Galil DMC-13X8 User Manual
DMC-13X8
Manual Rev. 1.0e
By Galil Motion Control, Inc.
USER MANUAL
Galil Motion Control, Inc.
3750 Atherton Road
Rocklin, California 95765
Phone: (916) 626-0101
Fax: (916) 626-0102
Internet Address: support@galilmc.com
URL: www.galilmc.com
Rev Date: 5-06
Using This Manual
This user manual provides information for proper operation of the DMC-13X8 controller. The
appendix to this manual contains information regarding the accessories to these controllers. A separate
supplemental manual, the Command Reference, contains a description of the commands available for
use with the controller.
Your 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.
Please note that many examples are written for the DMC-1348 four-axes controller. Users of the
DMC-1338 3-axis controller, DMC-1328 2-axes controller, or DMC-1318 1-axis controller should
note that the DMC-1338 uses the axes denoted as XYZ, the DMC-1328 uses the axes denoted as XY,
and the DMC-1318 uses the X-axis only. The axes A,B,C,D may be used interchangeably with
X,Y,Z,W for any of the DMC-13X8 regardless of the number of axes.
This manual was written for the DMC-13X8 firmware revision 1.1 and later. For a DMC-13X8
controller with firmware previous to revision 1.1, please consult the original manual for your
hardware.
WARNING: Machinery in motion can be dangerous! It is the responsibility of the user to design
effective error handling and safety protection as part of the machine. Galil shall not
responsible for any incidental or consequential damages.
be liable or
Contents
Using This Manual ....................................................................................................................2
Chapter 1 Overview 9
Introduction ...............................................................................................................................9
Overview of Motor Types..........................................................................................................9
DMC-13X8 Functional Elements............................................................................................10
Chapter 2 Getting Started 15
The DMC-13X8 Motion Controller.........................................................................................15
Elements You Need.................................................................................................................16
Installing the DMC-13X8........................................................................................................17
Design Examples.....................................................................................................................30
Standard Servo Motor with +/- 10 Volt Command Signal........................................10
Brushless Servo Motor with Sinusoidal Commutation..............................................10
Stepper Motor with Step and Direction Signals........................................................10
Microcomputer Section.............................................................................................11
Motor Interface..........................................................................................................11
Communication.........................................................................................................11
General I/O................................................................................................................11
System Elements.......................................................................................................12
Motor.........................................................................................................................12
Amplifier (Driver).....................................................................................................12
Encoder......................................................................................................................13
Watch Dog Timer......................................................................................................13
Step 1. Determine Overall Motor Configuration.......................................................17
Step 2. Install Jumpers on the DMC-13X8................................................................18
Step 3. Install the DMC-13X8 in the VME Host.......................................................19
Step 4. Establish Communication with the Galil controller ......................................19
Step 5. Determine the Axes to be Used for Sinusoidal Commutation.......................19
Step 6. Make Connections to Amplifier and Encoder...............................................20
Step 7a. Connect Standard Servo Motors..................................................................22
Step 7b. Connect Sinusoidal Commutation Motors...................................................26
Step 7C. Connect Step Motors ..................................................................................29
Step 8. Tune the Servo System..................................................................................29
Example 1 - System Set-up.......................................................................................30
Example 2 - Profiled Move .......................................................................................31
Example 3 - Multiple Axes........................................................................................31
Example 4 - Independent Moves...............................................................................31
Example 5 - Position Interrogation............................................................................31
Example 6 - Absolute Position..................................................................................32
Example 7 - Velocity Control....................................................................................32
Example 8 - Operation Under Torque Limit.............................................................33
Example 9 - Interrogation..........................................................................................33
Example 10 - Operation in the Buffer Mode.............................................................33
Example 11 - Using the On-Board Editor.................................................................33
USER MANUAL Contents • 3
Example 12 - Motion Programs with Loops..............................................................34
Example 13 - Motion Programs with Trippoints.......................................................34
Example 14 - Control Variables................................................................................35
Example 15 - Linear Interpolation.............................................................................35
Example 16 - Circular Interpolation..........................................................................35
Chapter 3 Connecting Hardware 37
Overview .................................................................................................................................37
Using Optoisolated Inputs .......................................................................................................37
Limit Switch Input.....................................................................................................37
Home Switch Input....................................................................................................38
Abort Input................................................................................................................38
Uncommitted Digital Inputs......................................................................................39
Wiring the Optoisolated Inputs................................................................................................39
Using an Isolated Power Supply................................................................................40
Bypassing the Opto-Isolation:...................................................................................41
Analog Inputs ..........................................................................................................................41
Amplifier Interface..................................................................................................................41
TTL Inputs...............................................................................................................................42
TTL Outputs............................................................................................................................43
Chapter 4 Communication 45
Introduction .............................................................................................................................45
Communication with Controller..............................................................................................45
Communication Registers .........................................................................................45
Simplified Communication Procedure......................................................................46
Advanced Communication Techniques.....................................................................46
Communication with Controller - Secondary FIFO channel...................................................47
Polling FIFO..............................................................................................................47
DMA / Secondary FIFO Memory Map.....................................................................48
Explanation of Status Information and Axis Switch Information..............................50
Notes Regarding Velocity and Torque Information..................................................51
Interrupts..................................................................................................................................51
Setting up Interrupts..................................................................................................51
Configuring Interrupts...............................................................................................51
Servicing Interrupts...................................................................................................53
Example - Interrupts..................................................................................................53
Controller Response to DATA ................................................................................................54
Chapter 5 Command Basics 55
Introduction .............................................................................................................................55
Command Syntax - ASCII.......................................................................................................55
Coordinated Motion with more than 1 axis...............................................................56
Command Syntax – Binary......................................................................................................57
Binary Command Format..........................................................................................57
Binary command table...............................................................................................58
Controller Response to DATA ................................................................................................59
Interrogating the Controller.....................................................................................................59
Interrogation Commands...........................................................................................59
Summary of Interrogation Commands......................................................................60
Interrogating Current Commanded Values................................................................60
Operands....................................................................................................................60
Command Summary..................................................................................................61
4 • Contents USER MANUAL
Chapter 6 Programming Motion 63
Overview .................................................................................................................................63
Independent Axis Positioning..................................................................................................64
Command Summary - Independent Axis..................................................................65
Operand Summary - Independent Axis.....................................................................65
Independent Jogging ................................................................................................................67
Command Summary - Jogging..................................................................................67
Operand Summary - Independent Axis.....................................................................67
Linear Interpolation Mode.......................................................................................................68
Specifying Linear Segments......................................................................................68
Command Summary - Linear Interpolation...............................................................70
Operand Summary - Linear Interpolation..................................................................71
Example - Linear Move.............................................................................................71
Example - Multiple Moves........................................................................................72
Vector Mode: Linear and Circular Interpolation Motion.........................................................73
Specifying the Coordinate Plane...............................................................................73
Specifying Vector Segments .....................................................................................73
Additional commands................................................................................................74
Command Summary - Coordinated Motion Sequence..............................................76
Operand Summary - Coordinated Motion Sequence.................................................76
Electronic Gearing...................................................................................................................77
Command Summary - Electronic Gearing................................................................78
Electronic Cam........................................................................................................................79
Command Summary - Electronic CAM....................................................................83
Operand Summary - Electronic CAM.......................................................................84
Example - Electronic CAM.......................................................................................84
Contour Mode..........................................................................................................................85
Specifying Contour Segments...................................................................................85
Additional Commands...............................................................................................87
Command Summary - Contour Mode.......................................................................87
Operand Summary - Contour Mode..........................................................................87
Stepper Motor Operation.........................................................................................................91
Specifying Stepper Motor Operation.........................................................................91
Using an Encoder with Stepper Motors.....................................................................92
Command Summary - Stepper Motor Operation.......................................................93
Operand Summary - Stepper Motor Operation..........................................................93
Stepper Position Maintenance Mode (SPM)............................................................................93
Error Limit.................................................................................................................94
Correction..................................................................................................................94
Dual Loop (Auxiliary Encoder)...............................................................................................98
Backlash Compensation ............................................................................................99
Motion Smoothing.................................................................................................................100
Using the IT and VT Commands:............................................................................100
Using the KS Command (Step Motor Smoothing):.................................................101
Homing..................................................................................................................................102
Command Summary - Homing Operation...............................................................104
Operand Summary - Homing Operation..................................................................104
High Speed Position Capture (The Latch Function)..............................................................104
Fast Update Rate Mode .........................................................................................................105
Chapter 7 Application Programming 107
Overview ...............................................................................................................................107
Using the DMC-13X8 Editor to Enter Programs...................................................................107
Edit Mode Commands.............................................................................................108
USER MANUAL Contents • 5
Program Format.....................................................................................................................108
Using Labels in Programs .......................................................................................109
Special Labels..........................................................................................................109
Commenting Programs............................................................................................110
Executing Programs - Multitasking.......................................................................................110
Debugging Programs.............................................................................................................111
Program Flow Commands.....................................................................................................113
Event Triggers & Trippoints....................................................................................113
Event Trigger Examples:.........................................................................................115
Conditional Jumps...................................................................................................117
Using If, Else, and Endif Commands......................................................................119
Subroutines..............................................................................................................121
Stack Manipulation..................................................................................................121
Auto-Start Routine ..................................................................................................121
Automatic Subroutines for Monitoring Conditions.................................................122
Mathematical and Functional Expressions............................................................................125
Mathematical Operators ..........................................................................................125
Bit-Wise Operators..................................................................................................125
Functions.................................................................................................................126
Variables................................................................................................................................127
Programmable Variables.........................................................................................127
Operands ................................................................................................................................129
Special Operands (Keywords).................................................................................129
Arrays ....................................................................................................................................130
Defining Arrays.......................................................................................................130
Assignment of Array Entries...................................................................................130
Automatic Data Capture into Arrays.......................................................................131
Deallocating Array Space........................................................................................133
Input of Data (Numeric and String).......................................................................................133
Input of Data............................................................................................................133
Output of Data (Numeric and String)....................................................................................134
Sending Messages ...................................................................................................134
Displaying Variables and Arrays.............................................................................135
Interrogation Commands.........................................................................................136
Formatting Variables and Array Elements..............................................................137
Converting to User Units.........................................................................................138
Hardware I/O......................................................................................................................... 138
Digital Outputs........................................................................................................138
Digital Inputs...........................................................................................................139
Input Interrupt Function ..........................................................................................140
Analog Inputs..........................................................................................................141
Example Applications............................................................................................................142
Wire Cutter..............................................................................................................142
X-Y Table Controller ..............................................................................................143
Speed Control by Joystick.......................................................................................145
Position Control by Joystick....................................................................................146
Backlash Compensation by Sampled Dual-Loop....................................................146
Chapter 8 Hardware & Software Protection
Introduction ...........................................................................................................................149
Hardware Protection..............................................................................................................149
Output Protection Lines...........................................................................................149
Input Protection Lines .............................................................................................150
Software Protection ...............................................................................................................150
Programmable Position Limits................................................................................150
6 • Contents USER MANUAL
149
Off-On-Error ...........................................................................................................151
Automatic Error Routine.........................................................................................151
Limit Switch Routine ..............................................................................................151
Chapter 9 Troubleshooting 153
Overview ...............................................................................................................................153
Installation.............................................................................................................................153
Communication......................................................................................................................154
Stability..................................................................................................................................155
Operation...............................................................................................................................155
Chapter 10 Theory of Operation 157
Overview ...............................................................................................................................157
Operation of Closed-Loop Systems.......................................................................................159
System Modeling...................................................................................................................160
Motor-Amplifier......................................................................................................161
Encoder....................................................................................................................163
DAC ........................................................................................................................164
Digital Filter............................................................................................................164
ZOH.........................................................................................................................165
System Analysis.....................................................................................................................165
System Design and Compensation.........................................................................................167
The Analytical Method............................................................................................167
Appendices 171
Electrical Specifications ........................................................................................................171
Servo Control ..........................................................................................................171
Stepper Control........................................................................................................171
Input/Output............................................................................................................171
Power.......................................................................................................................172
Performance Specifications ...................................................................................................172
Connectors for DMC-13X8 Main Board...............................................................................173
Pin-Out Description for DMC-13X8.....................................................................................174
Accessories and Options........................................................................................................175
ICM-1900 Interconnect Module............................................................................................176
ICM-1900 Drawing ...............................................................................................................180
AMP-19X0 Mating Power Amplifiers...................................................................................180
ICM-2900 Interconnect Module............................................................................................181
Opto-Isolated Outputs ICM-1900 / ICM-2900 (-Opto option)..............................................184
Standard Opto-isolation and High Current Opto-isolation:.....................................184
64 Extended I/O of the DMC-13X8 Controller.....................................................................184
Configuring the I/O of the DMC-13X8...................................................................185
Connector Description:............................................................................................186
IOM-1964 Opto-Isolation Module for Extended I/O Controllers..........................................189
Description:............................................................................................................. 189
Overview................................................................................................................. 190
Configuring Hardware Banks..................................................................................190
Digital Inputs...........................................................................................................191
High Power Digital Outputs....................................................................................193
Standard Digital Outputs.........................................................................................194
Electrical Specifications..........................................................................................195
Relevant DMC Commands......................................................................................196
Screw Terminal Listing...........................................................................................196
Coordinated Motion - Mathematical Analysis.......................................................................198
USER MANUAL Contents • 7
DMC-13X8/DMC-1300 Comparison....................................................................................202
List of Other Publications......................................................................................................202
Training Seminars..................................................................................................................203
Contacting Us ........................................................................................................................204
WARRANTY........................................................................................................................205
Index 207
8 • Contents USER MANUAL
Chapter 1 Overview
Introduction
The DMC-13X8 series motion control cards install directly into the VME bus. This controller series
offers many enhanced features including high-speed communications, non-volatile program memory,
faster encoder speeds, and improved cabling for EMI reduction.
The DMC-13X8 provides two channels for high speed communication. Both controllers use a high
speed main FIFO for sending and receiving commands. Additionally, the DMC-13X8 provides a
secondary polling FIFO for instant access to controller status and parameters. The controller allows
for high-speed servo control up to 12 million encoder counts/sec and step motor control up to 3 million
steps per second. Sample rates as low as 62.5μsec per axis are available.
A 2 meg Flash EEPROM provides non-volatile memory for storing application programs, parameters,
arrays, and firmware. New firmware revisions are easily upgraded in the field without removing the
controller from the VME backplane.
The DMC-13X8 is available with up to four axes on a single VME card. The DMC-1318, 1328, 1338
and 1348 controllers fit on a single 6U format VME card.
Designed to solve complex motion problems, the DMC-13X8 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-13X8 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-13X8 provides uncommitted I/O, including 8 optoisolated digital inputs, 8 digital outputs and 8 analog inputs for interface to joysticks, sensors, and
pressure transducers. The DMC-13X8 controller also comes standard with an additional 64
configurable I/O. Dedicated optoisolat e d input s are provided on all DMC-13X8 controllers for
forward and reverse limits, abort, home, and definable input interrupts. The DMC-13X8 is addressed
through the 16 bit short I/O space of your VME system. Vectored hardware interrupts are available to
coordinate events on the controller with the rest of the VME system. Commands can be sent in either
Binary or ASCII.
Overview of Motor Types
The DMC-13X8 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
USER MANUAL Chapter 1 Overview • 9
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-13X8 achieves superior precision through use of a 16-bi t m ot or com m a nd output DAC and
a sophisticated PID filter that features velocity and acceleration feedforward, an extra pole and notch
filter, and integration limits.
The controller is configured by the factory for standard servo motor operation. In this configuration,
the controller provides an analog signal (+/- 10Volt) to connect to a servo amplifier. This connection
is described in Chapter 2.
Brushless Servo Motor with Sinusoidal Commutation
The DMC-13X8 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 also 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*. For faster
motors, please contact the factory.
To simplify the wiring, the controller provides a one-time, automatic set-up procedure. The
parameters determined by this procedure can then be saved in non-volatile memory to be used
whenever the system is powered on.
The DMC-13X8 can control BLMs equipped with or without Hall sensors. If hall sensors are
available, once the controller has been setup, the controller will automatically estimate the
commutation phase upon reset. This allows the motor to function immediately upon power up. The
hall effect sensors also provides a method for setting the precise commutation phase. Chapter 2
describes the proper connection and procedure for using sinusoidal commutation of brushless motors.
* 6 Milliseconds per magnetic cycle assumes a servo update of 1 msec (default rate).
Stepper Motor with Step and Direction Signals
The DMC-13X8 can control stepper motors. In this mode, the controller provides two signals to
connect to the stepper motor: Step and Direction. For stepper motor operation, the controller does not
require an encoder and operates the stepper motor in an open loop fashion. Chapter 2 describes the
proper connection and procedure for using stepper motors.
DMC-13X8 Functional Elements
The DMC-13X8 circuitry can be divided into the following functional groups as shown in Figure 1.1
and discussed below.
Chapter 1 Overview • 10 USER MANUAL
2ND FIFO
Primary
FIFO
VME HOST
INTERRUPTS
WATCHDOG TIMER
68331
MICROCOMPUTER
WITH
2 Meg RAM
2 Meg FLASH EEPROM
I/O INTERFACE
HIGH-SPEED
MOTOR/ENCODER
INTERFACE
FOR
X,Y,Z,W
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
USER INTERFACE
8 UNCOMMITTED
ANALOG IN PUTS
HIGH-SPEED LATCH FOR EACH AXIS
8 PROGRAMMABLE,
OPTOISOLATED
INPUTS
8 PROGRAMMABLE
OUTPUTS
Figure 1.1 - DMC-13X8 Functional Elements
Microcomputer Section
The main processing unit of the controller is a specialized 32-bit Motorola 68331 Series
Microcomputer with 2M RAM and 2M 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 firmware of the controller.
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 2 DACs to generate 2 +/-10Volt
analog signals. For stepper motor operation the controller generates a step and direction signal.
Communication
The DMC-13X8 is an A16D08(O) 6U VME card. The communication interface with the VME host
contains a primary and secondary communication channel. The primary channel uses a bi-directional
FIFO (AM4701). The secondary channel is a 512 byte Polling FIFO (IDT7201) where data is placed
into the controller’s FIFO buffer. The DMC- 13 X 8 uses vectored hardware interrupts throug h t he
VME host.
General I/O
The controller provides interface circuitry for 8 bi-directional, optoisolated inputs, 8 TTL outputs, and
8 analog inputs with 12-Bit ADC (16-bit optional). The general inputs can also be used for triggering a
high-speed positional latch for each axis.
USER MANUAL Chapter 1 Overview • 11
The DMC-13X8 also provides standard 64 extended I/O points. These TTL I/O points are software
configurable in banks of 8 points, and can be brought out directly on the IOM-1964 I/O module.
Each axis on the controller has 2 encoders, the main encoder and an auxiliary encoder. Each unused
auxiliary encoder provides 2 additional inputs available for general use (except when configured for
stepper motor operation).
System Elements
As shown in Fig. 1.2, the DMC-13X8 is part of a motion control system which includes amplifiers,
motors, and encoders. These elements are described below.
Power Supply
Computer
Figure 1.2 - Elements of Servo systems
DMC-1700/1800
Controller
Encoder Motor
Driver
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 operate 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.
Chapter 1 Overview • 12 USER MANUAL
Encoder
An encoder translates motion into electrical pulses which are fed back into the controller. The DMC13X8 accepts feedback from either a rotary or linear encoder. Typical encoders provide two channels in
quadrature, known as CHA and CHB. This type of encoder is known as a quadrature encoder.
Quadrature encoders may be either single-ended (CHA and CHB) or differential (CHA, CHA-, CHB,
CHB-). The controller 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-13X8 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 10,000 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-13X8. Singleended 12 Volt signals require a bias voltage input to the complementary inputs).
The DMC-13X8 can accept analog feedback instead of an encoder for any axis. For more information
see the command AF in the command reference.
To interface with other types of position sensors such as resolvers or absolute encoders, Galil can
customize the controller and command set. Please contact Galil to talk to one of our applications
engineers about your particular system requirements.
Watch Dog Timer
The DMC-13X8 provides an internal watchdog timer which checks for proper microprocessor
operation. The timer toggles the Amplifier Enable Output (AEN), which can be used to switch the
amplifiers off in the event of a serious controller failure. The AEN output is normally high. During
power-up and if the microprocessor ceases to function properly, the AEN output will go low. The
error light for each axis will also turn on at this stage. A reset is required to restore the controller to
normal operation. Consult the factory for a Return Materials Authorization (RMA) Number if your
DMC-13X8 is damaged.
USER MANUAL Chapter 1 Overview • 13
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Chapter 1 Overview • 14 USER MANUAL
Chapter 2 Getting Started
The DMC-13X8 Motion Controller
Figure 2-1 - Outline of the DMC-13X8
USER MANUAL Chapter 2 Getting Started • 15
1 Flash EEPROM J6 VME Connector
2 RAM JP1 Master Reset & UPGRD jumpers
3 Motorola 68331 microprocessor JP3 INCOM & LSCOM jumpers. Used for
bypassing opto-isolation for the limit, home, and
abort switches and the digital inputs IN1 - IN8.
See section “Bypassing Opto-Isolation”, Chap3.
4 GL-1800 custom gate array JP5 Jumpers used for configuring stepper motor
operation on axes 1-4.
5 Error LED JP9 IRQ jumper. Interrupts may be set on IRQ 1–7.
J1 100-pin high density connector for axes 1-4.
(Part number Amp #2-178238-9)
J3 80 Pin high-density connector for 64
extended I/O points.
J5 26-pin header connector for the auxiliary
encoder cable. (Axes 1-4)
Note: Above schematics are for most current controller revision. For older revision boards, please refer to Appendix.
JP10 Address jumpers. The base address of the
controller is FFF0. Address jumpers A4-A15
may be set as offsets to that address
JP11 IAD1-IAD4 allows transfer of the IRQ between
the controller and host. This three bit binary
combination must be set equal to the IRQ line
chosen.
Elements You Need
Before you start, you must get all the necessary system elements. These include:
1. DMC-13X8, (1) 100-pin cable and (1) ICM-1900. Connection to the exten ded I/O can be
made through the IOM-1964 opto-isolation module. Using the IOM-1964 requires (1)
IOM-1964, (1) CB-50-100 and (1) 100 pin cable.
2. Servo motors with Optical Encoder (one per axis) or step motors.
3. Power Amplifiers.
4. Power Supply for Amplifiers.
5. VME host and user interface.
The motors may be servo (brush type or brushless) or steppers. The amplifiers should be suitable for
the motor and may be linear or pulse-width-modulated. An amplifier may have current feedback,
voltage feedback or velocity feedback.
Chapter 2 Getting Started • 16 USER MANUAL
For servo motors in current mode, the amplifiers should accept an analog signal in the +/-10 Volt range
as a command. 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. For velocity mode amplifiers, a command signal of 10 Volts should run the motor at the
maximum required speed. Set the velocity gain so that an input signal of 10V, runs the motor at the
maximum required speed.
For step motors, the amplifiers should accept step and direction signals. For start-up of a step motor
system refer to Step 7c “Connecting Step Motors”.
Installing the DMC-13X8
Installation of a complete, operational DMC-13X8 system consists of 8 steps.
Step 1. Determine overall motor configuration.
Step 2. Install Jumpers on the DMC-13X8.
Step 3. Install the DMC-13X8 in the PC.
Step 4. Establish communications with the Galil controller.
Step 5. Determine the Axes to be used for sinusoidal commutation.
Step 6. Make connections to amplifier and encoder.
Step 7a. Connect standard servo motors.
Step 7b. Connect sinusoidal commutation motors.
Step 7c. Connect step motors.
Step 8. Tune the servo system.
Step 1. Determine Overall Motor Configuration
Before setting up the motion control system, the user must determine the desired motor configuration.
The DMC-13X8 can control any combination of standard servo motors, sinusoidally commutated
brushless motors, and stepper motors. Other types of actuators, such as hydraulics can also be
controlled. Please consult Galil for more information.
The following configuration information is necessary to determine the proper motor configuration:
Standard Servo Motor Operation:
The DMC-13X8 has been setup by the factory for standard servo motor operation providing an analog
command signal of +/- 10V. No hardware or software configuration is required for standard servo
motor operation.
Sinusoidal Commutation:
Sinusoidal commutation is configured through a single software command, BA. This configuration
causes the controller to reconfigure the number of available control axes.
Each sinusoidally commutated motor requires two DAC's. In standard servo operation, the DMC13X8 has one DAC per axis. In order to have the additional DAC for sinusoidal commutation, the
controller must be designated as having one additional axis for each sinusoidal commutation axis. For
example, to control two standard servo axes and one axis of sinusoidal commutation, the controller
will require a total of four DAC's and the controller must be a DMC-1348.
Sinusoidal commutation is configured with the command, BA. For example, BAX sets the X axis to
be sinusoidally commutated. The second DAC for the sinusoidal signal will be the highest available
DAC on the controller. For example: Using a DMC-1348, the command BAX will configure the X
axis to be the main sinusoidal signal and the 'W' axis to be the second sinuso idal signal.
The BA command also reconfigures the controller to indicate that the controller has one less axis of
'standard' control for each axis of sinusoidal commutation. For example, if the command BAX is
given to a DMC-1348 controller, the controller will be re-configured to a DMC-1338 controller. By
definition, a DMC-1338 controls 3 axes: X,Y and Z. The 'W' axis is no longer available since the
output DAC is being used for sinusoi dal c om mutation.
Further instruction for sinusoidal commutation connections are discussed in Step 5.
USER MANUAL Chapter 2 Getting Started • 17
Stepper Motor Operation:
To configure the DMC-13X8 for stepper motor operation, the controller requires a jumper for each
stepper motor and the command, MT, must be given. The installation of the stepper motor jumper is
discussed in the following section entitled "Installing Jumpers on the DMC-13X8". Further
instruction for stepper motor connections are disc usse d in St ep 7c.
Step 2. Install Jumpers on the DMC-13X8
Address Jumpers
The DMC-13X8 resides in the 16-bit short I/O space of the VME system. The base address of the
DMC-13X8 is set at FFF0. The address jumpers at JP10 are used to select the specific address for the
DMC-13X8 in the VME system. Placing a jumper on an address A4 through A15 makes that location
a 0.
For example, to set the controller address to FFE0, a jumper is placed on location A4.
Master Reset and Upgrade Jumpers
JP1 contains two jumpers, MRST and UPGRD. The MRST jumper is the Master Reset jumper. With
MRST connected, the controller will perform a master reset upon PC power up or upon the reset input
going low. Whenever the controller has a master reset, all programs, arrays, variables, and motion
control parameters stored in EEPROM will be ERASED.
The UPGRD jumper enables the user to unconditionally update the controller’s firmware. This jumper
is not necessary for firmware updates when the controller is operating normally, but may be necessary
in cases of corrupted EEPROM. EEPROM corruption should never occur, however, it is possible if
there is a power fault during a firmware update. If EEPROM corruption occurs, your controller may
not operate properly. In this case, install the UPGRD Jumper and use the update firmware function on
the Galil Terminal to re-load the system firmware.
Opto Isolation Jumpers
The inputs and limit switches are optoisolated. If you are not using an isolated supply, the internal
+5V supply from the PC may be used to power the optoisolators. This is done by installing jumpers on
JP3.
For each axis that will be used for stepper motor operation, the corresponding stepper mode (SM)
jumper must be connected. The stepper motor jumpers, labeled JP5, are located directly beside the
GL-1800 IC on the main board (see the diagram for the DMC-13X8). The individual jumpers are
labeled SMX, SMY, SMZ and SMW.
Stepper Motor Jumpers
Hardware IRQ (Interrupt) Jumpers
The DMC-13X8 controller supports vectored hardware interrupts. The jumper locations JP9 and JP11
are used to select the IRQ line which will interrupt the bus. IRQ1 through IRQ7 are available to the
user as hardware interrupts, and are set at location JP9. The second set of jumpers located at JP11 are
labeled IAD4, IAD2 and IAD1. The summation of these jumpers should be set equal to the IRQ
selected on JP9.
For example, suppose the VME host for a certain system requires a hardware interrupt on IRQ 5. A
jumper would therefore be placed at location JP9 on the pins labeled IRQ5. In addition, IAD4 and
IAD1, which add up to 5, will be jumpered at location JP11.
The vector and the conditions triggering the hardware interrupt on the DMC-13X8 are set through
software using the EI or the UI command. The DMC-13X8 will provide the hardware interrupt to the
Chapter 2 Getting Started • 18 USER MANUAL
system upon the specified conditions. It is up to the user to supply an appropriate interrupt handling
routine for the VME host.
(Optional) Motor Off Jumpers
The state of the motor upon power up may be selected with the placement of a hardware jumper on the
controller. With a jumper installed at the OPT location, the controller will be powered up in the ‘motor
off’ state. The SH command will need to be issued in order for the motor to be enabled. With no
jumper installed, the controller will immediately enable the motor upon power up. The MO command
will need to be issued to turn the motor off.
The OPT jumper is always located on the same block of jumpers as the stepper motor jumpers (SM).
This feature is only available to newer revision controllers. Please consult Galil for adding this
functionality to older revision controllers.
Step 3. Install the DMC-13X8 in the VME Host
The DMC-13X8 is installed directly into the VME bus. The procedure is outlined below.
Step A. Make sure the VME host is in the power-off condition.
Step B. Insert DMC-13X8 card into a slot in the VME bus.
Step E. Attach 100-pin cable to your controller card. If you are using a Galil ICM-1900 or
AMP-19X0, this cable connects into the J2 connection on the interconnect module. If
you are not using a Galil interconnect module, you will need to appropriately terminate
the cable to your system components, see the appendix for cable pin outs. The auxiliary
encoder connections are accessed through the 36-pin high-density connector, which will
mate via the CB-36-25 to the ICM-1900.
Step 4. Establish Communication with the Galil controller
The customer will be required to provide a communication interface for the DMC-13X8 and their
specified host VME system. For development of the software interface, refer to Chapter 4 to find
information on the communication registers of the controller.
NOTE: It is highly recommended that communication be established with the controller prior to
applying any power to the amplifiers or other components.
Step 5. Determine the Axes to be Used for Sinusoidal Commutation
* This step is only required when the controller will be used to control a brushless motor(s) with
sinusoidal commutation.
The command, BA is used to select the axes of sinusoidal commutation. For example, BAXZ sets X
and Z as axes with sinusoidal commutation.
Notes on Configuring Sinusoidal Commutation:
The command, BA, reconfigures the controller such that it has one less axis of 'standard' control for
each axis of sinusoidal commutation. For example, if the command BAX is given to a DMC-1338
controller, the controller will be re-configured to be a DMC-1328 controller. In this case the highest
axis is no longer available except to be used for the 2
the highest axis on a controller can never be configured for sinusoidal commutation.
The first phase signal is the motor command signal. The second phase is derived from the highest
DAC on the controller. When more than one axis is configured for sinusoidal commutation, the
highest sinusoidal commutation axis will be assigned to the highest DAC and the lowest sinusoidal
commutation axis will be assigned to the lowest available DAC. Note the lowest axis is the X axis.
nd
phase of the sinusoidal commutation. Note that
USER MANUAL Chapter 2 Getting Started • 19
Example: Sinusoidal Commutation Configuration using a DMC-1348
BAXZ
This command causes the controller to be reconfigured as a DMC-1328 controller. The X and Z axes
are configured for sinusoidal commutation. The first phase of the X axis will be the motor command
X signal. The second phase of the X axis will be Y signal. The first phase of the Z axis will be the
motor command Z signal. The second phase of the Z axis will be the motor command W signal.
Step 6. Make Connections to Amplifier and Encoder.
Once you have established communications between the software and the DMC-13X8, you are ready
to connect the rest of the motion control system. The motion control system typically consists of an
ICM-1900 Interface Module, an amplifier for each axis of motion, and a motor to transform the current
from the amplifier into torque for motion. Galil also offers the AMP-19X0 series Interface Modules
which are ICM-1900’s equipped with servo amplifiers for brush type DC motors.
If you are using an ICM-1900, connect the 100-pin high-density cable to the D MC-13X8 and to the
connector located on the AMP-19x0 or ICM-1900 board. The ICM-1900 provides screw terminals for
access to the connections described in the following discussion.
System connection procedures will depend on system components and motor types. Any combination
of motor types can be used with the DMC-13X8. If sinusoidal commutation is to be used, special
attention must be paid to the reconfiguration of axes.
Here are the first steps for connecting a motion control system:
Step A. Connect the motor to the amplifier with no connection to the controller. Consult the
amplifier documentation for instructions regard ing proper connections. Connect and
turn-on the amplifier power supply. If the amplifiers are operating properly, the motor
should stand still even when the amplifiers are powered up.
Step B. Connect the amplifier enable signal.
Before making any connections from the amplifier to the controller, you need to verify
that the ground level of the amplifier is either floating or at the same potential as earth.
WARNING: When the amplifier ground is not isolated from the power line or when it has a different potential
than that of the computer ground, serious damage may result to the computer controller and amplifier.
If you are not sure about the potential of the ground levels, connect the two ground
signals (amplifier ground and earth) by a 10 KΩ resistor and measure the voltage across
the resistor. Only if the voltage is zero, connect the two ground signals directly.
The amplifier enable signal is used by the controller to disable the motor. This signal is
labeled AMPENX for the X axis on the ICM-1900 and should be connected to the enable
signal on the amplifier. Note that many amplifiers designate this signal as the INHIBIT
signal. Use the command, MO, to disable the motor amplifiers - check to insure that the
motor amplifiers have been disabled (often this is indicated by an LED on the amplifier).
This signal changes under the following conditions: the watchdog timer activates, the
motor-off command, MO, is given, or the OE1 command (Enable Off-On-Error) is given
and the position error exceeds the error limit. As shown in Figure 3-3, AEN can be used
to disable the amplifier for these conditions.
The standard configuration of the AEN signal is TTL active high. In other words, the
AEN signal will be high when the controller expects the amplifier to be enabled . The
polarity and the amplitude can be changed if you are using the ICM-1900 interface board.
To change the polarity from active high (5 volts = enable, zero volts = disable) to active
low (zero volts = enable, 5 volts = disable), replace the 7407 IC with a 7406. Note that
many amplifiers designate the enable input as ‘inhibit’.
Chapter 2 Getting Started • 20 USER MANUAL
To change the voltage level of the AEN signal, note the state of the resistor pack on the
ICM-1900. When Pin 1 is on the 5V mark, the output voltage is 0-5V. To change to 12
volts, pull the resistor pack and rotate it so that Pin 1 is on the 12 volt side. If you
remove the resistor pack, the output signal is an open collector, allowing the user to
connect an external supply with voltages up to 24V.
Step C. Connect the encoders
For stepper motor operation, an encoder is optional.
For servo motor operation, if you have a preferred definition of the forward and reverse
directions, make sure that the encoder wiring is consistent with that definition.
The DMC-13X8 accepts single-ended or differential encoder feedback with or without an
index pulse. If you are not using the AMP-19x0 or the ICM-1900 you will need to
consult the appendix for the encoder pinouts for connection to the motion controller. The
AMP-19x0 and the ICM-1900 can accept encoder feedback from a 10-pin ribbon cable or
individual signal leads. For a 10-pin ribbo n cable encoder, connect the cable to the
protected header connector labeled X ENCODER (repeat for each axis necessary). For
individual wires, simply match the leads from the encoder you are using to the encoder
feedback inputs on the interconnect board. The signal leads are labeled CHA (channel
A), CHB (channel B), and INDEX. For differential encoders, the complement signals are
labeled CHA-, CHB-, and INDEX-.
Note: When using pulse and direction encoders, the pulse signal is connected to CHA
and the direction signal is connected to CHB. The controller must be configured for
pulse and direction with the command CE. See the command summary for further
information on the command CE.
Step D. Verify proper encoder operation.
Start with the X encoder first. Once it is connected, turn the motor shaft and interrogate
the position with the instruction TPX <return>. The controller response will vary as the
motor is turned.
At this point, if TPX does not vary with encoder rotation, there are three possibilities:
1. The encoder connections are incorrect - check the wiring as necessary.
2. The encoder has failed - using an oscilloscope, observe the encoder signals. Verify
that both channels A and B have a peak magnitude between 5 and 12 volts. Note
that if only one encoder channel fails, the position reporting varies by one count
only. If the encoder failed, replace the encoder. If you cannot observe the encoder
signals, try a different encoder.
3. There is a hardware failure in the controller - connect the same encoder to a different
axis. If the problem disappears, you probably have a hardware failure. Consult the
factory for help.
Step E. Connect Hall Sensors if available.
Hall sensors are only used with sinusoidal commutation and are not necessary for proper
operation. The use of hall sensors allows the controller to automatically estimate the
commutation phase upon reset and also provides the controller the ability to set a more
precise commutation phase. Without hall sensors, the commutation phase must be
determined manually.
The hall effect sensors are connected to the digital inputs of the controller. These inputs
can be used with the general use inputs (bits 1-8), the auxiliary encoder inputs (bits 81-
96), or the extended I/O inputs of the DMC-13X8 controller (bits 17-80). Note: The
general use inputs are optoisolated and require a voltage connection at the INCOM point
- for more information regarding the digital inputs, see Chapter 3, Connecting H ardware.
USER MANUAL Chapter 2 Getting Started • 21
Each set of sensors must use inputs that are in consecutive order. The input lines are
specified with the command, BI. For example, if the Hall sensors of the Z axis are
connected to inputs 6, 7 and 8, use the instruction:
BI ,, 6
or
BIZ = 6
Step 7a. Connect Standard Servo Motors
The following discussion applies to connecting the DMC-13X8 controller to standard servo motor
amplifiers:
The motor and the amplifier may be configured in the torque or the velocity mode. In the torque
mode, the amplifier gain should be such that a 10 Volt signal generates the maximum required current.
In the velocity mode, a command signal of 10 Volts should run the motor at the maximum required
speed.
Check the Polarity of the Feedback Loop
It is assumed that the motor and amplifier are connected together and that the encoder is operating
correctly (Step B). Before connecting the motor amplifiers to the controller, read the following
discussion on setting Error Limits and Torque Limits. Note that this discussion only uses the X axis as
an example.
Step A. Set the Error Limit as a Safety Precaution
Usually, there is uncertainty about the correct polarity of the feedback. The wrong
polarity causes the motor to run away from the starting position. Using a terminal
program, such as DMCTERM, the following parameters can be given to avoid system
damage:
Input the commands:
ER 2000 <CR> Sets error limit on the X axis to be 2000 encoder counts
OE 1 <CR> Disables X axis amplifier when excess position error exists
If the motor runs away and creates a position error of 2000 counts, the motor amplifier
will be disabled. Note: This function requires the AEN signal to be connected from the
controller to the amplifier.
Step B. Set Torque Limit as a Safety Precaution
To limit the maximum voltage signal to your amplifier, the DMC-13X8 controller has a
torque limit command, TL. This command sets the maximum voltage output of the
controller and can be used to avoid excessive torque or speed when initially setting up a
servo system.
When operating an amplifier in torque mode, the v
voltage output of the controller will be directly related to the torque output of the motor.
The user is responsible for determining this relationship using the documentation of the
motor and amplifier. The torque limit can be set to a value that will limit the motors
output torque.
When operating an amplifier in velocity or voltage mode, the voltage output of the
controller will be directly related to the velocity of the motor. The user is responsible for
determining this relationship using the documentation of the motor and amplifier. The
torque limit can be set to a value that will limit the speed of the motor.
Chapter 2 Getting Started • 22 USER MANUAL
For example, the following command will limit the output of the controller to 1 volt on
the X axis:
TL 1 <CR>
Note: Once the correct polarity of the feedback loop has been determined, the torque limit
should, in general, be increased to the default value of 9.99. The servo will not operate
properly if the torque limit is below the normal operating range. See description of TL in
the command reference.
Step C. Enable Off-On-Error as a safety precaution. To limit the maximum distance the
motor will move from the commanded position, enable the Off-On-Error function using
the command , OE 1. If the motor runs away due to positive feedback or another
systematic problem the controller will disable the amplifier when the position error
exceeds the value set by the command, ER.
Step D. Disable motor with the command MO (Motor off).
Step E. Connect the Motor and issue SH
Once the parameters have been set, connect the analog motor command signal (ACMD)
to the amplifier input.
To test the polarity of the feedback, command a move with the instruction:
PR 1000 <CR> Position relative 1000 counts
BGX <CR> Begin motion on X axis
When the polarity of the feedback is wrong, the motor will attempt to run away. The
controller should disable the motor when the position error exceeds 2000 counts. If the
motor runs away, the polarity of the loop must be inverted.
Inverting the Loop Polarity
When the polarity of the feedback is incorrect, the user must invert the loop polarity and this may be
accomplished by several methods. If you are driving a brush-type DC motor, the simplest way is to
invert the two motor wires (typically red and black). For example, switch the M1 and M2 connections
going from your amplifier to the motor. When driving a brushless motor, the polarity reversal may be
done with the encoder. If you are using a single-ended encoder, interchange the signal CHA and CHB.
If, on the other hand, you are using a differential encoder, interchange only CHA+ and CHA-. The
loop polarity and encoder polarity can also be affected through software with the MT, and CE
commands. For more details on the MT command or the CE command, see the Command Reference
section.
Sometimes the feedback polarity is correct (the motor does not attempt to run away) but the direction
of motion is reversed with respect to the commanded motion. If this is the case, reverse the motor
leads AND the encoder signals.
If the motor moves in the required direction but stops short of the target, it is most likely due to
insufficient torque output from the motor command signal ACMD. This can be alleviated by reducing
system friction on the motors. The instruction:
TTX (CR) Tell torque on X
reports the level of the output signal. It will show a non-zero value that is below the friction level.
Once you have established that you have closed the loop with the correct polarity, you can move on to
the compensation phase (servo system tuning) to adjust the PID filter parameters, KP, KD and KI. It is
necessary to accurately tune your servo system to ensure fidelity of position and minimize motion
oscillation as described in the next section.
USER MANUAL Chapter 2 Getting Started • 23
AUX encoder
input connector
DB25 female
AUX encoder
input connector
26 pin header
Reset Sw it ch Error LED
100 pin high density connector
AMP part # 2-178238-9
Filter
Chokes
J7
J51
J6
X
M1X
M2X
Y
LSCOM
INCOM
VCC
VCC
REV B
MADE IN USA
M1Y
M2Y
ICM/ AMP-1900
GALIL MOTION CONTROL
GND
EARTH
GND
VAMP
VAMP
Z
W
M1W
M1Z
M2Z
M2W
+
+
DC Power Supply
-
Encoder
DC Servo Motor
-
Figure 2-2 - System Connections with the AMP-1900 Amplifier. Note: this figure shows a Galil Motor and
Encoder which uses a flat ribbon cable for connection to the AMP-1900 unit.
Chapter 2 Getting Started • 24 USER MANUAL
AUX encoder
input connector
DB25 female
AUX encoder
input connector
26 pin header
Rese t Swi t ch
Error LED
100 pin high density connector
AMP part # 2-178238-9
J7
J51
Amp enable
buffer circuit
RP2
ADG202
U1
U6RP1
7407
GND
MOCMDX
AMPENX
REV D
ICM/ AM P -1900
GALIL MOTION CONTROL
J6
Motor Command
buffer circuit
LSCOM
INCOM
VCC
VCC
MADE IN USA
-MAX
-MBX
-INX
+5 VDC
GND
+INX
+MBX
+MAX
Encoder Wire Connections
Encoder: ICM-1900:
Channel A+ +MAX
Channel A- -MAX
Channel B+ +MBX
Channel B- -MBX
Index Channel + +INX
Index Channel - -INX
+
Encoder
DC Brush
Signal Gnd 2
BRUSH-TYPE
PWM SERVO
AMPLIFIER
MSA 12-80
+Ref In 4
Inhibit 11
Motor + 1
Motor - 2
Power Gnd 3
Power Gnd 4
High Volt 5
+
DC Power Supply
-
Figure 2-3 System Connections with a separate amplifier (MSA 12-80). This diagram shows the connections for a
standard DC Servo Motor and encoder
USER MANUAL Chapter 2 Getting Started • 25
Serv o Motor
-
Step 7b. Connect Sinusoidal Commutation Motors
When using sinusoidal commutation, the parameters for the commutation must be determined
and saved in the controllers non-volatile memory. The servo can then be tuned as
described in Step 8.
Step A. Disable the motor amplifier
Use the command, MO, to disable the motor amplifiers. For example, MOX will turn the
X axis motor off.
Step B. Connect the motor amplifier to the controller.
The sinusoidal commutation amplifier requires 2 signals, usually denoted as Phase A &
Phase B. These inputs should be connected to the two sinusoidal signals generated by the
controller. The first signal is the axis specified with the command, BA (Step 5). The
second signal is associated with the highest analog command signal available on the
controller - note that this axis was made unavailable for standard servo operation by the
command BA.
When more than one axis is configured for sinusoidal commutation, the controller will
assign the second phase to the command output which has been made available through
the axes reconfiguration. The 2
be the highest command output and the 2
axis will be the lowest command output.
It is not necessary to be concerned with cross-wiring the 1
is incorrect, the setup procedure will alert the user (Step D).
nd
phase of the highest sinusoidal commutation axis will
nd
phase of the lowest sinusoidal commutation
st
and 2nd signals. If this wiring
Example: Sinusoidal Commutation Configuration using a
DMC-1348
BAXZ
This command causes the controller to be reconfigu red as a DMC-13X8 controller. The
X and Z axes are configured for sinusoidal commutation. The first phase of the X axis
will be the motor command X signal. The second phase of the X axis will be the motor
command the motor command Y signal. The first phase of the Z axis will be the motor
command Z signal. The second phase of the Z axis will be the motor command W signal.
Step C. Specify the Size of the Magnetic Cycle.
Use the command, BM, to specify the size of the brushless motors magnetic cycle in
encoder counts. For example, if the X axis is a linear motor where the magnetic cycle
length is 62 mm, and the encoder resolution is 1 micron, the cycle equals 62,000 counts.
This can be commanded with the command.
BM 62000
On the other hand, if the Z axis is a rotary motor with 4000 counts per revolution and 3
magnetic cycles per revolution (three pole pairs) the command is
BM,, 1333.333
Step D. Test the Polarity of the DACs and Hall Sensor Configuration.
Use the brushless motor setup command, BS, to test the polarity of the output DACs.
This command applies a certain voltage, V, to each phase for some time T, and checks to
see if the motion is in the correct direction.
The user must specify the value for V and T. For example, the command
BSX = 2,700
Chapter 2 Getting Started • 26 USER MANUAL
will test the X axis with a voltage of 2 volts, applying it for 700 millisecond for each
phase. In response, this test indicates whether the DAC wiring is correct and will
indicate an approximate value of BM. If the wiring is correct, the approximate value for
BM will agree with the value used in the previous step.
Note: In order to properly conduct the brushless setup, the motor must be allowed to
move a minimum of one magnetic cycle in both directions.
Note: When using Galil Windows software, the timeout must be set to a minimum of 10
seconds (time-out = 10000) when executing the BS command. This allows the software
to retrieve all messages returned from the controller.
If Hall Sensors are Available:
Since the Hall sensors are connected randomly, it is very likely that they are wired in the
incorrect order. The brushless setup command indicates the correct wiring of the Hall
sensors. The hall sensor wires should be re-configured to reflect the results of this test.
The setup command also reports the position offset of the hall transition point and the
zero phase of the motor commutation. The zero transition of the Hall sensors typically
occur at 0°, 30° or 90° of the phase commutation. It is necessary to inform the
controller about the offset of the Hall sensor and this is done with the instruction, BB.
Step E. Save Brushless Motor Configuration
It is very important to save the brushless motor configuration in non-volatile memory.
After the motor wiring and setup parameters have been properly configured, the burn
command, BN, should be given.
If Hall Sensors are Not Available:
Without hall sensors, the controller will not be able to estimate the commutation phase of
the brushless motor. In this case, the controller could become unstable until the
commutation phase has been set using the BZ command (see next step). It is highly
recommended that the motor off command be give n before executing the BN command.
In this case, the motor will be disabled upon power up or reset and the commutation
phase can be set before enabling the motor.
Step F. Set Zero Commutation Phase
When an axis has been defined as sinusoidally commutated, the controller must have an
estimate for commutation phase. When hall sensors are used, the controller automatically
estimates this value upon reset of the controller. If no hall sensors are used, the controller
will not be able to make this estimate and the commutation phase must be set before
enabling the motor.
If Hall Sensors are Not Available:
To initialize the commutation without Hall effect sensor use the command, BZ. This
function drives the motor to a position where the commutation phase is zero, and sets the
phase to zero.
The BZ command argument is a real number which represents the voltage to be applied
to the amplifier during the initialization. When the voltage is specified by a positive
number, the initialization process ends up in the motor off (MO) state. A negative
number causes the process to end in the Servo Here (SH) state.
Warning: This command must move the motor to find the zero commutation phase.
This movement is instantaneous and will cause the system to jerk. Larger applied
voltages will cause more severe motor jerk. The applied voltage will typically be
sufficient for proper operation of the BZ command. For systems with significant friction,
USER MANUAL Chapter 2 Getting Started • 27
this voltage may need to be increased and for systems with very small motors, this value
should be decreased.
For example,
BZ -2
will drive the X axis to zero, using a 2V signal. The controller will then leave the motor
enabled. For systems that have external forces working against the motor, such as
gravity, the BZ argument must provide a torque 10x the external force. If the torque is
not sufficient, the commutation zero may not be accurate.
If Hall Sensors are Available:
The estimated value of the commutation phase is good to within 30°. This estimate can
be used to drive the motor but a more accurate estimate is needed for efficient motor
operation. There are 3 possible methods for commutation phase initialization:
Method 1. Use the BZ command as described above.
Method 2. Drive the motor close to commutation phase of zero and then use BZ
command. This method decreases the amount of system jerk by moving the motor close
to zero commutation phase before executing the BZ command. The controller makes an
estimate for the number of encoder counts between the current position and the position
of zero commutation phase. This value is stored in the operand _BZx. Using this
operand the controller can be commanded to move the motor. The BZ command is then
issued as described above. For example, to initialize the X axis motor upon power or
reset, the following commands may be given:
SHX ;Enable X axis motor
PRX=-1*(_BZX) ;Move X motor close to zero commutation phase
BGX ;Begin motion on X axis
AMX ;Wait for motion to complete on X axis
BZX=-1 ;Drive motor to commutation phase zero and leave
;motor on
Method 3. Use the command, BC. This command uses the hall transitions to determine
the commutation phase. Ideally, the hall sensor transitions will be separated by exactly
60° and any deviation from 60° will affect the accuracy of this method. If the hall
sensors are accurate, this method is recommended. The BC command monitors the hall
sensors during a move and monitors the Hall sensors for a transition point. When that
occurs, the controller computes the commutation phase and sets it. For example, to
initialize the X axis motor upon power or reset, the following commands may be given:
SHX ;Enable X axis motor
BCX ;Enable the brushless calibration command
PRX=50000 ;Command a relative position movement on X axis
BGX ;Begin motion on X axis. When the hall sensors
detect a phase transition, the commutation phase is re-set.
Chapter 2 Getting Started • 28 USER MANUAL
Step 7C. Connect Step Motors
In Stepper Motor operation, the pulse output signal has a 50% duty cycle. Step motors operate open
loop and do not require encoder feedback. When a stepper is used, the auxiliary encoder for the
corresponding axis is unavailable for an external connection. If an encoder is used for position
feedback, connect the encoder to the main encoder input corresponding to that axis. The commanded
position of the stepper can be interrogated with RP o r DE. The encod er position can b e interrogated
with TP.
The frequency of the step motor pulses can be smoothed with the filter parameter, KS. The KS
parameter has a range between 0.5 and 8, where 8 implies the largest amount of smoothing. See
Command Reference regarding KS.
The DMC-13X8 profiler commands the step motor amplifier. All DMC-13X8 motion commands
apply such as PR, PA, VP, CR and JG. The acceleration, deceleration, slew speed and smoothing are
also used. Since step motors run open-loop, the PID filter does not function and the position error is
not generated.
To connect step motors with the DMC-13X8 you must follow this proc edure:
Step A. Install SM jumpers
Each axis of the DMC-13X8 that will operate a stepper motor must hav e the
corresponding stepper motor jumper installed. For a discussion of SM jumpers, see
section “Step 2. Install Jumpers on the DMC-13X8”.
Step B. Connect step and direction signals
For each axis of stepper control, connect the step and direction signals from the controller
to respective signals on your step motor amplifier. (These signals are labeled PULSX
and DIRX for the X-axis on the ICM-1900). Consult the documentation for your step
motor amplifier.
Step C. Configure DMC-13X8 for motor type using MT command. You can configure the
DMC-13X8 for active high or active low pulses. Use the command MT 2 for active high
step motor pulses and MT -2 for active low step motor pulses. See description of the MT
command in the Command Reference.
Step 8. Tune the Servo System
The final step for setting up the motion control system is adjusting the tuning parameters for optimal
performance of the servo motors (standard or sinusoidal commutation). The system compensation
provides fast and accurate response and the following presentation suggests a simple and easy way for
compensation.
The filter has three parameters: the damping, KD; the proportional gain, KP; and the integrator, KI.
The parameters should be selected in this order.
To start, set the integrator to zero with the instruction
KI 0 (CR) Integrator gain
and set the proportional gain to a low value, such as
KP 1 (CR) Proportional gain
KD 100 (CR) Derivative gain
For more damping, you can increase KD (maximum is 4095). Increase gradually and stop after the
motor vibrates. A vibration is noticed by audible sound or by interrogation. If you send the command
USER MANUAL Chapter 2 Getting Started • 29
TE X (CR) Tell error
a few times, and get varying responses, especially with reversing polarity, it indicates system vibration.
When this happens, simply reduce KD.
Next you need to increase the value of KP gradually (maximum allowed is 1023). You can monitor the
improvement in the response with the Tell Error instruction
KP 10 (CR) Proportion gain
TE X (CR) Tell error
As the proportional gain is increased, the error decreases.
Again, the system may vibrate if the gain is too high. In this case, reduce KP. Typically, KP should
not be greater than KD/4. (Only when the amplifier is configured in the current mode).
Finally, to select KI, start with zero value and increase it gradually. The integrator eliminates the
position error, resulting in improved accuracy. Therefore, the response to the instruction
TE X (CR)
becomes zero. As KI is increased, its effect is amplified and it may lead to vibrations. If this occurs,
simply reduce KI. Repeat tuning for the Y, Z and W axes.
For a more detailed description of the operation of the PID filter and/or servo system theory, see
Chapter 10 - Theory of Operation.
Design Examples
Here are a few examples for tuning and using your controller. These examples have remarks next to
each command - these remarks must not be included in the actual program.
Example 1 - System Set-up
This example assigns the system filter parameters, error limits and enables the automatic error shut-off.
Instruction Interpretation
KP10,10,10,10 Set gains for a,b,c,d (or X,Y,Z,W axes)
KP*=10 Alternate method for setting gain on all axes
KPX=10 Alternate method for setting X (or A) axis gain
KPA=10 Alternate method for setting A (or X) axis gain
KP, 20 Set Y axis gain only
Instruction Interpretation
OE 1,1,1,1 Enable automatic Off on Error function for all axes
ER*=1000 Set error limit for all axes to 1000 counts
KP10,10,10,10 Set gains for a,b,c and d axes
KP*=10 Alternate method for setting gain on all axes
KPX=10 Alternate method for setting X (or A) axis gain
KPA=10 Alternate method for setting A (or X) axis gain
KP,,10 Set Z axis gain only
KPZ=10 Alternate method for setting Z axis gain
Chapter 2 Getting Started • 30 USER MANUAL
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