Galil DMC-1510 User manual

USER MANUAL
DMC-1500
Manual Rev. 2.0xf
By Galil Motion Control, Inc.
Galil Motion Control, Inc.
270 Technology Way
Rocklin, California 95765
Phone: [phone]
Fax: [phone]
Internet Address: [email protected]
URL: www.galilmc.com
Rev 05-06

Using This Manual
This user manual provides information for proper operation of the DMC-1500 controller. A separate
supplemental manual, the Command Reference, contains a description of the commands available for
use with this controller.
Your DMC-1500 motion controller has been designed to work with both servo and stepper type
motors. In addition, the DMC-1500 has a daughter board for controllers with more than 4 axes.
Installation and system setup will vary depending upon whether the controller will be used with
stepper motors, or servo motors, and whether the controller has more than 4 axes of control. 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.
1580 Attention: Pertains to controllers with more than 4 axes.
Please note that many examples are written for the DMC-1540 four-axis controller or the DMC-1580
eight axes controller. Users of the DMC-1530 3-axis controller, DMC-1520 2-axis controller or
DMC-1510 1-axis controller should note that the DMC-1530 uses the axes denoted as XYZ, the
DMC-1520 uses the axes denoted as XY, and the DMC-1510 uses the X-axis only.
Examples for the DMC-1580 denote the axes as A,B,C,D,E,F,G,H. Users of the DMC-1550 5-axis
controller, DMC-1560 6-axis controller or DMC-1570, 7-axis controller should note that the DMC-
1550 denotes the axes as A,B,C,D,E, the DMC-1560 denotes the axes as A,B,C,D,E,F and the DMC-
1570 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,W.
This manual was written for the DMC-1500 firmware revision 2.0 and later. For controllers with
firmware previous to revision 2.0, please consult the original manual for your hardware. The later
revision firmware was previously specified as DMC-1500-18.
WARNING: Machinery in motion can be dangerous! It is the responsibility of the user to design
effective error handling and safety protection as part of the machine. Galil shall not be liable or
responsible for any incidental or consequential damages.

Firmware Updates
New feature for Rev 2.0h April 1998:
Feature Description
1. CMDERR enhanced to support multitasking: If CMDERR occurs on thread 1,2 or 3, thread will be holted.
Thread can be re-started with
XQ _ED2, _ED1, 1 for retry
XQ _ED3, _ED1, 1 for next instruction
2. _VM returns instantaneous commanded vector velocity
3. FA resolution increased to 0.25.
New feature for Rev 2.0g November 1997:
Feature Description
1. CR radius now has range of 16 million Allows for large circular interpolation radii
2. _AB returns abort input Allows for monitoring of abort input
3. CW,1 When output FIFO full application program will not
pause but data will be lost Allows for output FIFO buffer to fill up without affecting the execution of a program
4. List Variable (LV), List Array (LA), List app program labels
(LL) Allows for the user to interrogate RAM
New feature for Rev 2.0e May 1997:
Feature Description
1. ER now accepts argument < 0 Disables error output (LED and Error Output does not turn on
for that axis)
2. During a PR decel can now be changed on an unnatural stop Allows for monitoring of abort input
New feature for Rev 2.0d February 1997:
Feature Description
1. AP, MF, MR in stepper now uses _DE instead of _RP Trippoints based on register after buffer
2. \ now terminates QD Download array no longer requires control sequence to end
3. KS can now be fraction (down to .5) Allows for smaller stepper motor smoothing delay (due to filter)
4. New arguments for MT of 2.5 and -2.5 Reverses the direction of motion from MT 2 and MT -2
5. MG now can go to 80 characters Increased message size
New feature for Rev 2.0c October 1996:
Feature Description
1. MC now works for steppers More accurate trippoint for stepper motor completion
New feature for Rev 2.0b September 1996:

Feature Description
1. Operand ‘&’ and ‘|’ for conditional statements Allows for multiple conditional statements in jump routines
IE. (A>=3) & (B<55) | (C=78)
New feature for Rev 2.0 March 1996. (This revision is also designated DMC-1500-18).
DAC resolution increased to 16-bits.
Step motor control method improved.
Command Description
KS Step Motor Smoothing
New feature for Rev 1.1
Electronic Cam
New commands:
Command Description
EA Choose ECAM master
EM Cam Cycle Command
EP Cam table interval and starting point
ET ECAM table entry
EB Enable ECAM
EG Engage ECAM cycle
EQ Disengage ECAM
New features added Jan 1995:
Allow circular array recording.
New commands added July 1994 Rev 1.4:
Command Description
RI,N N is a new interrupt mask which allows changing the interrupt
mask
QU Upload array
QD Download array
MF x,y,z,w Trippoint for motion - forward direction
MR x,y,z,w Trippoint for motion - reverse direction
MC XYZW In position trippoint
TW x,y,z,w Sets timeout for in position
VR r Sets speed ratio for VS
New commands added January 1994 Rev 1.3:
Can specify parameters with axis designator. For example:
Command Description
KPZ=10 Set Z axis gain to 10
KP*=10 Set all axes gains to 10

(KPXZ=10 is invalid. Only one or all axes can be specified at a time).
New commands added July 1993 Rev 1.2:
Command Description
_UL Gives available variables
_DL Give available labels
@COM[n] 2's complement function
New commands added March 1993: Rev 1.2
Command Description
_CS Segment counter in LM, VM and CM modes
_AV Return distance travelled in LM and VM modes
_VPX
Return the coordinate of the last point in a motion sequence, LM or VM
VP x,y<n Can specify vector speed with each vector segment Where <n
sets vector speed
New commands added January 1993:
Command Description
HX Halt execution for multitasking
AT At time trippoint for relative time from reference
ES Ellipse scale factor
OB n,expression Defines output n where expression is logical operation, such as
I1 & I6, variable or array element
XQ#Label,n Where n = 0 through 3 and is program thread for multitasking
DV Dual velocity for Dual Loop
Feature Description
1. Allows gearing and coordinated move simultaneously
2. Multitasking for up to four independent programs
3. Velocity Damping from auxiliary encoder for dual loop

DMC-1500 Contents •i
Contents
Chapter 1 Overview 1
Introduction ...............................................................................................................................1
Overview of Motor Types .........................................................................................................2
Standard Servo Motors with +/- 10 Volt Command Signal ........................................2
Stepper Motor with Step and Direction Signals..........................................................2
DMC-1500 Functional Elements...............................................................................................2
Microcomputer Section...............................................................................................3
Motor Interface............................................................................................................3
Communication ...........................................................................................................3
General I/O..................................................................................................................3
System Elements .........................................................................................................3
Motor...........................................................................................................................4
Amplifier (Driver).......................................................................................................4
Encoder or Position Sensor.........................................................................................4
Watch Dog Timer........................................................................................................4
Chapter 2 Getting Started 7
Elements You Need...................................................................................................................7
Installing the DMC-1500...........................................................................................................8
Step 1. Determine Overall Motor Configuration.........................................................8
Step 2. Install Jumpers on the DMC-1500 ..................................................................8
Step 3. Configure DIP switches on the DMC-1500....................................................9
Step 4. Connect AC Power to the Controller ..............................................................9
Step 5. Install Communications Software ...................................................................9
Step 6. Establish Communications with Galil Software............................................10
Step 7. Connect Amplifiers and Encoders.................................................................11
Step 8a. Connect Standard Servo Motors..................................................................13
Step 8b. Connect Step Motors...................................................................................16
Step 9. Tune the Servo System..................................................................................17
Design Examples.....................................................................................................................18
Example 1 - System Set-up.......................................................................................18
Example 2 - Profiled Move.......................................................................................18
Example 3 - Multiple Axes........................................................................................19
Example 4 - Independent Moves...............................................................................19
Example 5 - Position Interrogation............................................................................19
Example 6 - Absolute Position..................................................................................20
Example 7 - Velocity Control....................................................................................20
Example 8 - Operation Under Torque Limit.............................................................20

ii •Contents DMC-1500
Example 9 - Interrogation..........................................................................................21
Example 10 - Operation in the Buffer Mode.............................................................21
Example 11 - Motion Programs.................................................................................21
Example 12 - Motion Programs with Loops..............................................................22
Example 13 - Motion Programs with Trippoints.......................................................22
Example 14 - Control Variables................................................................................22
Example 15 - Linear Interpolation.............................................................................23
Example 16 - Circular Interpolation..........................................................................23
Chapter 3 Connecting Hardware 25
Overview..................................................................................................................................25
Using Opto-isolated Inputs......................................................................................................25
Limit Switch Input.....................................................................................................25
Home Switch Input....................................................................................................26
Abort Input................................................................................................................26
Uncommitted Digital Inputs......................................................................................27
Wiring the Optoisolated Inputs................................................................................................27
Using an Isolated Power Supply................................................................................28
Bypassing the Opto-Isolation:...................................................................................29
Changing Optoisolated Inputs From Active Low to Active High.............................30
Amplifier Interface ..................................................................................................................30
TTL Inputs...............................................................................................................................31
Analog Inputs...........................................................................................................................31
TTL Outputs ............................................................................................................................32
Offset Adjustment....................................................................................................................32
Chapter 4 Communication 33
Introduction..............................................................................................................................33
RS232 Ports.............................................................................................................................33
RS232 - Main Port {P1} DATATERM................................................................33
RS232 - Auxiliary Port {P2} DATASET..............................................................33
*RS422 - Main Port {P1}..........................................................................................33
*RS422 - Auxiliary Port {P2}...................................................................................34
Configuration...........................................................................................................................34
Baud Rate Selection ..................................................................................................34
Daisy-Chaining..........................................................................................................35
Daisy Chain Example:...............................................................................................35
Synchronizing Sample Clocks...................................................................................36
Controller Response to DATA ................................................................................................36
Galil Software Tools and Libraries..........................................................................................36
Chapter 5 Command Basics 37
Introduction..............................................................................................................................37
Command Syntax.....................................................................................................................37
Coordinated Motion with more than 1 axis...............................................................38
Program Syntax.........................................................................................................38
Controller Response to DATA ................................................................................................38
Interrogating the Controller.....................................................................................................39
Interrogation Commands...........................................................................................39
Summary of Interrogation Commands ......................................................................39
Additional Interrogation Methods.............................................................................40
Operands....................................................................................................................40
Command Summary..................................................................................................40

DMC-1500 Contents •iii
Chapter 6 Programming Motion 41
Overview .................................................................................................................................41
Independent Axis Positioning..................................................................................................41
Command Summary - Independent Axis ..................................................................42
Operand Summary - Independent Axis.....................................................................42
Independent Jogging................................................................................................................44
Command Summary - Jogging..................................................................................44
Operand Summary - Independent Axis.....................................................................44
Linear Interpolation Mode.......................................................................................................45
Specifying Linear Segments......................................................................................45
Specifying Vector Acceleration, Deceleration and Speed:........................................46
Additional Commands...............................................................................................46
Command Summary - Linear Interpolation...............................................................47
Operand Summary - Linear Interpolation .................................................................48
Vector Mode: Linear and Circular Interpolation Motion ........................................................50
Specifying Vector Segments.....................................................................................50
Specifying Vector Acceleration, Deceleration and Speed:........................................51
Additional Commands...............................................................................................51
Command Summary - Vector Mode Motion.............................................................53
Operand Summary - Vector Mode Motion................................................................53
Electronic Gearing...................................................................................................................54
Command Summary - Electronic Gearing ................................................................55
Operand Summary - Electronic Gearing...................................................................55
Electronic Cam ........................................................................................................................57
Command Summary - ECAM Mode.........................................................................61
Operand Summary - ECAM Mode............................................................................61
Contour Mode..........................................................................................................................63
Specifying Contour Segments...................................................................................63
Additional Commands...............................................................................................64
Command Summary - Contour Mode.......................................................................64
Teach (Record and Play-Back)..................................................................................66
Stepper Motor Operation.........................................................................................................67
Specifying Stepper Motor Operation.........................................................................68
Using an Encoder with Stepper Motors ....................................................................69
Command Summary - Stepper Motor Operation.......................................................69
Operand Summary - Stepper Motor Operation .........................................................69
Dual Loop (Auxiliary Encoder)...............................................................................................70
Backlash Compensation ............................................................................................70
Command Summary - Using the Auxiliary Encoder.................................................72
Operand Summary - Using the Auxiliary Encoder ...................................................72
Motion Smoothing...................................................................................................................72
Using the IT and VT Commands (S curve profiling):...............................................72
Using the KS Command (Step Motor Smoothing):...................................................74
Homing....................................................................................................................................74
High Speed Position Capture (The Latch Function)................................................................77
Chapter 7 Application Programming 79
Overview .................................................................................................................................79
Using the DMC-1500 Editor to Enter Programs .....................................................................79
Edit Mode Commands...............................................................................................80
Program Format.......................................................................................................................81
Using Labels in Programs .........................................................................................81
Special Labels............................................................................................................81

iv •Contents DMC-1500
Commenting Programs..............................................................................................82
Executing Programs & Multitasking .......................................................................................83
Debugging Programs ...............................................................................................................84
Debugging Programs ...............................................................................................................86
Commands.................................................................................................................86
Operands....................................................................................................................86
Program Flow Commands .......................................................................................................87
Event Triggers & Trippoints .....................................................................................87
DMC-1500 Event Triggers........................................................................................88
Event Trigger Examples:...........................................................................................88
Conditional Jumps.....................................................................................................91
Subroutines................................................................................................................94
Stack Manipulation....................................................................................................94
Auto-Start Routine.....................................................................................................95
Automatic Subroutines for Monitoring Conditions...................................................95
Mathematical and Functional Expressions ..............................................................................98
Mathematical Expressions.........................................................................................98
Bit-Wise Operators....................................................................................................99
Functions.................................................................................................................100
Variables................................................................................................................................100
Assigning Values to Variables:...............................................................................101
Operands................................................................................................................................102
Special Operands (Keywords).................................................................................103
Arrays ....................................................................................................................................103
Defining Arrays.......................................................................................................103
Assignment of Array Entries...................................................................................104
Automatic Data Capture into Arrays.......................................................................105
Command Summary - Automatic Data Capture......................................................105
Data Types for Recording: ......................................................................................105
Operand Summary - Automatic Data Capture.........................................................106
Deallocating Array Space........................................................................................106
Input of Data (Numeric and String).......................................................................................107
Input of Data............................................................................................................107
Operator Data Entry Mode......................................................................................108
Using Communication Interrupt..............................................................................108
Output of Data (Numeric and String) ....................................................................................110
Sending Messages ...................................................................................................110
Specifying the Serial Port for Messages:.................................................................111
Formatting Messages...............................................................................................111
Using the MG Command to Configure Terminals ..................................................112
Summary of Message Functions:.............................................................................112
Displaying Variables and Arrays.............................................................................112
Interrogation Commands.........................................................................................112
Formatting Variables and Array Elements..............................................................114
Converting to User Units.........................................................................................115
Programmable Hardware I/O.................................................................................................115
Digital Outputs ........................................................................................................115
Digital Inputs...........................................................................................................116
Input Interrupt Function ..........................................................................................117
Analog Inputs..........................................................................................................118
Example Applications............................................................................................................119
Wire Cutter..............................................................................................................119
X-Y Table Controller ..............................................................................................120
Speed Control by Joystick.......................................................................................122
Position Control by Joystick....................................................................................123

DMC-1500 Contents •v
Backlash Compensation by Sampled Dual-Loop....................................................123
Chapter 8 Hardware & Software Protection 126
Introduction ...........................................................................................................................126
Hardware Protection..............................................................................................................126
Output Protection Lines...........................................................................................126
Input Protection Lines.............................................................................................126
Software Protection ...............................................................................................................127
Programmable Position Limits................................................................................127
Off-On-Error ...........................................................................................................127
Automatic Error Routine.........................................................................................128
Limit Switch Routine ..............................................................................................128
Chapter 9 Troubleshooting 130
Overview ...............................................................................................................................130
Installation .............................................................................................................................130
Communication......................................................................................................................131
Stability..................................................................................................................................131
Operation...............................................................................................................................131
Chapter 10 Theory of Operation 132
Overview ...............................................................................................................................132
Operation of Closed-Loop Systems.......................................................................................134
System Modeling...................................................................................................................135
Motor-Amplifier......................................................................................................136
Encoder....................................................................................................................138
DAC ........................................................................................................................139
Digital Filter............................................................................................................139
ZOH.........................................................................................................................139
System Analysis.....................................................................................................................140
System Design and Compensation ........................................................................................142
The Analytical Method............................................................................................142
Appendices 146
Electrical Specifications ........................................................................................................146
Servo Control ..........................................................................................................146
Stepper Control .......................................................................................................146
Input/Output............................................................................................................146
Power.......................................................................................................................147
Performance Specifications...................................................................................................147
Card Level Layout.................................................................................................................148
Connectors for DMC-1500 Main Board................................................................................149
J2 - Main (60 pin IDC)............................................................................................149
J5 - General I/O (26 pin IDC) .................................................................................150
J3 - Aux Encoder (20 pin IDC)...............................................................................150
J4 - Driver (20 pin IDC)..........................................................................................151
J6 - Daughter Board Connector (60 pin )................................................................151
J7 - 10 pin................................................................................................................151
Connectors for Auxiliary Board (Axes E,F,G,H)..................................................................152
JD2 - Main (60 pin IDC).........................................................................................152
JD5 - I/O (26 pin IDC)...........................................................................................153
JD3 - 20 pin IDC - Auxiliary Encoders...................................................................153

vi •Contents DMC-1500
JD4 - 20 pin IDC - Amplifiers.................................................................................154
JD6 - Daughterboard Connector (60 pin)................................................................154
Cable Connections for DMC-1500........................................................................................154
Standard RS-232 Specifications..............................................................................154
DMC-1500 Serial Cable Specifications...................................................................155
Pin-Out Description for DMC-1500......................................................................................157
Configuration Description for DMC-1500............................................................................159
Jumpers....................................................................................................................159
Address Configuration Jumpers ..............................................................................159
Front Panel Baud Rate Switches .............................................................................159
Adjustment Pots.......................................................................................................160
Dip Switch Settings ...............................................................................................................160
Offset Adjustments for DMC-1500.......................................................................................160
Accessories and Options........................................................................................................161
ICM-1100 Interconnect Module............................................................................................162
AMP/ICM-1100 Connections................................................................................................162
J2 - Main (60 pin IDC)............................................................................................165
J3 - Aux Encoder (20 pin IDC)...............................................................................165
J4 - Driver (20 pin IDC)..........................................................................................165
J5 - General I/O (26 pin IDC)..................................................................................165
JX6, JY6, JZ6, JW6 - Encoder Input (10 pin IDC).................................................165
ICM-1100 Drawing ...............................................................................................................166
AMP-11x0 Mating Power Amplifiers ...................................................................................167
TERM-1500 Operator Terminal............................................................................................167
DB-15072 OPTO-22 Expansion Option................................................................................175
Configuring the I/O for the DB-15072....................................................................175
Connector Description of the DB-15072.................................................................176
Coordinated Motion - Mathematical Analysis.......................................................................179
DMC-700/DMC-1500 Comparison.......................................................................................182
List of Other Publications......................................................................................................184
Contacting Us ........................................................................................................................184
WARRANTY ........................................................................................................................185
Index 191

DMC-1500 Chapter 1 Overview •1
Chapter 1 Overview
Introduction
The DMC-1500 Series are packaged motion controllers designed for stand-alone operation. Features
include coordinated motion profiling, uncommitted inputs and outputs, non-volatile memory for
stand-alone operation and RS232/RS422 communication. Extended performance capability over the
previous generation of controllers includes: fast 8 MHz encoder input frequency, precise 16-bit motor
command output DAC, +/-2 billion counts total travel per move, faster sample rate, and multitasking
of up to four programs. The controllers provide increased performance and flexibility and yet are
smaller in size and lower in cost than the previous generation. The DMC-1500 is also available as a
cost-effective, card-level product making it ideal for OEM applications.
Designed for maximum system flexibility, the DMC-1500 is available for one to eight axes and can be
interfaced to a variety of motors and drives including step motors, servo motors and hydraulics.
Each axis accepts feedback from a quadrature linear or rotary encoder with input frequencies up to 8
million quadrature counts per second. For dual-loop applications that require one encoder on both the
motor and the load, auxiliary encoder inputs are included for each axis.
The powerful controller provides many modes of motion including jogging, point-to-point positioning,
linear and circular interpolation with infinite vector feed, electronic gearing and user-defined path
following. Several motion parameters can be specified including acceleration and deceleration rates,
and slew speed. The DMC-1500 also provides S-curve acceleration for motion smoothing.
For synchronizing motion with external events, the DMC-1500 includes 8 opto-isolated inputs, 8
programmable outputs and 7 analog inputs. For controllers with 5 or more axes, the DMC-1500 has
an additional 8 opto-isolated inputs and 8 TTL inputs. I/O expansion boards provide additional inputs
and outputs or interface to OPTO 22 racks. Event triggers can automatically check for elapsed time,
distance and motion complete.
Despite its full range of sophisticated features, the DMC-1500 is easy to program. Instructions are
represented by two letter commands such as BG for Begin and SP for Speed. Conditional Instructions,
Jump Statements, and arithmetic functions are included for writing self-contained applications
programs. An internal editor allows programs to be quickly entered and edited, and support software
such as the Servo Design Kit allows quick system set-up and tuning.
To prevent system damage during machine operation, the DMC-1500 provides several error handling
features. These include software and hardware limits, automatic shut-off on excessive error, abort
input, and user-definable error and limit routines.

2 •Chapter 1 Overview DMC-1500
Overview of Motor Types
The DMC-1500 can provide the following types of motor control:
Standard servo motors with +/- 10 volt command signals
Step motors with step and direction signals
Other actuators such as hydraulics - For more information, contact Galil.
The user can configure each axis for any combination of motor types, providing maximum flexibility.
Standard Servo Motors with +/- 10 Volt Command Signal
The DMC-1500 achieves superior precision through use of a 16-bit motor command output DAC and
a sophisticated PID filter that features velocity and acceleration feedforward, an extra pole filter and
integration limits.
The controller is configured by the factory for standard servo motor operation. In this configuration,
the controller provides an analog signal (+/- 10Volt) to connect to a servo amplifier. This connection
is described in Chapter 2.
Stepper Motor with Step and Direction Signals
The DMC-1500 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.
DMC-1500 Functional Elements
The DMC-1500 circuitry can be divided into the following functional groups as shown in Figure 1.1
and discussed in the following.
Figure 1.1 - DMC-1500 Functional Elements
6834
Microcompute
256K
64K
128K EEPROM
I/
Interfac
GL-
4-
Motor/Encode
Interfac
RS-232 / RS-422
Communication
80
Watch
Timer
8 TTL
8 Digital
8 Analog
To
To
Fro
Limit
Fro
Encoder

DMC-1500 Chapter 1 Overview •3
Microcomputer Section
The main processing unit of the DMC-1500 is a specialized 32-bit Motorola 68340 Series
Microcomputer with 256K RAM, 64 K EPROM and 128 K bytes EEPROM. The RAM provides
memory for variables, array elements and application programs. The EPROM stores the firmware of
the DMC-1500. The EEPROM allows parameters and programs to be saved in non-volatile memory
upon power down.
Motor Interface
For each axis, a GL-1800 custom gate array performs quadrature decoding of the encoders at up to 8
MHz, generates the +/-10 Volt analog signal (16 Bit DAC) for input to a servo amplifier, and
generates step and direction signal for step motor drivers.
Communication
Communication to the DMC-1500 is via two separately addressable RS232 ports. The ports may also
be configured by the factory for RS422. The serial ports may be daisy-chained to other DMC-1500
controllers.
General I/O
The DMC-1500 provides interface circuitry for eight optoisolated inputs, eight general outputs and
seven analog inputs (12 Bit ADC with option for 16 Bit ADC).
An auxiliary board, the DB-15072 provides interface to up to three OPTO 22 racks with 24 I/O
modules each. 24 bits can be configured for interface to output or input modules and the remaining 48
for input modules.
1580 Controllers with 5 or more axes provide 24 inputs and 16 outputs.
System Elements
As shown in Fig. 1.2, the DMC-1500 is part of a motion control system which includes amplifiers,
motors and encoders. These elements are described below
Computer DMC-1500 Controller Driver
Power Supply
Encoder Motor
Figure 1.2 - Elements of Servo systems

4 •Chapter 1 Overview DMC-1500
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 desired speed and acceleration. Galil's Motion Component
Selector software can help you calculate motor size and drive size requirements. Contact Galil at 800-
377-6329 if you would like this product.
The motor may be a step or servo motor and can be brush-type or brushless, rotary or linear. For step
motors, the controller can be configured to control full-step, half-step, or microstep drives.
Amplifier (Driver)
For each axis, the power amplifier converts a +/-10 Volt signal from the controller into current to
drive the motor. 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. The amplifiers
may be either pulse-width-modulated (PWM) or linear. They may also be configured for operation
with or without a tachometer. For current amplifiers, the amplifier gain should be set such that a 10
Volt command generates the maximum required current. For example, if the motor peak current is
10A, the amplifier gain should be 1 A/V. For velocity mode amplifiers, 10 Volts should run the motor
at the maximum speed.
For stepper motors, the amplifier converts step and direction signals into current.
Encoder or Position Sensor
An encoder translates motion into electrical pulses which are fed back into the controller. The DMC-
1500 accepts feedback from either a rotary or linear encoder. Typical encoders provide two channels
in quadrature, known as CHA and CHB. This type of encoder is known as a quadrature encoder.
Quadrature encoders may be either single-ended (CHA and CHB) or differential (CHA,CHA-
,CHB,CHB-). The DMC-1500 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-1500 can also interface to encoders with pulse and direction signals.
There is no limit on encoder line density, however, the input frequency to the controller must not
exceed 2,000,000 full encoder cycles/second or 8,000,000 quadrature counts/sec. For example, if the
encoder line density is 10,000 cycles per inch, the maximum speed is 200 inches/second.
The standard voltage level is TTL (zero to five volts), however, voltage levels up to 12 Volts are
acceptable. If using differential signals, 12 Volts can be input directly to the DMC-1500. Single-
ended 12 Volt signals require a bias voltage input to the complementary inputs.
The DMC-1500 can accept analog feedback instead of an encoder for any axis. Note: the DMC-1580
controller must be modified by the factory to allow for analog feedback on axis H. For more
information see description of analog feedback in Chapter 2 under section entitled "Test the encoder
operation".
To interface with other types of position sensors such as resolvers or absolute encoders, Galil can
customize the controller and command set. Please contact Galil to talk to one of our applications
engineers about your particular system requirements.
Watch Dog Timer
The DMC-1500 provides an internal watch dog timer which checks for proper microprocessor
operation. The timer toggles the Amplifier Enable Output (AEN) which can be used to switch the
amplifiers off in the event of a serious DMC-1500 failure. The AEN output is normally high. During
power-up and if the microprocessor ceases to function properly, the AEN output will go low. The

DMC-1500 Chapter 1 Overview •5
error light for each axis will also turn on at this stage. A reset is required to restore the DMC-1500 to
normal operation. Consult the factory for a Return Materials Authorization (RMA) Number if your
DMC-1500 is damaged.

6 •Chapter 1 Overview DMC-1500
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DMC-1500 Chapter 2 Getting Started •7
Chapter 2 Getting Started
Elements You Need
Before you start, you will need the following system elements:
1. DMC-1500 Motion Controller and included cables, RS232, 60 pin ribbon cable and 26-pin
ribbon cable.
1a. For stepper motor operation, you will need an additional 20-pin ribbon cable, J4.
2. Servo motors with Optical Encoder (one per axis) or step motors
3. Power Amplifiers for motors
4. Power Supply for Amplifiers
5. PC (Personal Computer with RS232 port)
Software from Galil (Optional - but strongly recommended for first time users)
Communication Disk (COMMdisk)
-AND -
WSDK-16 Servo Design Software for Windows 3.1, and 3.11 for Workgroups
-OR -
WSDK-32 for Windows 95 or NT
ICM-1100 Interface Module (Optional, but strongly recommended). The Galil ICM-1100 is an
interconnect module with screw type terminals that directly interfaces to the DMC-1500 controller.
Note: An additional ICM-1100 is required for the DMC-1550 through DMC-1580.
The motors may be servo (brush type or brushless) or steppers. The amplifiers should be suitable for
the motor and may be linear or pulse-width-modulated. An amplifier may have current feedback or
voltage feedback.
For servo motors, the amplifiers should accept an analog signal in the +/-10 Volt range as a command.
The amplifier gain should be set so that a +10V command will generate the maximum required
current. For example, if the motor peak current is 10A, the amplifier gain should be 1 A/V. For
velocity mode amplifiers, a command signal of 10 Volts should run the motor at the maximum
required speed.
For step motors, the amplifiers should accept step and direction signals.
The WSDK software is highly recommended for first time users of the DMC-1500. It provides step-
by-step instructions for system connection, tuning and analysis.

8 •Chapter 2 Getting Started DMC-1500
Installing the DMC-1500
Installation of a complete, operational DMC-1500 system consists of 9 steps.
Step 1. Determine overall motor configuration.
Step 2. Install jumpers on the DMC-1500.
Step 3. Configure the DIP switches on the DMC-1500.
Step 4. Connect AC power to controller
Step 5. Install communications software.
Step 6. Establish communications with Galil Software.
Step 7. Connect amplifiers and Encoders.
Step 8a. Connect standard servo motors.
Step 8b. Connect step motors.
Step 9. Tune the servo system
Step 1. Determine Overall Motor Configuration
Before setting up the motion control system, the user must determine the desired motor configuration.
The DMC-1500 can control any combination of standard servo motors, and stepper motors. Other
types of actuators, such as hydraulics can also be controlled, please consult Galil.
The following configuration information is necessary to determine the proper motor configuration:
Standard Servo Motor Operation:
The DMC-1500 has been setup by the factory for standard servo motor operation providing an analog
command signal of +/- 10V. No hardware or software configuration is required for standard servo
motor operation.
Stepper Motor Operation:
To configure the DMC-1500 for stepper motor operation, the controller requires a jumper for each
stepper motor and the command, MT, must be given. The installation of the stepper motor jumper is
discussed in the following section entitled "Installing Jumpers on the DMC-1500". Further
instruction for stepper motor connections are discussed in Step 8b.
Step 2. Install Jumpers on the DMC-1500
The DMC-1500 has jumpers inside the controller box which may need to be installed. To access these
jumpers, the cover of the controller box must be removed. The following describes each of the
jumpers.
WARNING: Never open the controller box when AC power is applied to it.
For each axis that will be driving a stepper motor, a stepper mode (SM) jumper must be connected.
1580 If you using a controller with more than 4 axis, you will have two pc-cards inside the controller box.
In this case, you will have 2 sets of stepper motor jumpers, one on each card. The jumpers on the
bottom card will be for axes X,Y,Z and W (or A,B,C, and D) and the top will be E,F,G and H. To
access the bottom card, the top card must be carefully removed.