Galil DMC-2X00 User manual

USER MANUAL
DMC-2x00
Manual Rev. 2.1
By Galil 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 03/2011

Using This Manual
This user manual provides information for proper operation of the DMC-2x00 controller. A separate
supplemental manual, the Command Reference, contains a description of the commands available for
use with this controller.
Your DMC-2x00 motion controller has been designed to work with both servo and stepper type
motors. Installation and system setup will vary depending upon whether the controller will be used
with stepper motors or servo motors. To make finding the appropriate instructions faster and easier,
icons will be next to any information that applies exclusively to one type of system. Otherwise,
assume that the instructions apply to all types of systems. The icon legend is shown below.
Attention: Pertains to servo motor use.
Attention: Pertains to stepper motor use.
2x80 Attention: Pertains to controllers with more than 4 axes.
Please note that many examples are written for the DMC-2x40 four-axes controller or the DMC-2x80
eight axes controller. Users of the DMC-2x30 3-axis controller, DMC-2x20 2-axes controller or
DMC-2x10 1-axis controller should note that the DMC-2x30 uses the axes denoted as XYZ, the DMC-
2x20 uses the axes denoted as XY, and the DMC-2x10 uses the X-axis only.
Examples for the DMC-2x80 denote the axes as A,B,C,D,E,F,G,H. Users of the DMC-2x50 5-axes
controller. DMC-2x60 6-axes controller or DMC-2x70, 7-axes controller should note that the DMC-
2x50 denotes the axes as A,B,C,D,E, the DMC-2x60 denotes the axes as A,B,C,D,E,F and the DMC-
2x70 denotes the axes as A,B,C,D,E,F,G. The axes A,B,C,D may be used interchangeably with
A,B,C,D.
WARNING: Machinery in motion can be dangerous! It is the responsibility of the user to design
effective error handling and safety protection as part of the machinery. Galil shall not be liable or
responsible for any incidental or consequential damages.

Contents
Using This Manual ....................................................................................................................ii
Contents i
Chapter 1 Overview 1
Introduction ............................................................................................................................... 1
Specifications............................................................................................................................. 2
DMC- 2000 Family Part Number Definition...............................................................2
Electrical Specifications ..............................................................................................2
Mechanical Specifications........................................................................................... 2
Environmental Specifications......................................................................................3
Equipment Maintenance.............................................................................................. 3
Overview of Motor Types..........................................................................................................3
Standard Servo Motor with +/- 10 Volt Command Signal .......................................... 3
Brushless Servo Motor with Sinusoidal Commutation................................................3
Stepper Motor with Step and Direction Signals ..........................................................4
Overview of Amplifiers............................................................................................................. 4
Amplifiers in Current Mode ........................................................................................4
Amplifiers in Velocity Mode....................................................................................... 4
Stepper Motor Amplifiers............................................................................................4
DMC-2x00 Functional Elements ............................................................................................... 5
Microcomputer Section ............................................................................................... 5
Motor Interface............................................................................................................5
Communication ...........................................................................................................5
General I/O..................................................................................................................6
System Elements .........................................................................................................6
Motor...........................................................................................................................6
Amplifier (Driver) .......................................................................................................6
Encoder........................................................................................................................7
Watch Dog Timer........................................................................................................7
Chapter 2 Getting Started 9
The DMC-2x00 Main Board......................................................................................................9
The DMC-2000 Daughter Board .............................................................................................10
The DMC-2200 Daughter Board .............................................................................................11
Elements You Need ................................................................................................................. 12
Installing the DMC-2x00 ......................................................................................................... 14
Step 1. Determine Overall Motor Configuration .......................................................14
Step 2. Install Jumpers on the DMC-2x00.................................................................15
Step 3a. Configure DIP switches on the DMC-2000................................................. 16
DMC-2x00 Contentsyi

Step 3b. Configure DIP switches on the DMC-2100................................................. 17
Step 3c. Configure DIP switches on the DMC-2200................................................. 17
Step 4. Install the Communications Software............................................................18
Step 5. Connect AC Power to the Controller............................................................. 18
Step 6. Establish Communications with Galil Software............................................ 19
Step 7. Determine the Axes to be Used for Sinusoidal Commutation.......................21
Step 8. Make Connections to Amplifier and Encoder. ..............................................22
Step 9a. Connect Standard Servo Motors.................................................................. 24
Step 9b. Connect Sinusoidal Commutation Motors...................................................27
Step 9c. Connect Step Motors ...................................................................................30
Step 10. Tune the Servo System................................................................................30
Design Examples .....................................................................................................................31
System Set-up............................................................................................................ 31
Profiled Move............................................................................................................ 32
Multiple Axes ............................................................................................................32
Objective: Move the four axes independently. ..........................................................32
Independent Moves ................................................................................................... 32
The motion parameters may be specified independently as illustrated below...........32
Position Interrogation ................................................................................................32
The position error, which is the difference between the commanded position and the
actual position can be interrogated with the instruction TE. ..................................... 33
Absolute Position ......................................................................................................33
Velocity Control ........................................................................................................ 33
Operation Under Torque Limit.................................................................................. 34
Interrogation .............................................................................................................. 34
Operation in the Buffer Mode ...................................................................................34
Using the On-Board Editor........................................................................................34
Motion Programs with Loops ....................................................................................35
Motion Programs with Trippoints .............................................................................35
Control Variables ...................................................................................................... 36
Linear Interpolation ................................................................................................... 36
Circular Interpolation ................................................................................................ 37
Chapter 3 Connecting Hardware 39
Overview .................................................................................................................................39
Using Optoisolated Inputs .......................................................................................................39
Limit Switch Input.....................................................................................................39
Home Switch Input.................................................................................................... 40
Abort Input ................................................................................................................40
Reset Input.................................................................................................................41
Uncommitted Digital Inputs ......................................................................................41
Wiring the Opto-Isolated Inputs ..............................................................................................41
The Opto-Isolation Common Point ...........................................................................41
Using an Isolated Power Supply................................................................................ 42
Bypassing the Opto-Isolation: ...................................................................................43
Analog Inputs ..........................................................................................................................43
Amplifier Interface .................................................................................................................. 43
TTL Inputs...............................................................................................................................44
The Auxiliary Encoder Inputs ...................................................................................44
TTL Outputs ............................................................................................................................ 45
General Use Outputs..................................................................................................45
Output Compare ........................................................................................................45
Error Output .............................................................................................................. 46
Extended I/O of the DMC-2x00 Controller .............................................................................46
ii •Contents DMC-2X00

Chapter 4 Communication 47
Introduction ............................................................................................................................. 47
RS232 Ports .............................................................................................................................47
RS232 - Main Port {P1} DATATERM..................................................................... 47
RS232 - Auxiliary Port {P2} DATASET ..............................................................47
*RS422 - Main Port {P1}.......................................................................................... 48
*RS422 - Auxiliary Port {P2}................................................................................... 48
RS-232 Configuration ............................................................................................... 48
Ethernet Configuration (DMC-2100/2200 only) ..................................................................... 50
Communication Protocols .........................................................................................50
Addressing.................................................................................................................51
Communicating with Multiple Devices.....................................................................53
Multicasting............................................................................................................... 54
Using Third Party Software....................................................................................... 54
Data Record .............................................................................................................................55
Data Record Map.......................................................................................................55
Explanation of Status Information and Axis Switch Information..............................57
Notes Regarding Velocity and Torque Information .................................................. 59
QZ Command ............................................................................................................59
Controller Response to Commands .........................................................................................59
Unsolicited Messages Generated by Controller.......................................................................60
Galil Software Tools and Libraries..........................................................................................60
Chapter 5 Command Basics 61
Introduction ............................................................................................................................. 61
Command Syntax - ASCII.......................................................................................................61
Coordinated Motion with more than 1 axis ...............................................................62
Command Syntax - Binary ...................................................................................................... 63
Binary Command Format .......................................................................................... 63
Binary Command Table ............................................................................................64
Controller Response to DATA ................................................................................................65
Interrogating the Controller .....................................................................................................66
Interrogation Commands...........................................................................................66
Summary of Interrogation Commands ...................................................................... 66
Interrogating Current Commanded Values................................................................ 66
Operands.................................................................................................................... 66
Command Summary.................................................................................................. 67
Chapter 6 Programming Motion 69
Overview .................................................................................................................................69
Independent Axis Positioning.................................................................................................. 70
Command Summary - Independent Axis .................................................................. 71
Operand Summary - Independent Axis ..................................................................... 71
Examples ...................................................................................................................72
Position Tracking.....................................................................................................................73
Example..................................................................................................................... 75
Example..................................................................................................................... 76
Trip Points .................................................................................................................78
Command Summary – Position Tracking Mode .......................................................79
Independent Jogging................................................................................................................ 79
Command Summary - Jogging..................................................................................79
Operand Summary - Independent Axis ..................................................................... 79
Examples ...................................................................................................................80
Linear Interpolation Mode.......................................................................................................81
DMC-2x00 Contentsyiii

Specifying the Coordinate Plane ...............................................................................81
Specifying Linear Segments...................................................................................... 81
Additional Commands...............................................................................................82
Command Summary - Linear Interpolation............................................................... 83
Operand Summary - Linear Interpolation..................................................................83
Example..................................................................................................................... 83
Vector Mode: Linear and Circular Interpolation Motion......................................................... 86
Specifying the Coordinate Plane ...............................................................................86
Specifying Vector Segments .....................................................................................87
Additional commands................................................................................................ 87
Command Summary - Coordinated Motion Sequence .............................................. 88
Operand Summary - Coordinated Motion Sequence................................................. 89
Example..................................................................................................................... 89
Electronic Gearing ................................................................................................................... 91
Ramped Gearing ...................................................................................................................... 91
Example..................................................................................................................... 93
Command Summary - Electronic Gearing ................................................................93
Electronic Cam ........................................................................................................................ 95
Command Summary - Electronic CAM .................................................................... 98
Operand Summary - Electronic CAM .......................................................................99
Example..................................................................................................................... 99
Contour Mode........................................................................................................................ 100
Specifying Contour Segments .................................................................................100
Additional Commands.............................................................................................101
Command Summary - Contour Mode .....................................................................102
General Velocity Profiles ........................................................................................ 102
Example................................................................................................................... 102
Virtual Axis ........................................................................................................................... 105
Ecam master example..............................................................................................105
Sinusoidal Motion Example ....................................................................................105
Stepper Motor Operation ....................................................................................................... 106
Specifying Stepper Motor Operation....................................................................... 106
Stepper Motor Smoothing .......................................................................................106
Monitoring Generated Pulses vs. Commanded Pulses ............................................ 106
Motion Complete Trip point.................................................................................... 107
Using an Encoder with Stepper Motors...................................................................107
Command Summary - Stepper Motor Operation.....................................................107
Operand Summary - Stepper Motor Operation........................................................108
Stepper Position Maintenance Mode (SPM)..........................................................................108
Error Limit............................................................................................................... 109
Correction................................................................................................................109
Dual Loop (Auxiliary Encoder)............................................................................................. 112
Additional Commands for the Auxiliary Encoder................................................... 113
Backlash Compensation ..........................................................................................113
Example................................................................................................................... 113
Motion Smoothing................................................................................................................. 114
Using the IT and VT Commands:............................................................................115
Example................................................................................................................... 115
Using the KS Command (Step Motor Smoothing):................................................. 116
Homing ..................................................................................................................................117
Example................................................................................................................... 117
Command Summary - Homing Operation...............................................................119
Operand Summary - Homing Operation.................................................................. 119
High Speed Position Capture (The Latch Function)..............................................................119
Example................................................................................................................... 120
iv •Contents DMC-2X00

Chapter 7 Application Programming 121
Overview ...............................................................................................................................121
Using the DOS Editor to Enter Programs (DMC-2000 only) ................................................ 121
Edit Mode Commands............................................................................................. 122
Example................................................................................................................... 122
Program Format..................................................................................................................... 123
Using Labels in Programs .......................................................................................123
Special Labels..........................................................................................................123
Commenting Programs............................................................................................124
Executing Programs - Multitasking .......................................................................................125
Debugging Programs .............................................................................................................126
Trace Commands ( DMC-2100/2200 only).............................................................126
Error Code Command.............................................................................................. 127
Stop Code Command............................................................................................... 127
RAM Memory Interrogation Commands ................................................................ 127
Operands.................................................................................................................. 127
Example................................................................................................................... 127
Program Flow Commands .....................................................................................................128
Event Triggers & Trippoints....................................................................................128
Conditional Jumps................................................................................................... 132
If, Else, and Endif....................................................................................................134
Subroutines..............................................................................................................136
Stack Manipulation.................................................................................................. 136
Auto-Start Routine .................................................................................................. 136
Automatic Subroutines for Monitoring Conditions ................................................. 137
Mathematical and Functional Expressions ............................................................................ 142
Mathematical Operators ..........................................................................................142
Bit-Wise Operators.................................................................................................. 142
Functions ................................................................................................................. 144
Variables................................................................................................................................144
Programmable Variables ......................................................................................... 145
Operands................................................................................................................................146
Special Operands (Keywords)................................................................................. 146
Arrays ....................................................................................................................................147
Defining Arrays....................................................................................................... 147
Assignment of Array Entries ...................................................................................147
Uploading and Downloading Arrays to On Board Memory.................................... 148
Automatic Data Capture into Arrays....................................................................... 148
Deallocating Array Space........................................................................................ 150
Input of Data (Numeric and String)....................................................................................... 150
Input of Data............................................................................................................150
Operator Data Entry Mode ......................................................................................151
Using Communication Interrupt.............................................................................. 152
Output of Data (Numeric and String) ....................................................................................153
Sending Messages ................................................................................................... 154
Displaying Variables and Arrays............................................................................. 155
Interrogation Commands......................................................................................... 155
Formatting Variables and Array Elements ..............................................................157
Converting to User Units.........................................................................................158
Hardware I/O ......................................................................................................................... 158
Digital Outputs ........................................................................................................ 158
Digital Inputs........................................................................................................... 159
The Auxiliary Encoder Inputs .................................................................................160
Input Interrupt Function .......................................................................................... 160
Analog Inputs ..........................................................................................................161
DMC-2x00 Contentsyv

Extended I/O of the DMC-2x00 Controller ...........................................................................162
Configuring the I/O of the DMC-2x00.................................................................... 162
Saving the State of the Outputs in Non-Volatile Memory....................................... 163
Accessing Extended I/O .......................................................................................... 163
Interfacing to Grayhill or OPTO-22 G4PB24 .........................................................164
Example Applications............................................................................................................164
Wire Cutter.............................................................................................................. 164
A-B Table Controller............................................................................................... 165
Speed Control by Joystick .......................................................................................167
Position Control by Joystick.................................................................................... 168
Backlash Compensation by Sampled Dual-Loop .................................................... 168
Chapter 8 Hardware & Software Protection 171
Introduction ........................................................................................................................... 171
Hardware Protection ..............................................................................................................171
Output Protection Lines........................................................................................... 171
Input Protection Lines .............................................................................................172
Software Protection ...............................................................................................................172
Programmable Position Limits ................................................................................ 173
Off-On-Error ...........................................................................................................173
Automatic Error Routine ......................................................................................... 173
Limit Switch Routine .............................................................................................. 174
Chapter 9 Troubleshooting 175
Overview ...............................................................................................................................175
Installation ............................................................................................................................. 175
Communication......................................................................................................................176
Stability.................................................................................................................................. 176
Operation ............................................................................................................................... 176
Chapter 10 Theory of Operation 177
Overview ...............................................................................................................................177
Operation of Closed-Loop Systems....................................................................................... 179
System Modeling...................................................................................................................180
Motor-Amplifier...................................................................................................... 181
Encoder....................................................................................................................183
DAC ........................................................................................................................184
Digital Filter ............................................................................................................ 184
ZOH.........................................................................................................................185
System Analysis.....................................................................................................................186
System Design and Compensation.........................................................................................188
The Analytical Method............................................................................................ 188
Appendices 191
Electrical Specifications ........................................................................................................191
Servo Control .......................................................................................................... 191
Stepper Control........................................................................................................191
Input / Output .......................................................................................................... 191
Power....................................................................................................................... 192
Performance Specifications ................................................................................................... 192
Minimum Servo Loop Update Time: ......................................................................192
Fast Update Rate Mode .........................................................................................................193
Connectors for DMC-2x00 Main Board ................................................................................194
vi •Contents DMC-2X00

DMC-2x00 Axes A-D High Density Connector...................................................... 194
DMC-2x00 Axes E-H High Density Connector...................................................... 195
DMC-2x00 Auxiliary Encoder 36 Pin High Density Connector .............................196
DMC-2x00 Extended I/O 80 Pin High Density Connector ..................................... 196
RS-232-Main Port ................................................................................................... 198
RS-232-Auxiliary Port............................................................................................. 198
USB - In USB - Out.........................................................................................198
Ethernet ...................................................................................................................199
Cable Connections for DMC-2x00 ........................................................................................199
Standard RS-232 Specifications ..............................................................................199
DMC-2x00 Serial Cable Specifications...................................................................200
Pin-Out Description for DMC-2x00 ......................................................................................202
Jumper Description for DMC-2x00 ....................................................................................... 204
Dimensions for DMC-2x00 ...................................................................................................205
Accessories and Options........................................................................................................ 206
ICM-2900 Interconnect Module ............................................................................................207
Mechanical Specifications....................................................................................... 207
Environmental Specifications.................................................................................. 207
Equipment Maintenance.......................................................................................... 207
Description ..............................................................................................................207
ICM-2900 Drawing: ................................................................................................ 211
ICM-2908 Interconnect Module ............................................................................................212
ICM-2908 Drawing: ................................................................................................ 213
PCB Layout of the ICM-2900: ................................................................................ 214
ICM-1900 Interconnect Module ............................................................................................215
Features ...................................................................................................................215
ICM-1900 Drawing: ................................................................................................ 218
AMP-19x0 Mating Power Amplifiers ...................................................................................218
Features ...................................................................................................................218
Specifications ..........................................................................................................219
Opto-Isolated Outputs for ICM-2900 / ICM-1900 / AMP-19x0............................................ 219
Standard Opto-Isolation and High Current Opto-isolation:..................................... 219
Configuring the Amplifier Enable for ICM-2900 / ICM-1900.............................................. 220
-LAEN Option:........................................................................................................220
-Changing the Amplifier Enable Voltage Level:..................................................... 220
IOM-1964 Opto-Isolation Module for Extended I/O............................................................. 221
Description: .............................................................................................................221
Overview .................................................................................................................221
Configuring Hardware Banks.................................................................................. 222
Digital Inputs........................................................................................................... 223
High Power Digital Outputs ....................................................................................224
Standard Digital Outputs ......................................................................................... 225
Electrical Specifications ..........................................................................................226
Relevant DMC Commands......................................................................................227
Screw Terminal Listing ........................................................................................... 227
CB-50-100 Adapter Board..................................................................................................... 230
Connectors:.............................................................................................................. 230
CB-50-100 Drawing: ............................................................................................... 233
CB-50-80 Adapter Board....................................................................................................... 234
Connectors:.............................................................................................................. 235
CB-50-80 Drawing: .................................................................................................237
TERM-1500 Operator Terminal ............................................................................................ 239
Features ...................................................................................................................240
Description ..............................................................................................................240
Specifications - Hand-Held ..................................................................................... 240
Specifications - Panel Mount................................................................................... 241
DMC-2x00 Contentsyvii

Keypad Maps - Hand-Held...................................................................................... 241
Keypad Map - Panel Mount – 6 columns x 5 rows .................................................242
Configuration........................................................................................................... 243
Function Keys.......................................................................................................... 244
Input/Output of Data – DMC-2x00 Commands ...................................................... 244
Ordering Information............................................................................................... 245
Coordinated Motion - Mathematical Analysis....................................................................... 246
Example- Communicating with OPTO-22 SNAP-B3000-ENET..........................................249
DMC-2x00/DMC-1500 Comparison..................................................................................... 252
List of Other Publications...................................................................................................... 253
Training Seminars.................................................................................................................. 253
Contacting Us ........................................................................................................................254
WARRANTY ........................................................................................................................254
Index 255
viii •Contents DMC-2X00