Galil DMC-4040 User manual

USER MANUAL
DMC-40x0
Manual Rev. 1.0f
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 8/09

Using This Manual
This user manual provides information for proper operation of the DMC-40x0 controller. A separate supplemental
manual, the Command Reference, contains a description of the commands available for use ith this controller.
Your DMC-40x0 motion controller has been designed to ork ith both servo and stepper type motors. Installation
and system setup ill vary depending upon hether the controller ill be used ith stepper motors or servo motors.
To make finding the appropriate instructions faster and easier, icons ill be next to any information that applies
exclusively to one type of system. Other ise, assume that the instructions apply to all types of systems. The icon
legend is sho n belo .
Attention: Pertains to servo motor use.
Attention: Pertains to stepper motor use.
4080
Attention: Pertains to controllers ith more than 4 axes.
Please note that many examples are ritten for the DMC-4040 four-axes controller or the DMC-4080 eight axes
controller. Users of the DMC-4030 3-axis controller, DMC-4020 2-axes controller or DMC-4010 1-axis controller
should note that the DMC-4030 uses the axes denoted as XYZ, the DMC-4020 uses the axes denoted as XY, and the
DMC-4010 uses the X-axis only.
Examples for the DMC-4080 denote the axes as A,B,C,D,E,F,G,H. Users of the DMC-4050 5-axes controller.
DMC-4060 6-axes controller or DMC-4070, 7-axes controller should note that the DMC-4050 denotes the axes as
A,B,C,D,E, the DMC-4060 denotes the axes as A,B,C,D,E,F and the DMC-4070 denotes the axes as
A,B,C,D,E,F,G. The axes A,B,C,D may be used interchangeably ith 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.
DMC-40x0 Contents • i

Contents
Contents iii
Chapter 1 Overview 1
Introduction ................................................................................................................... 1
Overvie of Motor Types ............................................................................................. 2
Standard Servo Motor ith +/- 10 Volt Command Signal ....... 2
Brushless Servo Motor ith Sinusoidal Commutation ............. 2
Stepper Motor ith Step and Direction Signals ....................... 2
Overvie of External Amplifiers .................................................................................. 3
Amplifiers in Current Mode ...................................................... 3
Amplifiers in Velocity Mode .................................................... 3
Stepper Motor Amplifiers ......................................................... 3
Overvie of Galil Amplifiers and Drivers ................................................................... 3
A1 – AMP-430x0 (-D3040, -D3020) ........................................ 3
A2 – AMP-43140 (-D3140) ...................................................... 3
A3 – SDM-44040 (-D4040) ...................................................... 3
A4 – SDM-44140 (-D4140) ...................................................... 3
DMC-40x0 Functional Elements .................................................................................. 4
Microcomputer Section ............................................................. 4
Motor Interface ......................................................................... 4
Communication ......................................................................... 4
General I/O ................................................................................ 4
System Elements ....................................................................... 5
Motor ......................................................................................... 5
Amplifier (Driver) ..................................................................... 5
Encoder ..................................................................................... 6
Watch Dog Timer ..................................................................... 6
Chapter 2 Getting Started 7
DMC-4040 Layout ........................................................................................................ 7
DMC-4080 Layout ........................................................................................................ 8
DMC-40x0 Po er Connections .................................................................................... 9
DMC-4040 Dimensions ................................................................................................ 10
DMC-4080 Dimensions ................................................................................................ 11
Elements You Need ...................................................................................................... 12
Installing the DMC-40x0 .............................................................................................. 13
Step 1. Determine Overall Motor Configuration ...................... 13
Step 2. Install Jumpers on the DMC-40x0 ................................ 14
Step 3. Install the Communications Soft are ........................... 14
Step 4. Connect 20-80VDC Po er to the Controller ................ 15
Step 5. Establish Communications ith Galil Soft are ........... 15
Step 6. Determine the Axes to be Used for Sinusoidal Commutation .......................................................... 17
Step 7. Make Connections to Amplifier and Encoder. ............. 18
Step 8a. Connect Standard Servo Motors ................................. 19
Step 8b. Connect Sinusoidal Commutation Motors .................. 21
Step 8c. Connect Step Motors ................................................... 24
Step 9. Tune the Servo System ................................................. 24
Design Examples .......................................................................................................... 25
Example 1 - System Set-up ....................................................... 25
Example 2 - Profiled Move ....................................................... 25
DMC-40x0 Contents • ii

Example 3 - Multiple Axes ....................................................... 26
Example 4 - Independent Moves .............................................. 26
Example 5 - Position Interrogation ........................................... 26
Example 6 - Absolute Position ................................................. 26
Example 7 - Velocity Control ................................................... 27
Example 8 - Operation Under Torque Limit ............................. 27
Example 9 - Interrogation ......................................................... 27
Example 10 - Operation in the Buffer Mode ............................ 28
Example 11 - Using the On-Board Editor ................................. 28
Example 12 - Motion Programs ith Loops ............................. 28
Example 13 - Motion Programs ith Trippoints ...................... 29
Example 14 - Control Variables ............................................... 29
Example 15 - Linear Interpolation ............................................ 30
Example 16 - Circular Interpolation ......................................... 30
Chapter Connecting Hardware 2
Overvie ....................................................................................................................... 32
Using Optoisolated Inputs ............................................................................................. 32
Limit S itch Input .................................................................... 32
Home S itch Input ................................................................... 33
Abort Input ................................................................................ 33
ELO (Electronic Lock-Out) Input ............................................. 34
Reset Input ................................................................................ 34
Uncommitted Digital Inputs ..................................................... 34
Wiring the Optoisolated Inputs ..................................................................................... 34
Electrical Specifications ............................................................ 34
Bi-Directional Capability .......................................................... 34
Using an Isolated Po er Supply ............................................... 36
Bypassing the Opto-Isolation: ................................................... 37
TTL Inputs .................................................................................................................... 37
The Auxiliary Encoder Inputs ................................................... 37
High Po er Opto-Isolated Outputs ............................................................................... 38
Electrical Specifications ............................................................ 38
Wiring the Opto-Isolated Outputs ............................................. 38
Analog Inputs ................................................................................................................ 39
AQ settings ................................................................................ 39
Electrical Specifications ............................................................ 39
TTL Outputs ................................................................................................................. 39
Output Compare ........................................................................ 39
Error Output .............................................................................. 39
Extended I/O of the DMC-40x0 Controller ................................................................. 40
Electrical Specifications (3.3V – Standard) .............................. 40
Electrical Specifications (5V – Option) .................................... 40
Amplifier Interface ........................................................................................................ 41
Electrical Specifications ............................................................ 41
Overvie ................................................................................... 41
ICM-42000 and ICM-42100 Amplifier Enable Circuit ............ 41
ICM-42200 Amplifier Enable Circuit ....................................... 44
Chapter 4 Software Tools and Communication 48
Introduction ................................................................................................................... 48
RS232 and RS422 Ports ................................................................................................ 48
RS-232 Configuration ............................................................... 48
RS-422 Configuration ............................................................... 50
Ethernet Configuration .................................................................................................. 50
Communication Protocols ......................................................... 50
Addressing ................................................................................ 51
Communicating ith Multiple Devices .................................... 52
Multicasting .............................................................................. 52
Using Third Party Soft are ...................................................... 52
Modbus ......................................................................................................................... 53
Modbus Examples .................................................................... 54
Data Record .................................................................................................................. 55
Explanation Data Record Bit Fields ......................................... 60
Notes Regarding Velocity and Torque Information ................. 61
QZ Command ............................................................................ 61
Controller Response to Commands .............................................................................. 61
Unsolicited Messages Generated by Controller ............................................................ 62
DMC-40x0 Contents • iii

GalilTools (Windo s and Linux) ................................................................................. 63
Creating Custom Soft are Interfaces ........................................................................... 65
HelloGalil – Quick Start to PC programming ........................... 65
GalilTools Communication Libraries ....................................... 65
ActiveX Toolkit ........................................................................ 66
DMCWin Programmers Toolkit ............................................... 66
Galil Communications API ith C/C++ ................................... 67
Galil Communications API ith Visual Basic ........................ 67
DOS, and QNX tools .................................................................................................... 69
Chapter 5 Command Basics 70
Introduction ................................................................................................................... 70
Command Syntax - ASCII ............................................................................................ 70
Coordinated Motion ith more than 1 axis .............................. 71
Command Syntax – Binary (advanced) ........................................................................ 72
Binary Command Format ......................................................... 72
Binary command table .............................................................. 73
Controller Response to DATA ...................................................................................... 74
Interrogating the Controller .......................................................................................... 74
Interrogation Commands .......................................................... 74
Summary of Interrogation Commands ...................................... 75
Interrogating Current Commanded Values. .............................. 75
Operands ................................................................................... 75
Command Summary ................................................................. 75
Chapter 6 Programming Motion 76
Overvie ....................................................................................................................... 76
Independent Axis Positioning ....................................................................................... 78
Command Summary - Independent Axis .................................. 78
Operand Summary - Independent Axis .................................... 78
Independent Jogging ..................................................................................................... 80
Command Summary - Jogging ................................................ 80
Operand Summary - Independent Axis .................................... 81
Position Tracking .......................................................................................................... 81
Example - Motion 2: ............................................................... 83
Example Motion 4 ................................................................... 84
Trip Points ................................................................................. 85
Command Summary – Position Tracking Mode ..................... 86
Linear Interpolation Mode ............................................................................................ 86
Specifying Linear Segments ..................................................... 86
Command Summary - Linear Interpolation .............................. 88
Operand Summary - Linear Interpolation ................................ 88
Example - Linear Move ............................................................ 89
Example - Multiple Moves ....................................................... 90
Vector Mode: Linear and Circular Interpolation Motion ............................................. 91
Specifying the Coordinate Plane ............................................... 91
Specifying Vector Segments ..................................................... 91
Additional commands ............................................................... 92
Command Summary - Coordinated Motion Sequence ............. 94
Operand Summary - Coordinated Motion Sequence ................ 94
Electronic Gearing ........................................................................................................ 95
Ramped Gearing ........................................................................................................... 96
Example – Electronic Gearing Over a Specified Interval ......... 97
Command Summary - Electronic Gearing ................................ 98
Example - Simple Master Slave ................................................ 98
Example - Electronic Gearing ................................................... 98
Example - Gantry Mode ............................................................ 98
Electronic Cam .............................................................................................................. 99
Command Summary - Electronic CAM ................................... 103
Operand Summary - Electronic CAM ...................................... 103
Example - Electronic CAM ...................................................... 103
PVT Mode ..................................................................................................................... 105
Specifying PVT Segments ........................................................ 105
Exiting PVT Mode .................................................................... 105
Error Conditions and Stop Codes ............................................. 105
Additional PVT Information ..................................................... 105
Command Summary – PVT ...................................................... 106
PVT Examples .......................................................................... 106
DMC-40x0 Contents • iv

Multi-Axis Coordinated Move .................................................. 108
Contour Mode ............................................................................................................... 110
Specifying Contour Segments ................................................... 110
Additional Commands .............................................................. 111
Command Summary - Contour Mode ...................................... 111
Stepper Motor Operation .............................................................................................. 115
Specifying Stepper Motor Operation ....................................... 115
Using an Encoder ith Stepper Motors .................................... 116
Command Summary - Stepper Motor Operation ..................... 116
Operand Summary - Stepper Motor Operation ......................... 116
Stepper Position Maintenance Mode (SPM) ................................................................. 117
Internal Controller Commands (user can query): ..................... 117
User Configurable Commands (user can query & change): ..... 117
Error Limit ................................................................................ 117
Correction ................................................................................. 117
Dual Loop (Auxiliary Encoder) .................................................................................... 120
Backlash Compensation ............................................................ 121
Motion Smoothing ....................................................................................................... 122
Using the IT Command: ............................................................ 122
Using the KS Command (Step Motor Smoothing): .................. 124
Homing ......................................................................................................................... 124
Stage 1: ...................................................................................... 124
Stage 2: ...................................................................................... 124
Stage 3: ...................................................................................... 124
Command Summary - Homing Operation ............................... 127
Operand Summary - Homing Operation ................................... 127
High Speed Position Capture (The Latch Function) .................................................... 127
Fast Update Rate Mode ................................................................................................ 129
Chapter 7 Application Programming 1 0
Overvie ....................................................................................................................... 130
Using the DMC-40x0 Editor to Enter Programs ........................................................... 130
Edit Mode Commands .............................................................. 131
Program Format ............................................................................................................ 131
Using Labels in Programs ......................................................... 131
Special Labels ........................................................................... 132
Commenting Programs ............................................................. 132
Executing Programs - Multitasking .............................................................................. 133
Debugging Programs .................................................................................................... 134
Program Flo Commands ............................................................................................ 135
Event Triggers & Trippoints ..................................................... 135
Event Trigger Examples: .......................................................... 137
Conditional Jumps .................................................................... 139
Using If, Else, and Endif Commands ........................................ 141
Subroutines ............................................................................... 142
Stack Manipulation ................................................................... 142
Auto-Start Routine .................................................................... 143
Automatic Subroutines for Monitoring Conditions .................. 143
JS Subroutine Stack Variables (^a, ^b, ^c, ^d, ^e, ^f, ^g, ^h) ... 147
Mathematical and Functional Expressions ................................................................... 149
Mathematical Operators ............................................................ 149
Bit-Wise Operators ................................................................... 150
Functions .................................................................................. 151
Variables ....................................................................................................................... 151
Programmable Variables ........................................................... 152
Operands ....................................................................................................................... 153
Special Operands (Key ords) .................................................. 153
Arrays ............................................................................................................................ 154
Defining Arrays ........................................................................ 154
Assignment of Array Entries .................................................... 154
Automatic Data Capture into Arrays ........................................ 155
De-allocating Array Space ........................................................ 157
Input of Data (Numeric and String) .............................................................................. 157
Input of Data ............................................................................. 157
Operator Data Entry Mode ....................................................... 158
Using Communication Interrupt .............................................. 158
Output of Data (Numeric and String) ........................................................................... 160
Sending Messages ..................................................................... 160
Displaying Variables and Arrays ............................................. 161
DMC-40x0 Contents • v

Interrogation Commands .......................................................... 162
Formatting Variables and Array Elements ............................... 163
Converting to User Units .......................................................... 164
Hard are I/O ................................................................................................................ 164
Digital Outputs .......................................................................... 164
Digital Inputs ............................................................................ 165
The Auxiliary Encoder Inputs ................................................... 166
Input Interrupt Function ............................................................ 166
Analog Inputs ............................................................................ 167
Extended I/O of the DMC-40x0 Controller ................................................................. 168
Configuring the I/O of the DMC-40x0 ..................................... 168
Saving the State of the Outputs in Non-Volatile Memory ........ 168
Accessing Extended I/O ............................................................ 169
Example Applications ................................................................................................... 169
Wire Cutter ................................................................................ 169
X-Y Table Controller ................................................................ 170
Speed Control by Joystick ........................................................ 173
Position Control by Joystick ..................................................... 174
Backlash Compensation by Sampled Dual-Loop ..................... 174
Chapter 8 Hardware & Software Protection 177
Introduction ................................................................................................................... 177
Hard are Protection ..................................................................................................... 177
Output Protection Lines ............................................................ 177
Input Protection Lines ............................................................... 178
Soft are Protection ....................................................................................................... 178
Programmable Position Limits ................................................. 179
Off-On-Error ............................................................................. 179
Automatic Error Routine ........................................................... 179
Limit S itch Routine ................................................................ 180
Chapter 9 Troubleshooting 181
Overvie ....................................................................................................................... 181
Installation ..................................................................................................................... 181
Stability ......................................................................................................................... 182
Operation ....................................................................................................................... 182
Chapter 10 Theory of Operation 18
Overvie ....................................................................................................................... 183
Operation of Closed-Loop Systems .............................................................................. 185
System Modeling .......................................................................................................... 186
Motor-Amplifier ....................................................................... 187
Encoder ..................................................................................... 189
DAC .......................................................................................... 189
Digital Filter .............................................................................. 190
ZOH .......................................................................................... 191
System Analysis ............................................................................................................ 191
System Design and Compensation ................................................................................ 193
The Analytical Method ............................................................. 193
Appendices 197
Electrical Specifications ................................................................................................ 197
Servo Control ............................................................................ 197
Stepper Control ......................................................................... 197
Input / Output ............................................................................ 197
Po er Requirements ................................................................. 198
Max Po er Output .................................................................... 198
Performance Specifications .......................................................................................... 199
Minimum Servo Loop Update Time: ........................................ 199
Fast Update Rate Mode ................................................................................................ 200
Ordering Options for the DMC-40x0 ........................................................................... 201
Overvie ................................................................................... 201
DMC-40x0 Controller Board Options ...................................... 201
CMB Communication Board Options ...................................... 202
ICM Interconnect Board Options .............................................. 202
AMP Internal Amplifier Options .............................................. 204
DMC-40x0 Contents • vi

Po er Connectors for the DMC-40x0 .......................................................................... 205
Overvie ................................................................................... 205
Molex Part Numbers Used ........................................................ 205
Cable Connections for DMC-40x0 ............................................................................... 206
Standard RS-232 Specifications ............................................... 206
DMC-40x0 Serial Cable Specifications .................................... 207
Pin-Out Description for DMC-40x0 ............................................................................. 208
Configuring the Amplifier Enable Circuit .................................................................... 210
ICM-42000 and ICM-42100 ..................................................... 210
DMC-4040 (Steps 1 and 2) ....................................................... 210
DMC-4080 (Steps 1 and 2) ....................................................... 212
DMC-4040 and DMC-4080 (Step 3) ........................................ 214
DMC-4040 (Steps 4 and 5) ....................................................... 221
DMC-4080 (Steps 4 and 5) ....................................................... 223
Coordinated Motion - Mathematical Analysis ............................................................. 225
Example- Communicating ith OPTO-22 SNAP-B3000-ENET ................................. 228
DMC-40x0/DMC-2200 Comparison ............................................................................ 230
List of Other Publications ............................................................................................. 231
Training Seminars ......................................................................................................... 231
Contacting Us ................................................................................................................ 232
WARRANTY ............................................................................................................... 233
Integrated Components 2 4
Overvie ....................................................................................................................... 234
A1 – AMP-430x0 (-D3040,-D3020) 2- and 4-axis 500W Servo Drives .................................................... 234
A2 – AMP-43140 (-D3140) 4-axis 20W Linear Servo Drives 234
A3 – SDM-44040 (-D4040) 4-axis Stepper Drives ................. 234
A4 – SDM-44140 (-D4140) 4-axis Microstep Drives .............. 234
A5 – CMB-41012 (-C012) Communications Board ................. 234
A6 – ICM-42000 (-I000) Interconnect Module ........................ 234
A7 – ICM-42100 (-I100) Sinusoidal Encoder Interpolation Module ......................................................... 235
A8 – ICM-42200 (-I200) Interconnect Module ........................ 235
A1 – AMP-4 0x0 (-D 040,-D 020) 2 6
Description .................................................................................................................... 236
Electrical Specifications ................................................................................................ 237
Mating Connectors .................................................................... 237
Operation ....................................................................................................................... 238
Brushless Motor Setup .............................................................. 238
Brushless Amplifier Soft are Setup ......................................... 238
Chopper Mode .......................................................................... 238
Brush Amplifier Operation ....................................................... 239
Using External Amplifiers ........................................................ 239
Error Monitoring and Protection ............................................... 239
Hall Error Protection ................................................................. 240
Under-Voltage Protection ......................................................... 240
Over-Voltage Protection ........................................................... 240
Over-Current Protection ............................................................ 240
Over-Temperature Protection ................................................... 241
ELO Input ................................................................................. 241
A2 – AMP-4 140 (-D 140) 242
Description .................................................................................................................... 242
Electrical Specifications ................................................................................................ 243
Mating Connectors .................................................................... 243
Operation ....................................................................................................................... 244
Using External Amplifiers ........................................................ 244
ELO Input ................................................................................. 244
-SSR Option .............................................................................. 244
A – SDM-44040 (-D4040) 245
Description .................................................................................................................... 245
Electrical Specifications ................................................................................................ 246
Mating Connectors .................................................................... 246
Operation ....................................................................................................................... 247
Current Level Setup (AG Command) ....................................... 247
DMC-40x0 Contents • vii

Lo Current Setting (LC Command) ....................................... 247
Step Drive Resolution Setting (YA command) ........................ 247
ELO Input ................................................................................. 248
A4 – SDM-44140 (-D4140) 249
Description .................................................................................................................... 249
Electrical Specifications ................................................................................................ 250
Mating Connectors .................................................................... 250
Operation ....................................................................................................................... 251
Current Level Setup (AG Command) ....................................... 251
Lo Current Setting (LC Command) ....................................... 251
ELO Input ................................................................................. 251
A5 – CMB-41012 (-C012) 252
Description .................................................................................................................... 252
Connectors for CMB-41012 Interconnect Board ......................................................... 252
CMB-41012 Extended I/O 44 pin HD D-Sub Connector (Male) ............................................................... 252
RS-232-Main Port (Male) ....................................................... 253
RS-232-Auxiliary Port (Female) ............................................... 253
RS-422-Main Port (Non-Standard Option) ............................... 253
RS-422-Auxiliary Port (Non-Standard Option) ........................ 254
Ethernet ..................................................................................... 254
Jumper Description for CMB-41012 ........................................ 255
A6 – ICM-42000 (-I000) 256
Description .................................................................................................................... 256
Connectors for ICM-42000 Interconnect Board ........................................................... 256
ICM-42000 I/O (A-D) 44 pin HD D-Sub Connector (Female) 256
ICM-42000 I/O (E-H) 44 pin HD D-Sub Connector (Female) . 257
ICM-42000 External Driver (A-D) 44 pin HD D-Sub Connector (Male) .................................................. 257
ICM-42000 External Driver (E-H) 44 pin HD D-Sub Connector (Male) .................................................. 258
ICM-42000 Encoder 15 pin HD D-Sub Connector (Female) ... 259
ICM-42000 Analog 15 pin D-sub Connector (Male) ............... 259
Jumper Description for ICM-42000 ......................................... 260
A7 – ICM-42100 (-I100) 261
Description .................................................................................................................... 261
Connectors for ICM-42100 Interconnect Board ........................................................... 261
ICM-42100 I/O (A-D) 44 pin HD D-Sub Connector (Female) 261
ICM-42100 I/O (E-H) 44 pin HD D-Sub Connector (Female) . 262
ICM-42100 External Driver (A-D) 44 pin HD D-Sub Connector (Male) .................................................. 262
ICM-42100 External Driver (E-H) 44 pin HD D-Sub Connector (Male) .................................................. 264
ICM-42100 Encoder 15 pin HD D-Sub Connector (Female) ... 265
ICM-42100 Analog 15 pin D-sub Connector (Male) ............... 265
Theory of Operation ...................................................................................................... 266
A8 – ICM-42200 (-I200) 268
Description .................................................................................................................... 268
Connectors for ICM-42200 Interconnect Board ........................................................... 268
ICM-42200 I/O (A-D) 44 pin HD D-Sub Connector (Female) 268
ICM-42200 DMC-40x0 I/O (E-H) 44 pin HD D-Sub Connector (Female) ............................................... 269
ICM-42200 Encoder 26 pin HD D-Sub Connector (Female) ... 269
ICM-42200 Analog 15 pin D-sub Connector (Male) ............... 270
Jumper Description for ICM-42000 ......................................... 270
Index 271
DMC-40x0 Contents • viii

Chapter 1 Overview
Introduction
The DMC-40x0 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-40x0 provides t o communication channels: high speed RS-232 (2 channels up to 115K Baud) and
10BaseT Ethernet. The controllers allo for high-speed servo control up to 22 million encoder counts/sec and step
motor control up to 6 million steps per second. Sample rates as lo as 31.25 µsec per axis are available.
A Flash EEPROM provides non-volatile memory for storing application programs, parameters, arrays and firm are.
Ne firm are revisions are easily upgraded in the field.
The DMC-40x0 is available ith up to eight axes in a single stand alone unit. The DMC-4010, 4020, 4030, 4040
are one thru four axes controllers and the DMC-4050, 4060, 4070, 4080 are five thru eight axes controllers. All
eight axes have the ability to use Galil’s integrated amplifiers or drivers and connections for integrating external
devices.
Designed to solve complex motion problems, the DMC-40x0 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 ith profile smoothing. For smooth
follo ing of complex contours, the DMC-40x0 provides continuous vector feed of an infinite number of linear and
arc segments. The controller also features electronic gearing ith multiple master axes as ell as gantry mode
operation.
For synchronization ith outside events, the DMC-40x0 provides uncommitted I/O, including 8 opto-isolated digital
inputs (16 inputs for DMC-4050 thru DMC-4080), 8 high po er optically isolated outputs (16 outputs for DMC-
4050 thru DMC-4080), and 8 analog inputs for interface to joysticks, sensors, and pressure transducers. The DMC-
40x0 also has an additional 32 I/O at 3.3V logic. Further I/O is available if the auxiliary encoders are not being used
(2 inputs / each axis). Dedicated optoisolated inputs are provided for for ard and reverse limits, abort, home, and
definable input interrupts.
Commands can be sent in either Binary or ASCII. Additional soft are is available for automatic-tuning, trajectory
vie ing on a PC screen, CAD translation, and program development using many environments such as Visual
Basic, C, C++ etc. Drivers for Windo s XP (32 & 64 bit).
Chapter 1 Overview • 1 DMC-40x0 User Manual

Overview of Motor Types
The DMC-40x0 can provide the follo ing types of motor control:
1. Standard servo motors ith +/- 10 volt command signals
2. Brushless servo motors ith sinusoidal commutation
3. Step motors ith 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-40x0 achieves superior precision through use of a 16-Bit motor command output DAC and a
sophisticated PID filter that features velocity and acceleration feed-for ard, 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-40x0 can provide sinusoidal commutation for brushless motors (BLM). In this configuration, the
controller generates t o sinusoidal signals for connection ith 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 ith linear and rotary BLMs. Ho ever, the motor velocity
should be limited such that a magnetic cycle lasts at least 6 milliseconds ith a standard update rate of 1
millisecond. For faster motors, please contact the factory.
To simplify the iring, 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-40x0 can control BLMs equipped ith Hall sensors as ell as ithout 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 ill automatically estimate the commutation phase upon reset. This allo s the motor to
function immediately upon po er 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-40x0 can control stepper motors. In this mode, the controller provides t o 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.
If encoders are available on the stepper motor, Galil’s Stepper Position Maintenance Mode may be used
for automatic monitoring and correction of the stepper position. See Stepper Position Maintenance
Mode (SPM) in Chapter 6 for more information.
DMC-40x0 User Manual Chapter 1 Overview • 2

Overview of External Amplifiers
The amplifiers should be suitable for the motor and may be linear or pulse- idth-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 ill 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.
Overview of Galil Amplifiers and Drivers
With the DMC-40x0 Galil offers a variety of Servo Amplifiers and Stepper Drivers that are integrated into the same
enclosure as the controller. Using the Galil Amplifiers and Drivers provides a simple straightfor ard motion control
solution in one box.
A1 – AMP-4 0x0 (-D 040, -D 020)
The AMP-43040 (four-axis) and AMP-43020 (t o-axis) are multi-axis brush/brushless amplifiers that are capable
of handling 500 atts of continuous po er per axis. The AMP-43040/43020 Brushless drive modules are connected
to a DMC-40x0. The standard amplifier accepts DC supply voltages from 18-80 VDC.
A2 – AMP-4 140 (-D 140)
The AMP-43140 contains four linear drives for operating small brush-type servo motors. The AMP-43140 requires
a ± 12–30 DC Volt input. Output po er is 20 W per amplifier or 60 W total. The gain of each transconductance
linear amplifier is 0.1 A/V at 1 A maximum current. The typical current loop band idth is 4 kHz.
A – SDM-44040 (-D4040)
The SDM-44040 is a stepper driver module capable of driving up to four bipolar t o-phase stepper motors. The
current is selectable ith options of 0.5, 0.75, 1.0, and 1.4 Amps/Phase. The step resolution is selectable ith
options of full, half, 1/4 and 1/16.
A4 – SDM-44140 (-D4140)
The SDM-44140 microstepper module drives four bipolar t o-phase stepper motors ith 1/64 microstep resolution
(the SDM-44140 drives t o). The current is selectable ith options of 0.5, 1.0, 2.0, & 3.0 Amps per axis.
Chapter 1 Overview • 3 DMC-40x0 User Manual

DMC-40x0 Functional Elements
The DMC-40x0 circuitry can be divided into the follo ing functional groups as sho n in Figure 1.1 and discussed
belo .
WATCHDOG TIMER
RISC BASED
MICROCOMPUTER
HIGH-SPEED
MOTOR/ENCODER
INTERFACE
FOR
A,B,C,D
I/O INTERFACE
ETHERNET
RS-232 /
RS-422
8 UNCOMMITTED
ANALOG INPUTS
HIGH-SPEED LATCH FOR EACH AXIS
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
8 PROGRAMMABLE,
OPTOISOLATED
INPUTS
8 PROGRAMMABLE
HIGH POWER OPTOISOLATED
OUTPUTS
32 Configurable I/O
Figure 1.1 - DMC-40x0 Functional Elements
Microcomputer Section
The main processing unit of the controller is a specialized Microcomputer ith RAM and 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. The Flash also contains the firm are of the controller, hich is
field upgradeable.
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 t o DACs to generate t o +/-10 volt analog signals. For stepper motor
operation, the controller generates a step and direction signal.
Communication
The communication interface ith the DMC-40x0 consists of high speed RS-232 and Ethernet. The Ethernet is
10/100Bt and the t o RS-232 channels can generate up to 115K.
General I/O
The DMC-40x0 provides interface circuitry for 8 bi-directional, optoisolated inputs, 8 high po er optoisolated
outputs and 8 analog inputs ith 12-Bit ADC (16-Bit optional). The DMC-40x0 also has an additional 32 I/O (3.3V
DMC-40x0 User Manual Chapter 1 Overview • 4

logic) 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.
4080
The DMC-4050 through DMC-4080 controller provides an additional 8 optoisolated inputs and 8 high
po er optoisolated outputs.
System Elements
As sho n in Fig. 1.2, the DMC-40x0 is part of a motion control system hich includes amplifiers, motors and
encoders. These elements are described belo .
Figure 1-.2 - Elements of Servo systems
Motor
A motor converts current into torque hich produces motion. Each axis of motion requires a motor sized properly
to move the load at the required speed and acceleration. (Galil’s MotorSizer Web tool can help you ith motor
sizing: 332H .galilmc.com/support/motorsizer)
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 hen
step motors are used.
Other motors and devices such as Ultrasonic Ceramic motors and voice coils can be controlled ith the DMC-40x0.
Amplifier (Driver)
For each axis, the po er 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 po er 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- idth-modulated (PWM) or linear. They may also be configured for operation ith or ithout
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.
Galil offers amplifiers that are integrated into the same enclosure as the DMC-40x0. See the Integrated section in
the Appendices or 334Hhttp://galilmc.com/products/accelera/dmc40x0.html for more information.
Chapter 1 Overview • 5 DMC-40x0 User Manual
Computer DMC-40x0 Controller Amplifier (Driver)
Power Supply
Encoder Motor

Encoder
An encoder translates motion into electrical pulses hich are fed back into the controller. The DMC-40x0 accepts
feedback from either a rotary or linear encoder. Typical encoders provide t o channels in quadrature, kno n as
CHA and CHB. This type of encoder is kno n as a quadrature encoder. Quadrature encoders may be either single-
ended (CHA and CHB) or differential (CHA,CHA- and CHB,CHB-). The DMC-40x0 decodes either type into
quadrature states or four times the number of cycles. Encoders may also have a third channel (or index) for
synchronization.
The DMC-40x0 can be ordered ith 120 Ohm termination resistors installed on the encoder inputs. See the
Ordering Options for the DMC-40x0 in the Appendix for more information.
The DMC-40x0 can also interface to encoders ith pulse and direction signals. Refer to the “CE” command in the
command reference for details.
There is no limit on encoder line density; ho ever, the input frequency to the controller must not exceed 5,500,000
full encoder cycles/second (22,000,000 quadrature counts/sec). For example, if the encoder line density is 10,000
cycles per inch, the maximum speed is 300 inches/second. If higher encoder frequency is required, please consult
the factory.
The standard encoder voltage level is TTL (0-5v), ho ever, voltage levels up to 12 Volts are acceptable. (If using
differential signals, 12 Volts can be input directly to the DMC-40x0. Single-ended 12 Volt signals require a bias
voltage input to the complementary inputs).
The DMC-40x0 can accept analog feedback (+/-10v) instead of an encoder for any axis. For more information see
the command AF in the command reference.
To interface ith other types of position sensors such as absolute encoders, Galil can customize the controller and
command set. Please contact Galil to talk to one of our applications engineers about your particular system
requirements.
Sinusoidal Encoders
The DMC-40x0 can be ordered ith an interconnect module that supports the use of 1Vp-p sinusoidal encoders.
This interconnect module is the ICM-42100. See A7 – ICM-42100 (-I100) in the Appendix for more information.
Watch Dog Timer
The DMC-40x0 provides an internal atch dog timer hich checks for proper microprocessor operation. The timer
toggles the Amplifier Enable Output (AMPEN) hich can be used to s itch the amplifiers off in the event of a
serious DMC-40x0 failure. The AMPEN output is normally high. During po er-up and if the microprocessor
ceases to function properly, the AMPEN output ill go lo . The error light ill also turn on at this stage. A reset is
required to restore the DMC-40x0 to normal operation. Consult the factory for a Return Materials Authorization
(RMA) Number if your DMC-40x0 is damaged.
DMC-40x0 User Manual Chapter 1 Overview • 6

Chapter 2 Getting Started
DMC-4040 Layout
The follo ing layouts assume either an ICM-42000(I000) or ICM-42100(I100) interconnect modules are installed.
For layouts of systems ith ICM-42200’s(I200) installed please contact Galil. Overall dimensions and footprint are
identical, the only differences are in connector type and location.
Figure 2-1 - Outline of t e of t e DMC-4040
Chapter 2 Getting Started • 7 DMC-40x0 User Manual

DMC-4080 Layout
Figure 2-2 - Outline of t e of t e DMC-4080
DMC-40x0 User Manual Chapter 2 Getting Started • 8

DMC-40x0 Power Connections
Figure 2-3 – Connector locations for t e DMC-40x0
Figure 2-4 – Power Connector used w en controller is ordered wit out Galil Amplifiers
*See Power connector information for specific amplifiers in t e Integrated section of t e Appendices.
For more information on Connectors (mfg PN’s and diagrams) see the Po er Connector Section in the Appendix.
Chapter 2 Getting Started • 9 DMC-40x0 User Manual
Po er Connectors for Galil integrated Amplifiers*
Po er Connector for Controller ithout
Galil Amplifiers or hen ISCNTL
option is orderd*
Po er Connector for Controller ithout
Galil Amplifiers or hen ISCNTL
option is ordered

DMC-4040 Dimensions
Figure 2-5 – Dimensions of DMC-4040
DMC-40x0 User Manual Chapter 2 Getting Started • 10

DMC-4080 Dimensions
Figure 2-6 Dimensions of DMC-4080
Chapter 2 Getting Started • 11 DMC-40x0 User Manual