x3 User manual

DMC-41x3 Installation Manual-ETL
DMC-41x3 Integrated
Amplifier Installation
Manual
Manual Rev. 1.0a3
By alil Motion Control, Inc.
Galil Motion Control, Inc.
270 Technology Way
Rocklin, California 95765
Phone [phone]
Fax [phone]
E-mail Address [email protected]
URL www.galilmc.com
Rev 02/29/12

Using This Manual
This manual provides information for the wiring, installation, powering-up, and basic communication
to the DMC-41x3 motion controller with the alil internal amplifiers, AMP-435x0 and AMP-432x0.
The following list of part numbers are examples of configurations of the DMC-41x3 motion controller
that are covered in this manual.
DMC-41x3
DMC-41x3-D3220
DMC-41x3-D3240
DMC-41x3-D3520
DMC-41x3-D3540
DMC-41x3-D3240-D3220
DMC-41x3-D3240-D3240
DMC-41x3-D3540-D3520
DMC-41x3-D3540-D3540
DMC-41x3-D3240-D3520
DMC-41x3-D3240-D3540
DMC-41x3-D3540-D3220
DMC-41x3-D3540-D3240
This manual covers the basic installation of the controller and amplifier modules. For full operational
information including specific I/O installation, detailed programming examples and additional internal
driver information, see the DMC-41x3 User Manual.
WARNIN : 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. alil shall
not be liable or responsible for any incidental or consequential damages.
If the DMC-41x3 motion controller and included amplifiers or stepper drivers are not used
in a manner specified by alil Motion Control, the protection provided by the controller,
amplifiers and drivers may be impaired.
Caution:
The DMC-41x3 controller with internal servo amplifiers
contain hot surfaces.

Chapter 1 Overview
Introduction
DMC- 1x3 Motion Controller
The DMC-41x3 Series are alil’s Econo motion controller that is a scaled-down version of the DMC-
40x0 Acclerra series controller. The controller series offers many enhanced features compared to prior
generation Econo series controllers including high speed communications, non-volatile program
memory, faster encoder speeds, and improved cabling for EMI reduction.
Each DMC-41x3 provides two communication channels: a high speed 100BaseT Ethernet connection
and a USB programming port. There is an auxiliary RS-232 port that can be used to communicate to
external devices such as HMI's. The controllers allow for high-speed servo control up to 15 million
encoder counts/sec and step motor control up to 3 million steps per second. Sample rates as low as 62
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-41x3 is available with up to eight axes in a single stand alone unit. The DMC-4113, 4123,
4133, 4143 are one thru four axes controllers and the DMC-4153, 4163, 4173, 4183 are five thru eight
axes controllers. All eight axes have the ability to use alil’s integrated amplifiers or drivers and
connections for integrating external devices.
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 Windows XP, Vista and 7 (32 & 64 bit) as well as Linux are available.
AMP- 3220/ 32 0 Servo Amplifier (-D3220/-D32 0)
The AMP-43240 and AMP-43220 amplifiers reside inside the DMC-41x3 enclosure. The AMP-43240
contains four transconductance, PWM amplifiers for driving brushless or brush-type servo motors (the
AMP-43240 contains 2 amplifiers). Each amplifier drives motors operating at up to 10 Amps
continuous, 20 Amps peak, 20–60 VDC. The gain settings of the amplifier are user-programmable at
0.5 Amp/Volt, 1.0 Amp/Volt and 2.0 Amp/Volt. The switching frequency is 24 kHz. The drive
operates in a Chopper Mode. The amplifier offers protection for over-voltage, under-voltage, over-
current, short-circuit and over-temperature. Two AMP-43240s or AMP-43220's can be used in 5- thru
8-axis controllers.

AMP- 3520/ 35 0 Servo Amplifier (-D3520/-D35 0)
The AMP-43540 and AMP-43520 amplifies reside inside the DMC-41x3 enclosure. The AMP-43540
contains four sinusoidally commutated, PWM amplifiers for driving brushless servo motors (the AMP-
43520 contains 2 amplifiers). Each amplifier drives motors operating at up to 8 Amps continuous, 15
Amps peak, 20–60 VDC. The gain settings of the amplifier are user-programmable at 0.4 Amp/Volt,
0.8 Amp/Volt and 1.6 Amp/Volt. The switching frequency is 33 kHz. The amplifier offers protection
for over-voltage, under-voltage, over-current, short-circuit and over-temperature. Two AMP-43540s or
AMP-43520's can be used for 5- thru 8-axis controllers.

Chapter 2 Installation
Pre-Installation
Operating Environment
The location for use of the DMC-41x3, AMP-432x0 and AMP-435x0 must meet the following
requirements.
Description Units Specification
Ambient Temperature C 0 to +40
Altitude feet 10,000
Humidity RH 20-95% (non-condensing)
Mounting Location
The DMC-41x3 motion controller must be mounted on a flat surface using the 4 mounting holes found
on the metal base-plate. The grating found on the side of the metal must not be obstructed in order
provide proper air flow for adequate heat dissipation. The dimensions for a 1-4 axis controller are
smaller than that of a 4-8 axis controller, these dimensions and the mounting hole locations are found
in Appendices A3 and A4.
Additional Mounting Consideration when using the AMP- 3xx0
When operating a DMC-41x3- D3xx0-D3xx0 or a DMC-41x3-D3xx0, special mounting
considerations must be made if the total continuous current output for the controller is greater than 15A
for a 1-4 axis controller and greater than 30A for a 5-8 axis controller. In this case, the controller base
must be mounted to an addition heat sink.
When the application requires that the DMC-41x3-D3xx0-D3xx0 be mounted to a heat sink, the heat
sink must be sized such that the base of the DMC-41x3 be kept at a temperature of 65O C or below.
This works out to a thermal resistance of 0.2O C/W at full continuous power. Full continuous power is
defined as a 100% duty cycle with all 8 axis running 10Amps continuous current (80 Amps total), with
a 60VDC bus.

Elements Needed for Installation
1. Isolated DC power supply
a. Ratings found in Appendix A1
2. Power Supply Cable
a. Cable from DC power supply to power input for AMP-43xx0.
b. DMC-4183 controller requires 2 cables.
3. PC or laptop with Ethernet and/or USB ports
4. alilTools, or alilTools-Lite software package
5. Ethernet Cable
a. Recommended shielded Cat 5 STP cable. Straight-through or Cross-over.
6. Male Type A – Male Type B USB cable
7. Molex pin Crimp Tool
8. Additional cables may be required for connection to motors, external amplifiers, digital or
analog I/O, and other devices. See the full DMC-41x3 User Manual for further information.
9. Disconnect switch or circuit breaker for AC power to DC Power Supply
Unpacking the Controller
Caution: The DMC-41x3 motion controller and included internal amplifier include electrostatic
sensitive components. Observe standard precautions for handling ESD sensitive devices
when handling the controller.
1. Verify that the following components have been shipped along the motion controller.
•Connectors and mating pins for motor power and amplifier power.
oQty 4 – 4 pin molex connectors for EACH internal amplifier
oQty 1 – 6 pin molex connector for EAH internal amplifier
•alil Software Installation CD
Note: Connectors and/or software installation CD may not be shipped to existing OEM
customers.
2. Check that no visible damage has occurred to the controller, or internal amplifiers. If any
damage has occurred to the controller, or the components shipped with the controller, contact
alil Motion Control immediately. Contact information can be found in the beginning of this
manual.
3. Verify the controller that has been shipped to you is in fact the controller that you have
ordered from alil or your authorized alil distributor. To do this, check the labeling on the
controller and compare it to the part number that was ordered.

Figure 1: Label for DMC-41x3
Figure 2: Label for DMC-41x3-D3220
Figure 3: Label for DMC-41x3-D3240
Figure 4: Label for DMC-41x3-D3520
Figure 5: Label for DMC-41x3-D3540

Figure 6: Label for DMC-41x3-D3240-D3220
Figure 7: Label for DMC-41x3-D3240-D3240
Figure 8: Label for DMC-41x3-D3540-D3520
Figure 9: Label for DMC-41x3-D3540-D3540
Figure 10: Label for DMC-41x3-D3240-D3520

Figure 11: Label for DMC-41x3-D3240-D3540
Figure 12: Label for DMC-41x3-D3540-D3220
Figure 13: Label for DMC-41x3-D3540-D3240
Figure 14: ETL Mark

Installation
Mounting the Controller
The DMC-41x3 motion controller must be mounted to a flat surface with 4 – #10 pan head screws
through each mounting hole found on the controller base as shown in Figure 15. If the controller is
mounted on a wall, the controller should be mounted so that the bottom of the controller is horizontal
to the floor (as shown in Figure 15). The enclosure must meet or exceed any fire ratings that are
required of the system as a whole.
If the AMP-43xx0 internal amplifiers are being used, it should be determined at this time whether or
not an additional heat sink will be required. This is determined based upon the continuous current
requirements of the system as defined in the “Additional Mounting Consideration when using the
AMP-43xx0” section above. The Motor Sizer tool found on our website can be used to determine this
value http://www.galilmc.com/learning/motorsizer.php.
Figure 15: Mounting the DMC-41x3
Powering the Controller
The DMC-41x3 is powered via the DC supply connections. All connectors share a common ground.
The DMC-41x3 is grounded through the metal enclosure and should be installed on an unpainted metal
surface. The Earth lugs should be used for additional electrical contact.

Wiring the Controller with internal AMP- 3xx0
The basic wiring for a DMC-41x3 motion controller with included AMP-43xx0 servo amplifiers is
shown in Figure 16. The disconnect switch or circuit breaker for AC power must be installed in a
location that meets the following requirements:
•Placed in close proximity to the equipment, within easy reach of the operator, and must not
block the installation of the controller
•Marked as the disconnect device for the equipment
Connectors for AMP- 3xx0
On Board Connector Terminal Pins
POWER 6-pin MATE-N-LOK
MOLEX# 39-31-0060 MOLEX#44476-3112
A,B,C,D: -pin Motor
Power Connectors
4-pin MATE-N-LOK
MOLEX# 39-31-0040 MOLEX#44476-3112
For mating connectors see http://www.molex.com/
Power Connector
Pin Number Connection
1,2,3 DC Power Supply round
4,5,6 +VS (DC Power)
Motor Connector - AMP- 32x0
1 Phase C (N/C for Bushed Motors)
2 Phase B
3 No Connect
4 Phase A
Motor Connector - AMP- 35x0
1 Phase C
2 Phase B (N/C for Bushed Motors)
3 No Connect
4 Phase A

Figure 16: DMC-41x3 wiring with AMP-43xx0

Communication Connection
Connect the serial cable or the Ethernet cable from your PC to the DMC-41x3 motion controller. The
Ethernet cable may be connected through a hub or switch, or directly to the PC.
If the controller is connected to a DHCP enabled network, the IP address will automatically be
assigned to the controller.
Powering the Controller
Once the connections have been made from the DC power supply to the DMC-41x3 motion controller,
the controller and internal amplifiers may be powered-up. At this time the Power LED should be
illuminated.
Additional Wiring
Additional wiring to the Analog and Digital I/O, encoders, limit switches and other connections found
on the D-Subs on the DMC-41x3 motion controller will be required to complete your applications.
The pinout for the connectors are shown below, for additional information regarding these
connections, see the DMC-41x3 User Manual.
J5 - I/O (A-D) pin HD D-Sub Connector (Female)
Pin# Label Description Pin# Label Description Pin# Label Description
1 ERR Error Output 16 RST Reset Input 31 ND Digital round
2 DI1 Digital Input 1/ A latch 17 INCOM0 Input Common (DI 1-8) 32 DI2 Digital Input 2 / B latch
3 DI4 Digital Input 4 / D latch 18 DI3 Digital Input 3 / C latch 33 DI5 Digital Input 5
4 DI7 Digital Input 7 19 DI6 Digital Input 6 34 DI8 Digital Input 8
5 ELO Electronic Lock Out 20 ABRT Abort Input 35 ND Digital round
6 LSCOM0 Limit Switch Com (A-D) 21 N/C No Connect 36 FLSA Forward Limit Switch A
7 HOMA Home Switch A 22 RLSA Reverse Limit Switch A 37 FLSB Forward Limit Switch B
8 HOMB Home Switch B 23 RLSB Reverse Limit Switch B 38 FLSC Forward Limit Switch C
9 HOMC Home Switch C 24 RLSC Reverse Limit Switch C 39 FLSD Forward Limit Switch D
10 HOMD Home Switch D 25 RLSD Reverse Limit Switch D 40 ND Digital round
11 OP0A Output ND/PWR 26 N/C No Connect 41 DO1 Digital Output 1
12 DO3 Digital Output 3 27 DO2 Digital Output 2 42 DO4 Digital Output 4
13 DO6 Digital Output 6 28 DO5 Digital Output 5 43 DO7 Digital Output 7
14 OP0B Output PWR/ ND 29 DO8 Digital Output 8 44 CMP Output Compare (A-D)
15 +5V +5V 30 +5V +5V

J8 - I/O (E-H) pin HD D-Sub Connector (Female)
4183
For DMC-4153 thru DMC-4183 controllers only.
Pin# Label Description Pin# Label Description Pin# Label Description
1 ERR Error Output 16 RST* Reset Input 31 ND Digital round
2 DI9 Digital Input 9 / E latch 17 INCOM1 Input Common (DI 9-16) 32 DI10 Digital Input 10 / F latch
3 DI12 Digital Input 12/H latch 18 DI11 Digital Input 11 / latch 33 DI13 Digital Input 13
4 DI15 Digital Input 15 19 DI14 Digital Input 14 34 DI16 Digital Input 16
5 ELO* Electronic Lock Out 20 ABRT* Abort Input 35 ND Digital round
6 LSCOM1 Limit Switch Com (E-H) 21 N/C No Connect 36 FLSE Forward Limit Switch E
7 HOME Home Switch E 22 RLSE Reverse Limit Switch E 37 FLSF Forward Limit Switch F
8 HOMF Home Switch F 23 RLSF Reverse Limit Switch F 38 FLS Forward Limit Switch
9 HOM Home Switch 24 RLS Reverse Limit Switch 39 FLSH Forward Limit Switch H
10 HOMH Home Switch H 25 RLSH Reverse Limit Switch H 40 ND Digital round
11 OP1A Output ND/PWR 26 N/C No Connect 41 DO9 Digital Output 9
12 DO11 Digital Output 11 27 DO10 Digital Output 10 42 DO12 Digital Output 12
13 DO14 Digital Output 14 28 DO13 Digital Output 13 43 DO15 Digital Output 15
14 OP1B Output PWR/ ND 29 DO16 Digital Output 16 44 CMP Output Compare (E-H)
15 +5V +5V 30 +5V +5V
* ABRT, RST and ELO use INCOM0
Jn1 - Encoder 26 pin HD D-Sub Connector (Female)
Pin
# Label Description Pin # Label Description
1 HALC Hall C 14 FLS Forward Limit Switch Input
2 AEN Amplifier Enable 15 AB+ B+ Aux Encoder Input
3 DIR Direction 16 MI- I- Index Pulse Input
4 HOM Home 17 MB+ B+ Main Encoder Input
5 LSCOMn Limit Switch Common* 18 ND Digital round
6 AA- A- Aux Encoder Input 19 MCMD Motor Command
7 MI+ I+ Index Pulse Input 20 ENBL+ Amp Enable Power
8 MA- A- Main Encoder Input 21 HALA Hall A
9 +5V +5V 22 RLS Reverse Limit Switch Input
10 ND Digital round 23 AB- B- Aux Encoder Input
11 ENBL- Amp Enable Return 24 AA+ A+ Aux Encoder Input
12 HALB Hall B 25 MB- B- Main Encoder Input
13 STP PWM/Step 26 MA+ A+ Main Encoder Input
* LSCOMn on JA1, JB1, JC1 and JD1 is common to LSCOM0 on J5
LSCOMn on JE1, JF1, J 1 and JH1 is common to LSCOM1 on J8

J - Analog 15 pin D-sub Connector (Male)
Pin # Label Description
1 A ND Analog round
2 AI1 Analog Input 1
3 AI3 Analog Input 3
4 AI5 Analog Input 5
5 AI7 Analog Input 7
6 A ND Analog round
7 -12V -12V
8 +5V +5V
9 A ND Analog round
10 AI2 Analog Input 2
11 AI4 Analog Input 4
12 AI6 Analog Input 6
13 AI8 Analog Input 8
14 N/C No Connect
15 +12V +12V
Communication with Galil Software
To communicate with the controller, the alilTools communications software must first be installed.
A free version of alilTools ( alilTools-Lite) may also be used. These software applications can be
found on the software installation CD shipped with the controller, or online at:
http://www.galilmc.com/support/software-downloads.php
Installation instructions for your operating system can be found in the alilTools user manual.
http://www.galilmc.com/support/manuals/galiltools/introduction.html
Once the software has been installed, run alilTools, or alilTools-Lite and choose your controller.
USB connection
If you are using a USB connection, connect the DMC-41x3 USB port to your computer via a Male
Type A – Male Type B USB cable. The port will be identified as a new Serial port. The USB port is
designed for basic communication to the controller and the standard baud rate of the DMC-41x3
motion controller is 115200.
Ethernet connection
If you are connected to the controller via an Ethernet connection, and your network is DHCP enabled,
then the controller will automatically have an IP addressed assigned to it. If your network is not
DHCP enabled, or the connection is only between the PC and the controller, then the controller be
found with the software as no IP address assigned. The alilTools software will allow you to assign
the controller with an IP address. See the alilTools documentation for detailed information on using
the software to assign the controller IP address.

Appendix – Specifications
A1 – Electrical Specifications
DMC- 183- D32 0-D32 0
Description Units Specification
Maximum Input Voltage VDC 60
Minimum Input Voltage VDC 20
Maximum Input Power W 2400
Maximum Output Current Amps 80
DMC- 183- D35 0-D35 0
Description Units Specification
Maximum Input Voltage VDC 60
Minimum Input Voltage VDC 20
Maximum Input Power W 1920
Maximum Output Current Amps 64
AMP- 32 0
Description Units Specification
Supply Voltage VDC 20-60
Maximum Input Power W 1200
Continuous Output Current per axis Amps 10
Peak Output Current per axis Amps 20
Amplifier ain A/V 0.5, 1.0 (default), 2.0
Switching Frequency kHz 24
Brushless Motor Commutation angle ° 120
° 60 (option available)
Supply Voltage Fuse Amps 30

AMP- 35 0
Description Units Specification
Supply Voltage VDC 20-60
Maximum Input Power W 960
Continuous Output Current per axis Amps 8
Peak Output Current per axis Amps 15
Amplifier ain A/V 0.4, 0.8 (default), 1.6
Switching Frequency kHz 33
Brushless Motor Commutation angle ° 120
Supply Voltage Fuse Amps 30
Fault Information
The AMP-43240 and AMP-43540 are protected from the following fault conditions.
Fault Condition AMP- 35 0 AMP- 32 0
Over-Current Protection yes yes
Under-Voltage Protection yes yes
Over-Temperature Protection yes yes
Over-Voltage Protection yes yes
Hall Error Detection yes yes
The Over-Current protection circuit is shown in Figure 17. For further specifics on fault conditions,
see the DMC-41x3 User Manual.

Figure 17: Overcurrent Circuit
A2 – Environmental Specifications
Description Units Specification
Storage Temperature C -40 to +125
Operating Temperature C 0 to +40
Operating Altitude feet 10,000
Humidity RH 20-95% (non-condensing)

A3 – Mechanical Specifications DMC- 183
DMC- 183
Description Units Specification
Weight lb 4.25 (DMC-4183-D3240-D3240)
Length in 11.50
Width in 7.25
Height in 1.50
DMC- 183- D32 0-D32 0
Included Components Quantiy Description
DMC-4183 1 Main Controller Board
AMP-43240 2 Servo Amplifier Board
DMC- 183- D35 0-D35 0
Included Components Quantiy Description
DMC-4183 1 Main Controller Board
AMP-43540 2 Servo Amplifier Board