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

Chapter 1 Overview
Introduction
The DMC-2x00 Series are Galil’s highest performance stand-alone controller. The controller series
offers many enhanced features including high speed communications, non-volatile program memory,
faster encoder speeds, and improved cabling for EMI reduction.
Each DMC-2x00 provides two communication channels: high speed RS-232 (2 channels up to 115K
Baud) and Universal Serial Bus (12Mb/s) for the DMC-2000 or 10BaseT Ethernet for the DMC-2100
and 100BaseT Ethernet for the DMC-2200.
A 4Meg Flash EEPROM provides non-volatile memory for storing application programs, parameters,
arrays and firmware. New firmware revisions are easily upgraded in the field.
The DMC-2x00 is available with up to eight axes in a single stand alone unit. The DMC-2x10, 2x20,
2x30, 2x40 are one thru four axes controllers and the DMC-2x50, 2x60, 2x70, 2x80 are five thru eight
axes controllers.
Designed to solve complex motion problems, the DMC-2x00 can be used for applications involving
jogging, point-to-point positioning, vector positioning, electronic gearing, multiple move sequences,
and contouring. The controller eliminates jerk by programmable acceleration and deceleration with
profile smoothing. For smooth following of complex contours, the DMC-2x00 provides continuous
vector feed of an infinite number of linear and arc segments. The controller also features electronic
gearing with multiple master axes as well as gantry mode operation.
For synchronization with outside events, the DMC-2x00 provides uncommitted I/O, including 8 opto-
isolated digital inputs (16 inputs for DMC-2x50 thru DMC-2x80), 8 digital outputs (16 outputs for
DMC-2x50 thru DMC-2x80), and 8 analog inputs for interface to joysticks, sensors, and pressure
transducers. The DMC-2x00 also has an additional 64 I/O. Further I/O is available if the auxiliary
encoders are not being used (2 inputs / each axis). Dedicated optoisolated inputs are provided for
forward and reverse limits, abort, home, and definable input interrupts.
Commands can be sent in either Binary or ASCII. Additional software is available for automatic-
tuning, trajectory viewing on a PC screen, CAD translation, and program development using many
environments such as Visual Basic, C, C++ etc. Drivers for DOS, Linux, Windows 3.1, 95, 98, 2000,
ME and NT are available.
DMC-2X00 Chapter 1 Overview y1

Specifications
DMC- 2000 Family Part Number Definition
D M C - 2 0 0 0
| |
Communication Options ------| |
0: USB |
2: Ethernet |
|
Number of Axis ---------------|
1: One Axes
2: Two Axes
3: Three Axes
4: Four Axes
5: Five Axes
6: Six Axes
7: Seven Axes
8: Eight Axes
Electrical Specifications
Description Unit Specification
----------- ---- -------------
AC Input Line Voltage VAC 100-240
AC Input Line Frequency Hz 50-60
Power Dissipation W 12
Mechanical Specifications
Description Unit Specification
----------- ---- -------------
Weight lb 5.2
Length in 12.25
Width in 5.49
Height in 2.37
2 •Chapter 1 Overview DMC-2X00

Environmental Specifications
Description Unit Specification
----------- ---- -------------
Storage Temperature C -25 to +70
Operating Temperature C 0 to +70
Operating Altitude feet 10,000
Equipment Maintenance
The DMC-2000 does not require maintenance.
Overview of Motor Types
The DMC-2x00 can provide the following types of motor control:
1. Standard servo motors with +/- 10 volt command signals
2. Brushless servo motors with sinusoidal commutation
3. Step motors with step and direction signals
4. Other actuators such as hydraulics - For more information, contact Galil.
The user can configure each axis for any combination of motor types, providing maximum flexibility.
Standard Servo Motor with +/- 10 Volt Command Signal
The DMC-2x00 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 (+/- 10 volts) to connect to a servo amplifier. This connection
is described in Chapter 2.
Brushless Servo Motor with Sinusoidal Commutation
The DMC-2x00 can provide sinusoidal commutation for brushless motors (BLM). In this
configuration, the controller generates two sinusoidal signals for connection with amplifiers
specifically designed for this purpose.
Note: The task of generating sinusoidal commutation may be accomplished in the brushless motor
amplifier. If the amplifier generates the sinusoidal commutation signals, only a single command signal
is required and the controller should be configured for a standard servo motor (described above).
Sinusoidal commutation in the controller can be used with linear and rotary BLMs. However, the
motor velocity should be limited such that a magnetic cycle lasts at least 6 milliseconds with a standard
update rate of 1 millisecond. For faster motors, please contact the factory.
To simplify the wiring, the controller provides a one-time, automatic set-up procedure. When the
controller has been properly configured, the brushless motor parameters may be saved in non-volatile
memory.
The DMC-2x00 can control BLMs equipped with Hall sensors as well as without Hall sensors. If Hall
sensors are available, once the controller has been setup, the brushless motor parameters may be saved
in non-volatile memory. In this case, the controller will automatically estimate the commutation phase
DMC-2X00 Chapter 1 Overview y3

upon reset. This allows the motor to function immediately upon power up. The Hall effect sensors
also provide a method for setting the precise commutation phase. Chapter 2 describes the proper
connection and procedure for using sinusoidal commutation of brushless motors.
Stepper Motor with Step and Direction Signals
The DMC-2x00 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.
Overview of Amplifiers
The amplifiers should be suitable for the motor and may be linear or pulse-width-modulated. An
amplifier may have current feedback, voltage feedback or velocity feedback.
Amplifiers in Current Mode
Amplifiers in current mode should accept an analog command signal in the +/-10 volt range. The
amplifier gain should be set such that a +10V command will generate the maximum required current.
For example, if the motor peak current is 10A, the amplifier gain should be 1 A/V.
Amplifiers in Velocity Mode
For velocity mode amplifiers, a command signal of 10 volts should run the motor at the maximum
required speed. The velocity gain should be set such that an input signal of 10V runs the motor at the
maximum required speed.
Stepper Motor Amplifiers
For step motors, the amplifiers should accept step and direction signals.
4 •Chapter 1 Overview DMC-2X00

DMC-2x00 Functional Elements
The DMC-2x00 circuitry can be divided into the following functional groups as shown in Figure 1.1
and discussed below.
WATCHDOG TIMER
68331
MICROCOMPUTER
WITH
4 Meg RAM
4 Meg FLASH EEPROM
HIGH-SPEED
MOTOR/ENCODER
INTERFACE
FOR
A,B,C,D
I/O INTERFACE
USB/ETHERNET
RS-232 /
RS-422
8 UNCOMMITTED
ANALOG INPUTS
HIGH-SPEED LATCH FOR EACH AXIS
8 PROGRAMMABLE,
OPTOISOLATED
INPUTS
8 PROGRAMMABLE
OUTPUTS
ISOLATED LIMITS AND
HOME INPUTS
MAIN ENCODERS
AUXILIARY ENCODERS
+/- 10 VOLT OUTPUT FOR
SERVO MOTORS
PULSE/DIRECTION OUTPUT
FOR STEP MOTORS
HIGH SPEED ENCODER
COMPARE OUTPUT
64 Configurable I/O
Figure 1.1 - DMC-2x00 Functional Elements
Microcomputer Section
The main processing unit of the DMC-2x00 is a specialized 32-Bit Motorola 68331 Series
Microcomputer with 4 Meg RAM and 4 Meg Flash EEPROM. The RAM provides memory for
variables, array elements and application programs. The flash EEPROM provides non-volatile storage
of variables, programs, and arrays. It also contains the DMC-2x00 firmware.
Motor Interface
Galil’s GL-1800 custom, sub-micron gate array performs quadrature decoding of each encoder at up to
12 MHz. For standard servo operation, the controller generates a +/-10 volt analog signal (16 Bit
DAC). For sinusoidal commutation operation, the controller uses two DACs to generate two +/-10
volt analog signals. For stepper motor operation, the controller generates a step and direction signal.
Communication
The communication interface with the DMC-2x00 consists of high speed RS-232 and USB or high
speed RS-232 and Ethernet. The USB channel accepts based rates up to 12Mb/sec and the two RS-232
channels can generate up to 115K.
DMC-2X00 Chapter 1 Overview y5

General I/O
The DMC-2x00 provides interface circuitry for 8 bi-directional, optoisolated inputs, 8 TTL outputs and
8 analog inputs with 12-Bit ADC (16-Bit optional). The DMC-2x00 also has an additional 64 I/O and
unused auxiliary encoder inputs may also be used as additional inputs (2 inputs / each axis). The
general inputs can also be used as high speed latches for each axis. A high speed encoder compare
output is also provided.
2x80 The DMC-2x50 through DMC-2x80 controller provides an additional 8 optoisolated inputs and 8 TTL
outputs.
System Elements
As shown in Fig. 1.2, the DMC-2x00 is part of a motion control system which includes amplifiers,
motors and encoders. These elements are described below.
Computer DMC-2x00 Controller
A
mplifier (Driver)
Power Supply
Encoder Motor
Figure 1.2 - Elements of Servo systems
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 required speed and acceleration. (Galil's "Motion Component
Selector" software can help you with motor sizing). 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. An encoder
is not required when step motors are used.
Amplifier (Driver)
For each axis, the power amplifier converts a +/-10 volt signal from the controller into current to drive
the motor. For stepper motors, the amplifier converts step and direction signals into current. The
amplifier should be sized properly to meet the power requirements of the motor. For brushless motors,
an amplifier that provides electronic commutation is required or the controller must be configured to
provide sinusoidal commutation. The amplifiers 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.
6 •Chapter 1 Overview DMC-2X00

Encoder
An encoder translates motion into electrical pulses which are fed back into the controller. The DMC-
2x00 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- and
CHB,CHB-). The DMC-2x00 decodes either type into quadrature states or four times the number of
cycles. Encoders may also have a third channel (or index) for synchronization.
For stepper motors, the DMC-2x00 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 3,000,000 full encoder cycles/second (12,000,000 quadrature counts/sec). For example, if the
encoder line density is 10000 cycles per inch, the maximum speed is 300 inches/second. If higher
encoder frequency is required, please consult the factory.
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-2x00. Single-
ended 12 volt signals require a bias voltage input to the complementary inputs).
The DMC-2x00 can accept analog feedback instead of an encoder for any axis.
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 and talk to one of our applications
engineers about your particular system requirements.
Watch Dog Timer
The DMC-2x00 provides an internal watch dog timer which checks for proper microprocessor
operation. The timer toggles the Amplifier Enable Output (AMPEN) which can be used to switch the
amplifiers off in the event of a serious DMC-2x00 failure. The AMPEN output is normally high.
During power-up and if the microprocessor ceases to function properly, the AMPEN output will go
low. The error light will also turn on at this stage. A reset is required to restore the DMC-2x00 to
normal operation. Consult the factory for a Return Materials Authorization (RMA) Number if your
DMC-2x00 is damaged.
DMC-2X00 Chapter 1 Overview y7

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8 •Chapter 1 Overview DMC-2X00

Chapter 2 Getting Started
The DMC-2x00 Main Board
GL-1800
Motorola
68331
GL-1800
DMC-2000
REV A
GALIL MOTION CONTROL
SRAM
EEPROM
1AUX ENCODERS AXES A-D (X-W)J5 J1
MADE IN USA
J9 AXES E-H
J2
JP5
SMA(X)
SMB(Y)
SMC(Z)
SMD(W)
OPT1
SW1
+5V
+12V
GND
-12V +5V
||| ||||| |||||
*AH-9999*
SRAM
JP7
SME
SMF
SMG
SMH
OPT2
AXES E-H
100 pin high density connector
AMP part # 2-178238-9
AXES A-D
100 pin high density connector
AMP part # 2-178238-9
AUX Encoder inputs
36 pin high density connector
9.50 "
Serial number label
5.80"
ADS7806
Stepper motor
configuration
header
Reset
Switch
Error,
Power
LED's
MicroprocessorPower connector
6 pin Molex
Jumper to
connect
optoisolators to
onboard 5V
supply
Jumper Master
Reset to clear
EEPROM
JP1
MASTER RESET
UPGRADE
*
JP3
LSCOM
INCOM
Stepper Motor
configuration
header
Analog to Digital
Converter IC
7806 - 12 bit
7807 - 16 bit
Communications
Daughterboard
connector
Figure 2-1 - Outline of the main board of the DMC-2x00
DMC-2X00 Chapter 2 Getting Started y9

The DMC-2000 Daughter Board
J4
CMB-2001 REV C
USB DAUGHTER CARD
GALIL MOTION CONTROL
U9
J6
MRST XON XOF HSHK 9600 19.2 38 A2 A1 A0 USB
EXTENDED I/O
J1
J3
MADE IN USA
1A1
B1
C1
AUX
JP4
JP3
R232 R232 R232 R485
TERM
MAIN J5
USB IN USB OUT
TERM
R485 R232 R232 R232
R422
S 8
8 S
D1
USB Communications
Status LED
MC1489 MC1488
U7U2 U6 U1
J2
100 pin connector
(attaches to DMC-2000
Main board)
AUX Serial port
DB-9 Female
MAIN Serial port
DB-9 Male 80 pin high
density connector
for extended I/O
USB type B
connector
Configuration DIP
Switches USB type A connector (x2)
3.94"
7.85 "
2.53"
RS-232 buffer
IC's
Figure 2-2 - Outline of the DMC-2000 Daughter Board
10 •Chapter 2 Getting Started DMC-2X00