Galil DMC-21x3 User manual

USER MANUAL / COMMAND REFERENCE
Manual Rev. 1.0m
Galil Motion Control, Inc.
270 Technology Way
Rocklin, California 95765
Phone: [phone]
Fax: [phone]
E-mail Address: [email protected]
URL: www.galilmc.com
Rev 12/08
DMC-21x3
Amplifiers
& Accessories

Using This Manual
This user manual provides information for proper operation of the daughter boards that connect to the
DMC-21x3 controllers. It also includes a small listing of commands that pertain to the daughter
boards. This is a subset of the commands listed in the command reference you received with your
motion controller.
Please note that many examples are written for the DMC-2143 four-axes controller or the DMC-2183
eight axes controller. Users of the DMC-2133 3-axis controller, DMC-2123 2-axes controller or
DMC-2113 1-axis controller should note that the DMC-2133 uses the axes denoted as XYZ, the DMC-
2123 uses the axes denoted as XY, and the DMC-2113 uses the X-axis only.
Examples for the DMC-2183 denote the axes as A,B,C,D,E,F,G,H. Users of the DMC-2153 5-axes
controller denotes the axes as A,B,C,D,E. DMC-2163 6-axes controller denotes the axes as
A,B,C,D,E,F. DMC-2173, 7-axes controller denotes the axes as A,B,C,D,E,F,G. In other words, the
axes names A,B,C,D may be used interchangeably with X, Y, Z, W.
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.

DMC-21x3 Accessories Contents• 1
Contents
CONTENTS................................................................................................................................................................ 1
CHAPTER 1 OVERVIEW........................................................................................................................................ 5
INTRODUCTION ......................................................................................................................................................... 5
DC TO DC OPTION ................................................................................................................................................... 5
PINOUT ..................................................................................................................................................................... 5
DC TO DC PASS THROUGH....................................................................................................................................... 6
MODULE TYPES ........................................................................................................................................................ 6
Servo Drives........................................................................................................................................................ 6
Stepper Drives..................................................................................................................................................... 6
Non Amplifier Modules....................................................................................................................................... 6
Cables ................................................................................................................................................................. 7
CHAPTER 2 SR-19900............................................................................................................................................ 9
INTRODUCTION ......................................................................................................................................................... 9
LAYOUT.................................................................................................................................................................. 11
PINOUT ................................................................................................................................................................... 11
CONFIGURATION..................................................................................................................................................... 11
CHAPTER 3 ICM-20100....................................................................................................................................... 13
INTRODUCTION ....................................................................................................................................................... 13
LAYOUT.................................................................................................................................................................. 14
PINOUT ................................................................................................................................................................... 15
AMPLIFIER ENABLE ................................................................................................................................................ 17
CHAPTER 4 ICM-20105....................................................................................................................................... 19
INTRODUCTION ....................................................................................................................................................... 19
ELECTRICAL SPECIFICATIONS ................................................................................................................................. 20
LAYOUT.................................................................................................................................................................. 20
PINOUT ................................................................................................................................................................... 21
CONFIGURATIONS FOR ICM-20105 ........................................................................................................................ 23
Amplifier Enable Circuit................................................................................................................................... 23
Opto Isolation Settings...................................................................................................................................... 25
CHAPTER 5 SDM-20240/20242............................................................................................................................ 27
INTRODUCTION ....................................................................................................................................................... 27
ELECTRICAL SPECIFICATIONS ................................................................................................................................. 28
LAYOUT.................................................................................................................................................................. 28
PINOUT ................................................................................................................................................................... 29
Mating Connectors............................................................................................................................................ 31

2 • Contents DMC-21x3 Accessories
CONFIGURATIONS FOR SDM-20240 &SDM-20242............................................................................................... 31
Motor Current Setting....................................................................................................................................... 31
Low Current Setting (JP1)................................................................................................................................ 32
ADDITIONAL SETTINGS FOR SDM-20242 ............................................................................................................... 33
Protection Circuitry and Error LED................................................................................................................. 33
ELO (Emergency Lock Out).............................................................................................................................. 33
Fault Output from SDM-20242......................................................................................................................... 33
CHAPTER 6 AMP-20341 ...................................................................................................................................... 35
INTRODUCTION ....................................................................................................................................................... 35
ELECTRICAL SPECIFICATIONS ................................................................................................................................. 36
LAYOUT.................................................................................................................................................................. 36
PINOUT ................................................................................................................................................................... 37
Mating Connectors............................................................................................................................................ 38
CHAPTER 7 AMP-20440/20420 ........................................................................................................................... 39
INTRODUCTION ....................................................................................................................................................... 39
ELECTRICAL SPECIFICATIONS ................................................................................................................................. 40
LAYOUT.................................................................................................................................................................. 40
PINOUT ................................................................................................................................................................... 41
OVER-VOLTAGE PROTECTION ................................................................................................................................43
OVER-CURRENT PROTECTION ................................................................................................................................43
ABORT INPUT OPTIONS........................................................................................................................................... 44
CHAPTER 8 ICM-20500....................................................................................................................................... 45
INTRODUCTION ....................................................................................................................................................... 45
ELECTRICAL SPECIFICATIONS ................................................................................................................................. 46
LAYOUT.................................................................................................................................................................. 46
PINOUT ................................................................................................................................................................... 47
CONFIGURATION..................................................................................................................................................... 48
CHAPTER 9 AMP-20540/20520 ............................................................................................................................. 49
INTRODUCTION ....................................................................................................................................................... 49
ELECTRICAL SPECIFICATIONS ................................................................................................................................. 50
LAYOUT.................................................................................................................................................................. 50
PINOUT ................................................................................................................................................................... 51
Mating Connectors............................................................................................................................................ 53
OPERATION............................................................................................................................................................. 54
Brushless Motor Setup ...................................................................................................................................... 54
Brushless Amplifier Software Setup.................................................................................................................. 54
Brush Amplifier Operation................................................................................................................................ 55
Using External Amplifiers................................................................................................................................. 55
Error Monitoring and Protection...................................................................................................................... 56
Hall Error Protection........................................................................................................................................ 56
Under-Voltage Protection................................................................................................................................. 57
Over-Voltage Protection................................................................................................................................... 57
Over-Current Protection................................................................................................................................... 57
Over-Temperature Protection........................................................................................................................... 57
ABORT INPUT OPTIONS........................................................................................................................................... 58
CHAPTER 10 AMP-20542 ...................................................................................................................................... 59
INTRODUCTION ....................................................................................................................................................... 59
ELECTRICAL SPECIFICATIONS ................................................................................................................................. 60
LAYOUT.................................................................................................................................................................. 60
PINOUT ................................................................................................................................................................... 61
Mating Connectors............................................................................................................................................ 63

DMC-21x3 Accessories Contents• 3
OPERATION............................................................................................................................................................. 64
Brushless Motor Setup ...................................................................................................................................... 64
Brushless Amplifier Software Setup.................................................................................................................. 64
Brush Amplifier Operation................................................................................................................................ 65
Using External Amplifiers................................................................................................................................. 65
Error Monitoring and Protection...................................................................................................................... 65
Hall Error Protection........................................................................................................................................ 66
Under-Voltage Protection................................................................................................................................. 66
Over-Voltage Protection................................................................................................................................... 66
Over-Current Protection................................................................................................................................... 66
ABORT INPUT OPTIONS........................................................................................................................................... 66
CHAPTER 11 SDM-20640/20620............................................................................................................................ 67
INTRODUCTION ....................................................................................................................................................... 67
ELECTRICAL SPECIFICATIONS ................................................................................................................................. 68
LAYOUT.................................................................................................................................................................. 68
PINOUT ................................................................................................................................................................... 68
Mating Connectors............................................................................................................................................ 70
CONFIGURATIONS FOR SDM-206X0....................................................................................................................... 71
Current Level Setup (AG Command)................................................................................................................ 71
Low Current Setting (LC Command)................................................................................................................ 71
ABORT INPUT OPTIONS........................................................................................................................................... 71
CHAPTER 12 PCM-20900 .................................................................................................................................... 73
INTRODUCTION ....................................................................................................................................................... 73
CHAPTER 13 DB-28040........................................................................................................................................ 75
INTRODUCTION ....................................................................................................................................................... 75
LAYOUT.................................................................................................................................................................. 76
PINOUT ................................................................................................................................................................... 77
ELECTRICAL SPECIFICATIONS ................................................................................................................................. 78
3.3V I/O (Standard)........................................................................................................................................... 78
5V I/O (-5V Option) .......................................................................................................................................... 78
Analog Inputs.................................................................................................................................................... 78
INTERFACING TO THE DIGITAL I/O ......................................................................................................................... 78
SSI ......................................................................................................................................................................... 79
DB-28040 AND AMP-205X0.................................................................................................................................. 79
DB-28040 AND AMP-205X2OR SDM-20640 ........................................................................................................ 79
CHAPTER 14 DB-28104.......................................................................................................................................... 81
INTRODUCTION ....................................................................................................................................................... 81
LAYOUT.................................................................................................................................................................. 83
THEORY OF OPERATION.......................................................................................................................................... 83
SETTING UP THE ENCODER ..................................................................................................................................... 85
TUNING THE SYSTEM .............................................................................................................................................. 87
EXAMPLE SIN/COS ENCODERS ................................................................................................................................89
CHAPTER 15 CABLES FOR AMP-20XXX ....................................................................................................... 91
APPENDIX A ABORT INPUT OPTIONS........................................................................................................... 97
ELO SCENARIOS..................................................................................................................................................... 97
DMC-2143 with AMP-20540............................................................................................................................ 97
DMC-2143 with SDM-20640............................................................................................................................ 98
DMC-2183 with two AMP-20440s.................................................................................................................... 98
APPENDIX B MATING D-SHELLS .................................................................................................................. 101

4 • Contents DMC-21x3 Accessories
APPENDIX C COMMAND REFERENCE........................................................................................................ 103
AE.................................................................................................................................................................... 104
AG................................................................................................................................................................... 105
AU................................................................................................................................................................... 106
AW................................................................................................................................................................... 107
BR.................................................................................................................................................................... 108
BS.................................................................................................................................................................... 109
CN................................................................................................................................................................... 110
CO................................................................................................................................................................... 111
LC.................................................................................................................................................................... 112
QH................................................................................................................................................................... 113
TA.................................................................................................................................................................... 114
TK.................................................................................................................................................................... 115
TL (Binary 8a)................................................................................................................................................ 116

DMC-21x3 Accessories Chapter 1 Overview• 5
Chapter 1 Overview
________________________________________________________________________
Introduction
Galil’s DMC-21x3 series motion controllers connect with daughterboard modules that mount directly
on the motion controller. This eliminates the need for a separate cable between the motion controller
and the amplifier or breakout module. This approach saves the cost of the cable and significantly
reduces the real estate required for the controls within a system.
The DMC-21x3 uses a rugged 96 pin DIN board-to-board connector to interface the daughter boards
with the motion controller. The same controller can be ordered with different modules for different
system requirements. This controller series supports modules ranging from passive breakout modules
to 500W-per-channel brush and brushless servo drives to stepper and microstepper drives. Each
module breaks out the I/O provided by the controller and some of the boards also provide additional
I/O functions such as analog inputs or optoisolation. If you do not find the exact module you are
looking for, please contact Galil at 800-377-6329. We will work closely with you to create a module
that will fit your needs.
DC to DC Option
The DMC-21x3 series controllers can be ordered with an optional DC-to-DC converter so that a single DC
power supply can be used to power the controller (as opposed to the standard 5 V and +/-12 V input). This
can be ordered as either the –DC24 (18-36 VDC range) or –DC48 (36-72 VDC range). With the DC
option, a 4-pin molex power connector is provided for DC supply to controller at J99.
Pinout
J99 4-Pin Molex
1 Earth (optional)
2 No connection
3 Vin (18-36 or 36-72 VDC)
4 GND
Mating connector = AMP #770 849-4
Pins = AMP #770 476-1

6 • Chapter 1 Overview DMC-21x3 Accessories
DC to DC Pass Through
When using the DC-to-DC converter in conjunction with the Galil amplifier daughter boards described in
this manual, there is an option to have the DC power supply input shared among both boards, which
alleviates the need to supply power to two connectors. Power is passed through from the amp to the
controller via the “Pass Through” header located at J98 (1-4 axes) or JP14 (5-8 axes) on the controller.
When using the pass through on a 1-4 axis DMC-21x3 controller, DC power must be applied only to the
amplifier’s power connector.
When using the pass through on a 5-8 axis DMC-21x3 controller, DC power must be applied to both
amplifier’s power connectors. Power is passed through to the controller only from the second (axes E-H)
amplifier
The proper DC-to-DC converter must be chosen so that the DC voltage range is compatible with the
amplifier and motor voltage requirements. The J98/JP14 header comes standard, hence the purchaser must
specify if they would not like this header present with –NOJ98.
Module Types
Servo Drives
Part Number Description
AMP-20340 4 Axis Brush Type 20 Watt Linear Servo Drives. OBSELETE
AMP-20341 4 Axis Brush Type 20 Watt Linear Servo Drives (bipolar supply)
AMP-20420 2 Axis Brush Type 200 Watt/Axis PWM Servo Drives
AMP-20440 4 Axis Brush Type 200 Watt/Axis PWM Servo Drives
AMP-20520 2 Axis Brushless/Brush 500 Watt/Axis PWM Servo Drives
AMP-20540 4 Axis Brushless/Brush 500 Watt/Axis PWM Servo Drives
Stepper Drives
Part Number Description
SDM-20240 4 Axis 2 Phase Full/Half Step Stepper Motor Drive
SDM-20620 2 Axis 2 Phase Micro Stepper Motor Drive
SDM-20640 4 Axis 2 Phase Micro Stepper Motor Drive
Non Amplifier Modules
Part Number Description
ICM-20100 4 Axis Breakout to D Shell Connectors
ICM-20105 4 Axis Breakout to D Shell Connectors with opto-isolated I/O
DB-28040 Additional Configurable I/O and 8 Dedicated Analog Inputs
DB-28104 Accepts Sin/Cos Encoder Feedback
PCM-20900 Breadboard Module to Aid Design of Customer Daughter Boards
SR-19900 Shunt Regulator

DMC-21x3 Accessories Chapter 1 Overview• 7
Cables
Part Number Description
CABLE-15-1m
15-pin high density D-sub cable with 1 m flying leads (AMP-204x0 and
AMP-205x0)
CABLE-44-1m
44-pin high density D-sub cable with 1 m flying leads (AMP-204x0 and
AMP-205x0)

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DMC-21x3 Accessories Chapter 2 SR-19900• 9
Chapter 2 SR-19900
____________________________________________________________________________
Introduction
For applications requiring a shunt regulator, Galil offers a small mountable model that can be configured for varying
voltage levels. Two fixed voltage threshold settings are available with jumpers, which can be set at either 33 or 66
volts. Additionally, a user defined voltage threshold can be set by changing a simple resistor. This shunt regulator
operates with hysteresis, where the regulator switches on at the set voltage threshold and switches off at 2 volts
below.
The shunt regulator should be placed in parallel with the power supply as in the figure below, and it should be
mounted to a metal surface using thermal grease to aid in heat transfer. Connections are made to the unit at VS
(voltage supply) and PG (power ground) using either the 4-pin Molex connector or the 8-pin Mate ‘N Lock
connector (AMP# 770579-1).
For a summary of shunt regulator operation, as well as details to help determine if one is required in your system,
please refer to application note #5448 at: (http://www.galilmc.com/support/appnotes/miscellaneous/note5448.pdf).

10 • Chapter 2 SR-19900 DMC-21x3 Accessories
Motor
+ -
PWM
Amplifier
DCPower
Supply
+ -
Controller
Encoder
SR-19900
Shunt
Regulator
M+
GND
AEN
MOCMDx
System Load
(Inertia)
M-
Figure 1 Shunt Regulator Placement in a Typical Servo System

DMC-21x3 Accessories Chapter 2 SR-19900• 11
Layout
Figure 2 SR-19900 Layout
Pinout
J2 4-pin Molex J1 8-pin Mate ‘N Lock
Power Ground 1PG 1Earth 5 PG
Voltage Supply 2VS 2VS 6 PG
Power Ground 3PG 3VS 7 PG
Voltage Supply 4VS 4VS 8 PG
Configuration
SR-19900 Configuration USR - User Settable Voltage
R8 = 1930 * Vs -42.2K
Voltage Threshold
Setting (Vs) JP1 Voltage (Vs) R8 value (ohms)
33 volts 33V 24 4.12 k
66 volts 66V 48 50.44 k
User selectable USR 72 96.76 k

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DMC-21x3 Accessories Chapter 3 ICM-20100• 13
Chapter 3 ICM-20100
__________________________________________________________________
Introduction
The ICM-20100 interconnect module provides D-Sub connections between the DMC-21x3 series
controllers and other system elements, such as amplifiers, encoders, and external switches. The
ICM-20100 provides access to the signals for up to 4 axes (two required for 5 or more axes).
Figure 3 ICM-20100

14 • Chapter 3 ICM-20100 DMC-21x3 Accessories
Layout
Drawing Not to Scale. For Reference Only. Dimensions are inches
Figure 4 ICM-20100 Layout
Board Dimensions are 3.7” x 4.25”. See Application Note #1231 for Hole Locations.

DMC-21x3 Accessories Chapter 3 ICM-20100• 15
Pinout
J6 X-Axis 15-pin Male D-sub J5 J5 Y-Axis 15-pin Male D-sub
1 Forward limit X 1 Forward limit Y
2 Home X 2 Home Y
3 5V 3 5V
4 A- X 4 A- Y
5 B- X 5 B- Y
6 I- X 6 I- Y
7 Amp enable X 7 Amp enable Y
8 Sign/dir X 8 Sign/dir Y
9 Reverse limit X 9 Reverse limit Y
10 Ground 10 Ground
11 A+ X 11 A+ Y
12 B+ X 12 B+ Y
13 I+ X 13 I+ Y
14 Motor command X 14 Motor command Y
15 PWM/step X 15 PWM/step Y
J4 J4 Z-Axis 15-pin Male D-sub J3 W-Axis 15-pin Male D-sub
1 Forward Limit Z 1 Forward Limit W
2 Home Z 2 Home W
3 5V 3 5V
4 A- Z 4 A- W
5 B- Z 5 B- W
6 I- Z 6 I- W
7 Amp enable Z 7 Amp enable W
8 Sign/dir Z 8 Sign/dir W
9 Reverse limit Z 9 Reverse limit W
10 Ground 10 Ground
11 A+ Z 11 A+ W
12 B+ Z 12 B+ W
13 I+ Z 13 I+ W
14 Motor command Z 14 Motor command W
15 PWM/step Z 15 PWM/step W

16 • Chapter 3 ICM-20100 DMC-21x3 Accessories
J10 Aux Encoders 25-pin Female D-Sub J11 I/O 25-pin Male D-Sub
1 Reset * 1 Ground
2 AB- W 2 Latch X/Input 1
3 AA- W 3 Latch Z/Input 3
4 AB- Z 4 Input 5
5 AA- Z 5 Input 7
6 AB- Y 6 Abort *
7 AA- Y 7 Output 1
8 AB- X 8 Output 3
9 AA- X 9 Output 5
10 5V 10 Output 7
11 5V 11 Ground
12 +12V 12 NC
13 NC 13 NC
14 Error Output * 14 5V
15 AB+ W 15 Latch Y/Input 2
16 AA+ W 16 Latch W/Input 4
17 AB+ Z 17 Input 6
18 AA+ Z 18 Input 8
19 AB+ Y 19 Encoder-compare output
20 AA+ Y 20 Output 2
21 AB+ X 21 Output 4
22 AA+ X 22 Output 6
23 Ground 23 Output 8
24 Ground 24 5V
25 -12V 25 NC
* Active Low Signal

DMC-21x3 Accessories Chapter 3 ICM-20100• 17
Amplifier Enable
The standard configuration of the AMPEN signal is TTL active high. In other words, the AMPEN
signal will be high when the controller expects the amplifier to be enabled. The polarity and the
amplitude can be changed. To change the polarity from active high (5 volts= enable, zero volts =
disable) to active low (zero volts = enable, 5 volts= disable), replace the 7407 IC with a 7406
(U2). Note that many amplifiers designate the enable input as ‘inhibit’.
To change the voltage level of the AMPEN signal, note the state of the resistor pack on the ICM-
20100. When pin 1 of the resistor matches pin 1 of the RP1, the output voltage is 0-5 V. To
change to 12 volts, pull the resistor pack and rotate it so that pin 1 is on the 12 volt side. Pin 1 of
the resistor will be marked with a designator, pin 1 of location RP1 can be determined by the
square through hole on the circuit board denoting pin 1. If you remove the resistor pack, the
output signal is open collector, allowing the user to connect an external supply with voltages up to
24V. Note that any external pull-up resistor should limit the current draw to 10 mA
Figure
Figure 5 ICM-20100 Amplifier Enable Circuit
RP1

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