DMC-40x0
Manual Rev. 1.0f
USER MANUAL
By Galil Motion Control, Inc.
Galil Motion Control, Inc.
270 Technology Way
Rocklin, California 95765
Phone: (916) 626-0101
Fax: (916) 626-0102
E-mail Address: support@galilmc.com
URL: www.galilmc.com
Rev 8/09
Using This Manual
4080
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 with this controller.
Your DMC-40x0 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.
Attention: Pertains to controllers with more than 4 axes.
Please note that many examples are written 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 with A,B,C,D.
WARNING: Machinery in motion can be dangerous! It is the responsibility of the user to design
effective error handling and safety protection as part of the machinery. Galil shall not be liable or
responsible for any incidental or consequential damages.
DMC-40x0 Contents • i
Contents
Contents iii
Chapter 1 Overview 1
Introduction ................................................................................................................... 1
Overview of Motor Types ............................................................................................. 2
Overview of External Amplifiers .................................................................................. 3
Overview of Galil Amplifiers and Drivers ................................................................... 3
DMC-40x0 Functional Elements .................................................................................. 4
Standard Servo Motor with +/- 10 Volt Command Signal ....... 2
Brushless Servo Motor with Sinusoidal Commutation ............. 2
Stepper Motor with Step and Direction Signals ....................... 2
Amplifiers in Current Mode ...................................................... 3
Amplifiers in Velocity Mode .................................................... 3
Stepper Motor Amplifiers ......................................................... 3
A1 – AMP-430x0 (-D3040, -D3020) ........................................ 3
A2 – AMP-43140 (-D3140) ...................................................... 3
A3 – SDM-44040 (-D4040) ...................................................... 3
A4 – SDM-44140 (-D4140) ...................................................... 3
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 Power Connections .................................................................................... 9
DMC-4040 Dimensions ................................................................................................ 10
DMC-4080 Dimensions ................................................................................................ 11
Elements You Need ...................................................................................................... 12
Installing the DMC-40x0 .............................................................................................. 13
Design Examples .......................................................................................................... 25
Step 1. Determine Overall Motor Configuration ...................... 13
Step 2. Install Jumpers on the DMC-40x0 ................................ 14
Step 3. Install the Communications Software ........................... 14
Step 4. Connect 20-80VDC Power to the Controller ................ 15
Step 5. Establish Communications with Galil Software ........... 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
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 with Loops ............................. 28
Example 13 - Motion Programs with Trippoints ...................... 29
Example 14 - Control Variables ............................................... 29
Example 15 - Linear Interpolation ............................................ 30
Example 16 - Circular Interpolation ......................................... 30
Chapter 3 Connecting Hardware 32
Overview ....................................................................................................................... 32
Using Optoisolated Inputs ............................................................................................. 32
Wiring the Optoisolated Inputs ..................................................................................... 34
TTL Inputs .................................................................................................................... 37
High Power Opto-Isolated Outputs ............................................................................... 38
Analog Inputs ................................................................................................................ 39
TTL Outputs ................................................................................................................. 39
Extended I/O of the DMC-40x0 Controller ................................................................. 40
Amplifier Interface ........................................................................................................ 41
Limit Switch Input .................................................................... 32
Home Switch Input ................................................................... 33
Abort Input ................................................................................ 33
ELO (Electronic Lock-Out) Input ............................................. 34
Reset Input ................................................................................ 34
Uncommitted Digital Inputs ..................................................... 34
Electrical Specifications ............................................................ 34
Bi-Directional Capability .......................................................... 34
Using an Isolated Power Supply ............................................... 36
Bypassing the Opto-Isolation: ................................................... 37
The Auxiliary Encoder Inputs ................................................... 37
Electrical Specifications ............................................................ 38
Wiring the Opto-Isolated Outputs ............................................. 38
AQ settings ................................................................................ 39
Electrical Specifications ............................................................ 39
Output Compare ........................................................................ 39
Error Output .............................................................................. 39
Electrical Specifications (3.3V – Standard) .............................. 40
Electrical Specifications (5V – Option) .................................... 40
Electrical Specifications ............................................................ 41
Overview ................................................................................... 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
Ethernet Configuration .................................................................................................. 50
Modbus ......................................................................................................................... 53
Data Record .................................................................................................................. 55
Controller Response to Commands .............................................................................. 61
Unsolicited Messages Generated by Controller ............................................................ 62
RS-232 Configuration ............................................................... 48
RS-422 Configuration ............................................................... 50
Communication Protocols ......................................................... 50
Addressing ................................................................................ 51
Communicating with Multiple Devices .................................... 52
Multicasting .............................................................................. 52
Using Third Party Software ...................................................... 52
Modbus Examples .................................................................... 54
Explanation Data Record Bit Fields ......................................... 60
Notes Regarding Velocity and Torque Information ................. 61
QZ Command ............................................................................ 61
DMC-40x0 Contents • iii
GalilTools (Windows and Linux) ................................................................................. 63
Creating Custom Software Interfaces ........................................................................... 65
DOS, and QNX tools .................................................................................................... 69
Chapter 5 Command Basics 70
Introduction ................................................................................................................... 70
Command Syntax - ASCII ............................................................................................ 70
Command Syntax – Binary (advanced) ........................................................................ 72
Controller Response to DATA ...................................................................................... 74
Interrogating the Controller .......................................................................................... 74
Chapter 6 Programming Motion 76
Overview ....................................................................................................................... 76
Independent Axis Positioning ....................................................................................... 78
Independent Jogging ..................................................................................................... 80
Position Tracking .......................................................................................................... 81
Linear Interpolation Mode ............................................................................................ 86
Vector Mode: Linear and Circular Interpolation Motion ............................................. 91
Electronic Gearing ........................................................................................................ 95
Ramped Gearing ........................................................................................................... 96
Electronic Cam .............................................................................................................. 99
PVT Mode ..................................................................................................................... 105
HelloGalil – Quick Start to PC programming ........................... 65
GalilTools Communication Libraries ....................................... 65
ActiveX Toolkit ........................................................................ 66
DMCWin Programmers Toolkit ............................................... 66
Galil Communications API with C/C++ ................................... 67
Galil Communications API with Visual Basic ........................ 67
Coordinated Motion with more than 1 axis .............................. 71
Binary Command Format ......................................................... 72
Binary command table .............................................................. 73
Interrogation Commands .......................................................... 74
Summary of Interrogation Commands ...................................... 75
Interrogating Current Commanded Values. .............................. 75
Operands ................................................................................... 75
Command Summary ................................................................. 75
Command Summary - Independent Axis .................................. 78
Operand Summary - Independent Axis .................................... 78
Command Summary - Jogging ................................................ 80
Operand Summary - Independent Axis .................................... 81
Example - Motion 2: ............................................................... 83
Example Motion 4 ................................................................... 84
Trip Points ................................................................................. 85
Command Summary – Position Tracking Mode ..................... 86
Specifying Linear Segments ..................................................... 86
Command Summary - Linear Interpolation .............................. 88
Operand Summary - Linear Interpolation ................................ 88
Example - Linear Move ............................................................ 89
Example - Multiple Moves ....................................................... 90
Specifying the Coordinate Plane ............................................... 91
Specifying Vector Segments ..................................................... 91
Additional commands ............................................................... 92
Command Summary - Coordinated Motion Sequence ............. 94
Operand Summary - Coordinated Motion Sequence ................ 94
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
Command Summary - Electronic CAM ................................... 103
Operand Summary - Electronic CAM ...................................... 103
Example - Electronic CAM ...................................................... 103
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
Contour Mode ............................................................................................................... 110
Stepper Motor Operation .............................................................................................. 115
Stepper Position Maintenance Mode (SPM) ................................................................. 117
Dual Loop (Auxiliary Encoder) .................................................................................... 120
Motion Smoothing ....................................................................................................... 122
Homing ......................................................................................................................... 124
High Speed Position Capture (The Latch Function) .................................................... 127
Fast Update Rate Mode ................................................................................................ 129
Chapter 7 Application Programming 130
Overview ....................................................................................................................... 130
Using the DMC-40x0 Editor to Enter Programs ........................................................... 130
Program Format ............................................................................................................ 131
Executing Programs - Multitasking .............................................................................. 133
Debugging Programs .................................................................................................... 134
Program Flow Commands ............................................................................................ 135
Mathematical and Functional Expressions ................................................................... 149
Variables ....................................................................................................................... 151
Operands ....................................................................................................................... 153
Arrays ............................................................................................................................ 154
Input of Data (Numeric and String) .............................................................................. 157
Output of Data (Numeric and String) ........................................................................... 160
Multi-Axis Coordinated Move .................................................. 108
Specifying Contour Segments ................................................... 110
Additional Commands .............................................................. 111
Command Summary - Contour Mode ...................................... 111
Specifying Stepper Motor Operation ....................................... 115
Using an Encoder with Stepper Motors .................................... 116
Command Summary - Stepper Motor Operation ..................... 116
Operand Summary - Stepper Motor Operation ......................... 116
Internal Controller Commands (user can query): ..................... 117
User Configurable Commands (user can query & change): ..... 117
Error Limit ................................................................................ 117
Correction ................................................................................. 117
Backlash Compensation ............................................................ 121
Using the IT Command: ............................................................ 122
Using the KS Command (Step Motor Smoothing): .................. 124
Stage 1: ...................................................................................... 124
Stage 2: ...................................................................................... 124
Stage 3: ...................................................................................... 124
Command Summary - Homing Operation ............................... 127
Operand Summary - Homing Operation ................................... 127
Edit Mode Commands .............................................................. 131
Using Labels in Programs ......................................................... 131
Special Labels ........................................................................... 132
Commenting Programs ............................................................. 132
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 Operators ............................................................ 149
Bit-Wise Operators ................................................................... 150
Functions .................................................................................. 151
Programmable Variables ........................................................... 152
Special Operands (Keywords) .................................................. 153
Defining Arrays ........................................................................ 154
Assignment of Array Entries .................................................... 154
Automatic Data Capture into Arrays ........................................ 155
De-allocating Array Space ........................................................ 157
Input of Data ............................................................................. 157
Operator Data Entry Mode ....................................................... 158
Using Communication Interrupt .............................................. 158
Sending Messages ..................................................................... 160
Displaying Variables and Arrays ............................................. 161
DMC-40x0 Contents • v
Interrogation Commands .......................................................... 162
Formatting Variables and Array Elements ............................... 163
Hardware I/O ................................................................................................................ 164
Extended I/O of the DMC-40x0 Controller ................................................................. 168
Example Applications ................................................................................................... 169
Chapter 8 Hardware & Software Protection 177
Introduction ................................................................................................................... 177
Hardware Protection ..................................................................................................... 177
Software Protection ....................................................................................................... 178
Converting to User Units .......................................................... 164
Digital Outputs .......................................................................... 164
Digital Inputs ............................................................................ 165
The Auxiliary Encoder Inputs ................................................... 166
Input Interrupt Function ............................................................ 166
Analog Inputs ............................................................................ 167
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
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
Output Protection Lines ............................................................ 177
Input Protection Lines ............................................................... 178
Programmable Position Limits ................................................. 179
Off-On-Error ............................................................................. 179
Automatic Error Routine ........................................................... 179
Limit Switch Routine ................................................................ 180
Chapter 9 Troubleshooting 181
Overview ....................................................................................................................... 181
Installation ..................................................................................................................... 181
Stability ......................................................................................................................... 182
Operation ....................................................................................................................... 182
Chapter 10 Theory of Operation 183
Overview ....................................................................................................................... 183
Operation of Closed-Loop Systems .............................................................................. 185
System Modeling .......................................................................................................... 186
System Analysis ............................................................................................................ 191
System Design and Compensation ................................................................................ 193
Appendices 197
Electrical Specifications ................................................................................................ 197
Performance Specifications .......................................................................................... 199
Fast Update Rate Mode ................................................................................................ 200
Ordering Options for the DMC-40x0 ........................................................................... 201
Motor-Amplifier ....................................................................... 187
Encoder ..................................................................................... 189
DAC .......................................................................................... 189
Digital Filter .............................................................................. 190
ZOH .......................................................................................... 191
The Analytical Method ............................................................. 193
Servo Control ............................................................................ 197
Stepper Control ......................................................................... 197
Input / Output ............................................................................ 197
Power Requirements ................................................................. 198
Max Power Output .................................................................... 198
Minimum Servo Loop Update Time: ........................................ 199
Overview ................................................................................... 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
Power Connectors for the DMC-40x0 .......................................................................... 205
Cable Connections for DMC-40x0 ............................................................................... 206
Pin-Out Description for DMC-40x0 ............................................................................. 208
Configuring the Amplifier Enable Circuit .................................................................... 210
Coordinated Motion - Mathematical Analysis ............................................................. 225
Example- Communicating with 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 234
Overview ....................................................................................................................... 234
Overview ................................................................................... 205
Molex Part Numbers Used ........................................................ 205
Standard RS-232 Specifications ............................................... 206
DMC-40x0 Serial Cable Specifications .................................... 207
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
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-430x0 (-D3040,-D3020) 236
Description .................................................................................................................... 236
Electrical Specifications ................................................................................................ 237
Operation ....................................................................................................................... 238
A2 – AMP-43140 (-D3140) 242
Description .................................................................................................................... 242
Electrical Specifications ................................................................................................ 243
Operation ....................................................................................................................... 244
A3 – SDM-44040 (-D4040) 245
Description .................................................................................................................... 245
Electrical Specifications ................................................................................................ 246
Operation ....................................................................................................................... 247
Mating Connectors .................................................................... 237
Brushless Motor Setup .............................................................. 238
Brushless Amplifier Software 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
Mating Connectors .................................................................... 243
Using External Amplifiers ........................................................ 244
ELO Input ................................................................................. 244
-SSR Option .............................................................................. 244
Mating Connectors .................................................................... 246
Current Level Setup (AG Command) ....................................... 247
DMC-40x0 Contents • vii
Low 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
Operation ....................................................................................................................... 251
A5 – CMB-41012 (-C012) 252
Description .................................................................................................................... 252
Connectors for CMB-41012 Interconnect Board ......................................................... 252
A6 – ICM-42000 (-I000) 256
Description .................................................................................................................... 256
Connectors for ICM-42000 Interconnect Board ........................................................... 256
Mating Connectors .................................................................... 250
Current Level Setup (AG Command) ....................................... 251
Low Current Setting (LC Command) ....................................... 251
ELO Input ................................................................................. 251
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
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
Theory of Operation ...................................................................................................... 266
A8 – ICM-42200 (-I200) 268
Description .................................................................................................................... 268
Connectors for ICM-42200 Interconnect Board ........................................................... 268
Index 271
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
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
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 two communication channels: high speed RS-232 (2 channels up to 115K Baud) and
10BaseT Ethernet. The controllers allow 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 low as 31.25 µsec per axis are available.
A Flash EEPROM provides non-volatile memory for storing application programs, parameters, arrays and firmware.
New firmware revisions are easily upgraded in the field.
The DMC-40x0 is available with 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, pointto-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-40x0 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-40x0 provides uncommitted I/O, including 8 opto-isolated digital
inputs (16 inputs for DMC-4050 thru DMC-4080), 8 high power optically isolated outputs (16 outputs for DMC4050 thru DMC-4080), and 8 analog inputs for interface to joysticks, sensors, and pressure transducers. The DMC40x0 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 forward and reverse limits, abort, home, and
definable input interrupts.
Commands can be sent in either Binary or ASCII. Additional software is available for automatic-tuning, trajectory
viewing on a PC screen, CAD translation, and program development using many environments such as Visual
Basic, C, C++ etc. Drivers for Windows XP (32 & 64 bit).
Chapter 1 Overview • 1 DMC-40x0 User Manual
Overview of Motor Types
The DMC-40x0 can provide the following types of motor control:
1. Standard servo motors with +/- 10 volt command signals
2. Brushless servo motors with sinusoidal commutation
3. Step motors with step and direction signals
4. Other actuators such as hydraulics - For more information, contact Galil.
The user can configure each axis for any combination of motor types, providing maximum flexibility.
Standard Servo Motor with +/- 10 Volt Command Signal
The DMC-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-forward, 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 two sinusoidal signals for connection with amplifiers specifically designed for this purpose.
Note: The task of generating sinusoidal commutation may be accomplished in the brushless motor amplifier. If the
amplifier generates the sinusoidal commutation signals, only a single command signal is required and the controller
should be configured for a standard servo motor (described above).
Sinusoidal commutation in the controller can be used with linear and rotary BLMs. However, the motor velocity
should be limited such that a magnetic cycle lasts at least 6 milliseconds with a standard update rate of 1
millisecond. For faster motors, please contact the factory.
To simplify the wiring, the controller provides a one-time, automatic set-up procedure. When the controller has
been properly configured, the brushless motor parameters may be saved in non-volatile memory.
The DMC-40x0 can control BLMs equipped with Hall sensors as well as without Hall sensors. If Hall sensors are
available, once the controller has been setup, the brushless motor parameters may be saved in non-volatile memory.
In this case, the controller will automatically estimate the commutation phase upon reset. This allows the motor to
function immediately upon power up. The Hall effect sensors also provide a method for setting the precise
commutation phase. Chapter 2 describes the proper connection and procedure for using sinusoidal commutation of
brushless motors.
Stepper Motor with Step and Direction Signals
The DMC-40x0 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.
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-width-modulated. An amplifier may
have current feedback, voltage feedback or velocity feedback.
Amplifiers in Current Mode
Amplifiers in current mode should accept an analog command signal in the +/-10 volt range. The amplifier gain
should be set such that a +10V command will generate the maximum required current. For example, if the motor
peak current is 10A, the amplifier gain should be 1 A/V.
Amplifiers in Velocity Mode
For velocity mode amplifiers, a command signal of 10 volts should run the motor at the maximum required speed.
The velocity gain should be set such that an input signal of 10V runs the motor at the maximum required speed.
Stepper Motor Amplifiers
For step motors, the amplifiers should accept step and direction signals.
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 straightforward motion control
solution in one box.
A1 – AMP-430x0 (-D3040, -D3020)
The AMP-43040 (four-axis) and AMP-43020 (two-axis) are multi-axis brush/brushless amplifiers that are capable
of handling 500 watts of continuous power 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-43140 (-D3140)
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 power 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 bandwidth is 4 kHz.
A3 – SDM-44040 (-D4040)
The SDM-44040 is a stepper driver module capable of driving up to four bipolar two-phase stepper motors. The
current is selectable with options of 0.5, 0.75, 1.0, and 1.4 Amps/Phase. The step resolution is selectable with
options of full, half, 1/4 and 1/16.
A4 – SDM-44140 (-D4140)
The SDM-44140 microstepper module drives four bipolar two-phase stepper motors with 1/64 microstep resolution
(the SDM-44140 drives two). The current is selectable with 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
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
The DMC-40x0 circuitry can be divided into the following functional groups as shown in Figure 1.1 and discussed
below.
Figure 1.1 - DMC-40x0 Functional Elements
Microcomputer Section
The main processing unit of the controller is a specialized Microcomputer with RAM and Flash EEPROM. The
RAM provides memory for variables, array elements, and application programs. The flash EEPROM provides nonvolatile storage of variables, programs, and arrays. The Flash also contains the firmware of the controller, which 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 two DACs to generate two +/-10 volt analog signals. For stepper motor
operation, the controller generates a step and direction signal.
Communication
The communication interface with the DMC-40x0 consists of high speed RS-232 and Ethernet. The Ethernet is
10/100Bt and the two 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 power optoisolated
outputs and 8 analog inputs with 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
4080
inputs can also be used as high speed latches for each axis. A high speed encoder compare output is also provided.
The DMC-4050 through DMC-4080 controller provides an additional 8 optoisolated inputs and 8 high
power optoisolated outputs.
System Elements
As shown in Fig. 1.2, the DMC-40x0 is part of a motion control system which includes amplifiers, motors and
encoders. These elements are described below.
Power Supply
Com puter DMC-40x0 Controller
Encoder Motor
Figure 1-.2 - Elements of Servo systems
Amplifier (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 MotorSizer Web tool can help you with motor
sizing: 332Hwww.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 when
step motors are used.
Other motors and devices such as Ultrasonic Ceramic motors and voice coils can be controlled with the DMC-40x0.
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.
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
Encoder
An encoder translates motion into electrical pulses which are fed back into the controller. The DMC-40x0 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 singleended (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 with 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 with pulse and direction signals. Refer to the “CE” command in the
command reference for details.
There is no limit on encoder line density; however, 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), however, 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 with 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 with 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 watch dog timer which checks for proper microprocessor operation. The timer
toggles the Amplifier Enable Output (AMPEN) which can be used to switch the amplifiers off in the event of a
serious DMC-40x0 failure. The AMPEN output is normally high. During power-up and if the microprocessor
ceases to function properly, the AMPEN output will go low. The error light will also turn on at this stage. A reset is
required to restore the DMC-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 following layouts assume either an ICM-42000(I000) or ICM-42100(I100) interconnect modules are installed.
For layouts of systems with 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 the of the DMC-4040
Chapter 2 Getting Started • 7 DMC-40x0 User Manual
DMC-4080 Layout
Figure 2-2 - Outline of the of the DMC-4080
DMC-40x0 User Manual Chapter 2 Getting Started • 8
DMC-40x0 Power Connections
Power Connector for Controller without
Power Connector for Controller without
Galil Amplifiers or when ISCNTL
Galil Amplifiers or when ISCNTL
option is ordered
option is orderd*
Power Connectors for Galil integrated Amplifiers*
Figure 2-3 – Connector locations for the DMC-40x0
Figure 2-4 – Power Connector used when controller is ordered without Galil Amplifiers
*See Power connector information for specific amplifiers in the Integrated section of the Appendices.
For more information on Connectors (mfg PN’s and diagrams) see the Power Connector Section in the Appendix.
Chapter 2 Getting Started • 9 DMC-40x0 User Manual
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
Elements You Need
For a complete system, Galil recommends the following elements:
1. DMC-4010, 4020, 4030, or DMC-4040 Motion Controller
or
DMC-4050, 4060, 4070 or DMC-4080
2. Motor Amplifiers (Integrated when using Galil amplifiers and
drivers)
3. Power Supply for Amplifiers and controller
4. Brush or Brushless Servo motors with Optical Encoders or stepper
motors.
a. Cables for connecting to the DMC-40x0’s integrated ICM’s.
5. PC (Personal Computer - RS232 or Ethernet for DMC-40x0)
6. GalilTools, or GalilTools-Lite Software package
GalilTools is highly recommended for first time users of the DMC-40x0. It provides step-by-step instructions for
system connection, tuning and analysis.
DMC-40x0 User Manual Chapter 2 Getting Started • 12
Installing the DMC-40x0
Installation of a complete, operational DMC-40x0 system consists of 9 steps.
Step 1. Determine overall motor configuration.
Step 2. Install Jumpers on the DMC-40x0.
Step 3. Install the communications software.
Step 4. Connect DC power to controller.
Step 5. Establish communications with the Galil Communication Software.
Step 6. Determine the Axes to be used for sinusoidal commutation.
Step 7. Make connections to amplifier and encoder.
Step 8a. Connect standard servo motors.
Step 8b. Connect sinusoidal commutation motors
Step 8c. Connect step motors.
Step 9. 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 DMC40x0 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.
The following configuration information is necessary to determine the proper motor configuration:
Standard Servo Motor Operation:
Unless ordered with stepper motor drivers or in a non-standard configuration, the DMC-40x0 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 DACs. In standard servo operation, the DMC-40x0 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 DACs and the controller must be a
DMC-4040.
Sinusoidal commutation is configured with the command, BA. For example, BAA sets the A 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-4040, the command BAA will configure the A axis to be the main sinusoidal signal and the
'D' axis to be the second sinusoidal 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 BAA is given to a DMC-4040
controller, the controller will be re-configured to a DMC-4030 controller. By definition, a DMC-4030 controls 3
axes: A,B and C. The 'D' axis is no longer available since the output DAC is being used for sinusoidal commutation.
Further instruction for sinusoidal commutation connections are discussed in Step 6.
Chapter 2 Getting Started • 13 DMC-40x0 User Manual
Stepper Motor Operation
To configure the DMC-40x0 for stepper motor operation, the controller requires that the command, MT, must be
given. Further instruction for stepper motor connections are discussed in Step 8c.
Step 2. Install Jumpers on the DMC-40x0
Master Reset and Upgrade Jumpers
JP1 on the main board contains two jumpers, MRST and UPGRD. The MRST jumper is the Master Reset jumper.
When MRST is 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.
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 MO 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,
unless an error occurs that will turn the motors off. The MO jumper is located on JP1, the same block as the Master
Reset and Upgrade jumpers.
Communications Jumpers for DMC-40x0
The baud rate for RS232 communication can be set with jumpers found on JP1 of the communication board (same
set of jumpers where MO, MRST and UPGD can be found). To set the baud rate to the desired value, see 703HT 2able- below.
19.2 38.4 BAUD RATE
ON ON 9600
ON OFF 19200
OFF ON 38400
OFF OFF 115200
Table 2-1 : Baud Rate Jumper Settings
Other serial communication protocols, such as RS-485, can be implemented as a special - consult Galil.
Step 3. Install the Communications Software
After applying power to the computer, you should install the Galil software that enables communication between the
controller and PC.
Using Windows XP (32 & 64 bit):
Install the Galil Software Products CD-ROM into your CD drive. A Galil .htm page should automatically appear
with links to the software products. Select the correct version of GalilTools software for your particular operating
system and click “Install…” Follow the installation procedure as outlined.
The most recent copy of the GalilTools software can be downloaded from the Galil website.
DMC-40x0 User Manual Chapter 2 Getting Started • 14
http://www.galilmc.com/products/software/galiltools.html
All other Galil software is also available for download at the Galil software downloads page.
33http://www.galilmc.com/support/download.html
Using Linux (32 & 64 bit):
The GalilTools software package is fully compatible with a number of Linux distributions. See the GalilTools
webpage and user manual for downloads and installation instructions.
http://www.galilmc.com/products/software/galiltools.html
Step 4. Connect 20-80VDC Power to the Controller
If the controller was ordered with Galil Amplifiers or Drivers, then power to the controller will be supplied through
those power connectors. Otherwise the power will come through the connector on the side of the controller. See
DMC-40x0 Power Connections.
WARNING: Dangerous voltages, current, temperatures and energy levels exist in this product and
the associated amplifiers and servo motor(s). Extreme caution should be exercised in the
application of this equipment. Only qualified individuals should attempt to install, set up and operate
this equipment. Never open the controller box when DC power is applied to it.
The green power light indicator should go on when power is applied.
Step 5. Establish Communications with Galil Software
Communicating through an Ethernet connection
The DMC-40x0 motion controller is equipped with DHCP. If the controller is connected to a DHCP enabled
network, an IP address will automatically be assigned to the controller. See Ethernet Configuration in Chapter 4 for
more information.
Using GalilTools Software for Windows
Registering controllers in the Windows registry is no longer required when using the GalilTools software package.
A simple connection dialog box appears when the software is opened that shows all available controllers.
Any available controllers with assigned IP addresses can be found under the ‘Available’ tab in the Connections
Dialog Box. If the controller is not connected to a DHCP enabled network, or the DH command is set to 0, and the
controller has not been assigned an IP address, the controller can be found under the ‘No IP Address’ tab.
For more information on establishing communication to the controller via the GalilTools software, see the
GalilTools user manual.
http://www.galilmc.com/support/manuals/galiltools/index.html
Using DMC-SmartTerminal or WSDK Software for Windows
NOTE: For new applications, Galil recommends using the GalilTools software package.
The controller must be registered in the Windows registry for the host computer to communicate with it. The
registry may be accessed via Galil software, such as WSDK or GALIL Smart Terminal.
A dedicated network card with a static IP address is recommended. To set your NIC card to a static IP, go to the
Control Panel Network Connections Local Area Connection Properties TCP/IP and choose “use the
following IP address”. If a “Dynamic” IP address is used, make sure there is a DHCP Server on your network or
you will encounter an error.
Chapter 2 Getting Started • 15 DMC-40x0 User Manual
Use the “New Controller” button to add a new entry in the registry or alternatively click on the “Find Ethernet
Controller” to have the software search for controllers connected to the network. When adding a new controller,
choose DMC-40x0 as the controller type. Enter the IP address obtained from your system administrator. Select the
button corresponding to the UDP or TCP protocol in which you wish to communicate with the controller. If the IP
address has not been already assigned to the controller, click on ASSIGN IP ADDRESS.
ASSIGN IP ADDRESS will check the controllers that are linked to the network to see which ones do not have an
IP address. The program will then ask you whether you would like to assign the IP address you entered to the
controller with the specified serial number. Click on YES to assign it, NO to move to next controller, or CANCEL
to not save the changes. If there are no controllers on the network that do not have an IP address assigned, the
program will state this.
When done registering, click on OK. If you do not wish to save the changes, click on CANCEL.
Once the controller has been registered, select the correct controller from the list and click on OK. If the software
successfully established communications with the controller, the registry entry will be displayed at the bottom of the
screen in the Status window.
NOTE: The controller must be registered via an Ethernet connection.
Communicating through the Main Serial Communications Port
Connect the DMC-40x0 MAIN serial port to your computer via the Galil CABLE-9PIN-D (RS-232 Cable). This is
a straight through serial cable – NOT a NULL modem.
Using GalilTools Software for Windows
Registering controllers in the Windows registry is no longer required when using the GalilTools software package.
A simple connection dialog box appears when the software is opened that shows all available controllers.
The serial ports are listed as COMn ‘communication speed’. (ex COM1 115200). The default serial communication
speed on the DMC-40x0 is 115200Bps.
For more information on establishing communication to the controller via the GalilTools software, see the
GalilTools user manual.
http://www.galilmc.com/support/manuals/galiltools/index.html
Using DMC-SmartTerminal or WSDK Software for Windows
NOTE: For new applications, Galil recommends using the GalilTools software package.
In order for the windows software to communicate with a Galil controller, the controller must be registered in the
Windows Registry. To register a controller, you must specify the model of the controller, the communication
parameters, and other information. The registry is accessed through the Galil software under the “File” menu in
WSDK or under the “Tools” menu in the Galil Smart Terminal.
Use the “New Controller” button to add a new entry to the Registry. You will need to supply the Galil Controller
model (eg: DMC-40x0). Pressing the down arrow to the right of this field will reveal a menu of valid controller
types. You then need to choose serial or Ethernet connection. The registry information will show a default Comm.
Port of 1 and a default Comm. Speed of 115200 appears. This information can be changed as necessary to reflect
the computers Comm. Port and the baud rate set by the jumpers found on the communications board. The registry
entry also displays timeout and delay information. These are advanced parameters which should only be modified
by advanced users (see software documentation for more information).
Once you have set the appropriate Registry information for your controller, Select OK and close the registry
window. You will now be able to communicate with the controller.
To establish communication to the controller, open up the Terminal and hit the “Enter” key. You should receive a
colon prompt. Communicating with the controller is described in later sections.
DMC-40x0 User Manual Chapter 2 Getting Started • 16
If you are not properly communicating with the controller, the program will pause for 3-15 seconds and an error
message will be displayed. In this case, there is most likely an incorrect setting of the serial communications port or
the serial cable is not connected properly. The user must ensure that the correct communication port and baud rate
are specified when attempting to communicate with the controller. Please note that the serial port on the controller
must be set for handshake mode for proper communication with Galil software. The user must also insure that a
“straight-through” serial cable is being used (NOT a Null Modem cable), see appendix for pin-out of serial cable.
Using Non-Galil Communication Software
The DMC-40x0 main serial port is configured as DATASET. Your computer or terminal must be configured as a
DATATERM for full duplex, no parity, 8 data bits, one start bit and one stop bit.
Check to insure that the baud rate jumpers have been set to the desired baud rate as described above.
Your computer needs to be configured as a "dumb" terminal which sends ASCII characters as they are typed to the
DMC-40x0.
Sending Test Commands to the Terminal:
After you connect your terminal, press <return> or the <enter> key on your keyboard. In response to carriage return
<return>, the controller responds with a colon, :
Now type
TPA <return>
This command directs the controller to return the current position of the A axis. The controller should respond with
a number such as
:0
Step 6. 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, BAAC sets A and C 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 BAA is given to a DMC-4040 controller, the controller will
be re-configured to be a DMC-4030 controller. In this case the highest axis is no longer available except to be used
for the 2nd phase of the sinusoidal commutation. Note that the highest axis on a controller can never be configured
for sinusoidal commutation.
The DAC associated with the selected axis represents the first phase. The second phase uses the highest available
DAC. When more than one axis is configured for sinusoidal commutation, the controller will assign the second
phases to the DACs which have been made available through the axes reconfiguration. The highest sinusoidal
commutation axis will be assigned to the highest available DAC and the lowest sinusoidal commutation axis will be
assigned to the lowest available DAC. Note that the lowest axis is the A axis and the highest axis is the highest
available axis for which the controller has been configured.
Example: Sinusoidal Commutation Configuration using a DMC-4070
BAAC
This command causes the controller to be reconfigured as a DMC-4050 controller. The A and C axes are configured
for sinusoidal commutation. The first phase of the A axis will be the motor command A signal. The second phase
Chapter 2 Getting Started • 17 DMC-40x0 User Manual
of the A axis will be F signal. The first phase of the C axis will be the motor command C signal. The second phase
of the C axis will be the motor command G signal.
Step 7. Make Connections to Amplifier and Encoder.
If the system is run solely by Galil’s integrated amplifiers or drivers, skip this section, the amplifier is already
connected to the controller.
Once you have established communications between the software and the DMC-40x0, you are ready to connect the
rest of the motion control system. The motion control system typically consists of the controller with interconnect
module, an amplifier for each axis of motion, and a motor to transform the current from the amplifier into torque for
motion.
System connection procedures will depend on system components and motor types. Any combination of motor
types can be used with the DMC-40x0. There can also be a combination of axes running from Galil integrated
amplifiers and drivers and external amplifiers or drivers. If sinusoidal commutation is to be used, special attention
must be paid to the reconfiguration of axes (see above section for more information).
Connecting to External Amplifiers
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 regarding 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. When configured with the ICM42000 or ICM-42100, this signal is labeled AENA for the A axis and is found on the 15 pin Dsub
connector associated with the A axis (if configured with the ICM-42200 the AENA signal is located on the
26 pin Dsub associated with the A axis). 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 OE3 command (Enable Off-On-Error) is given and the position error exceeds the error
limit. AMPEN can be used to disable the amplifier for these conditions.
The AMPEN signal from the DMC-40x0 is shipped as a default of 5V active high or high amp enable. In
other words, the AMPEN signal will be high when the controller expects the amplifier to be enabled.
If your amplifier requires a different configuration it is highly recommended that the DMC-40x0 is
ordered with the desired configuration. See the DMC-40x0 ordering information in the catalog
(http://www.galilmc.com/catalog/cat40x0.pdf) or contact Galil for more information on ordering different
configurations. If the amplifier enable needs to be changed, see the ICM-42000 and ICM-42100 Amplifier
Enable Circuit section in Chapter 3 Connecting Hardware.
DMC-40x0 User Manual Chapter 2 Getting Started • 18
4080
When ordered with ICM-42000’s or ICM-42100’s the AEN signal is configurable for axes 1-4 and axes 5-8.
Ex – axes 1-4 could be ordered as 5V high amp enable, and axes 5-8 could be ordered as 12V low amp
enable. When ordered with ICM-42200’s each axis is individually configurable.
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-40x0 accepts single-ended or differential encoder feedback with or without an index pulse. The
encoder signals are wired to that axis associated 15pin DSub connector found on top of the controller. The
signal leads are labeled MA+ (channel A), MB+ (channel B), and MI+. For differential encoders, the
complement signals are labeled MA-, MB-, and MI-. For complete pin-out information see in the
Appendices.
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 A encoder first. Once it is connected, turn the motor shaft and interrogate the position with
the instruction TPA <return>. The controller response will vary as the motor is turned.
At this point, if TPA 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 may 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-40x0 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 Hardware.
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 C axis are connected to inputs 6, 7 and 8, use the
instruction:
BI ,, 6 or
BIC = 6
Step 8a. Connect Standard Servo Motors
The following discussion applies to connecting the DMC-40x0 controller to standard servo motors:
Chapter 2 Getting Started • 19 DMC-40x0 User Manual
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. For Galil amplifiers, see Integrated .
Step A. Check the Polarity of the Feedback Loop
It is assumed that the motor and amplifier are connected together and that the encoder is operating correct
(Step 7). 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 A axis as an examples.
Step B. 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 Galil Tools, the
following parameters can be given to avoid system damage:
Input the commands:
ER 2000 <return> Sets error limit on the A axis to be 2000 encoder counts
OE 1 <return> Disables A 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 AMPEN signal to be connected from the controller to the amplifier.
Step C. Set Torque Limit as a Safety Precaution
To limit the maximum voltage signal to your amplifier, the DMC-40x0 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 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.
For example, the following command will limit the output of the controller to 1 volt on the X axis:
TL 1 <return>
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 D. Connect the Motor
Once the parameters have been set, connect the analog motor command signal (MCMn where n is A-H) to
the amplifier input.
To test the polarity of the feedback, command a move with the instruction:
PR 1000 <CR> Position relative 1000 counts
BGA <CR> Begin motion on A 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.
DMC-40x0 User Manual Chapter 2 Getting Started • 20
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 MA+ and MB+. If, on the other hand, you are using a differential encoder,
interchange only MA+ and MA-. 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.
To Invert Polarity using Hall-Commutated brushless motors, invert motor phases B & C, exchange Hall A with Hall
B, and invert encoder polarity as described above.
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 MCMn. This can be alleviated by reducing system friction on the motors.
The instruction:
TTA <return> Tell torque on A
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.
Step 8b. Connect Sinusoidal Commutation Motors
When using sinusoidal commutation, the parameters for the commutation must be determined and saved in the
controller’s non-volatile memory. The setup for sinusoidal commutation is different when using Hall Sensors. Each
step which is affected by Hall Sensor Operation is divided into two parts, part 1 and part 2. After connecting
sinusoidal commutation motors, the servos must be tuned as described in Step 9.
Step A. Disable the motor amplifier
Use the command, MO, to disable the motor amplifiers. For example, MOA will turn the A 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 6). 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
phase of the highest sinusoidal commutation axis will be the highest command output and the 2nd phase of
the lowest sinusoidal commutation axis will be the lowest command output.
It is not necessary to be concerned with cross-wiring the 1st and 2nd signals. If this wiring is incorrect, the
setup procedure will alert the user (Step D).
Example: Sinusoidal Commutation Configuration using a DMC-4070
BAAC
nd
Chapter 2 Getting Started • 21 DMC-40x0 User Manual
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