Galil DMC-41x3 Installation Manual

DMC-41x3 Installation Manual-ETL

DMC-41x3 Integrated

Amplifier Installation

Manual

Manual Rev. 1.0a3

By Galil Motion Control, Inc.

Galil Motion Control, Inc.

270 Technology Way

Rocklin, California 95765

Phone: [phone]

Fax: [phone]

E-mail Address: [e-mail]

URL: www.galilmc.com

Rev 02/29/12

Using This Manual

This manual provides information for the wiring, installation, powering-up, and basic communication
to the DMC-41x3 motion controller with the Galil internal amplifiers, AMP-435x0 and AMP-432x0.
The following list of part numbers are examples of configurations of the DMC-41x3 motion controller
that are covered in this manual.

DMC-41x3
DMC-41x3-D3220
DMC-41x3-D3240
DMC-41x3-D3520
DMC-41x3-D3540
DMC-41x3-D3240-D3220
DMC-41x3-D3240-D3240
DMC-41x3-D3540-D3520
DMC-41x3-D3540-D3540
DMC-41x3-D3240-D3520
DMC-41x3-D3240-D3540
DMC-41x3-D3540-D3220
DMC-41x3-D3540-D3240

This manual covers the basic installation of the controller and amplifier modules. For full operational
information including specific I/O installation, detailed programming examples and additional internal
driver information, see the DMC-41x3 User Manual.

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.

If the DMC-41x3 motion controller and included amplifiers or stepper drivers are not used
in a manner specified by Galil Motion Control, the protection provided by the controller,
amplifiers and drivers may be impaired.

Caution:
The DMC-41x3 controller with internal servo amplifiers
contain hot surfaces.

Chapter 1 Overview

Introduction

DMC-41x3 Motion Controller

The DMC-41x3 Series are Galil’s Econo motion controller that is a scaled-down version of the DMC­40x0 Acclerra series controller. The controller series offers many enhanced features compared to prior
generation Econo series controllers including high speed communications, non-volatile program
memory, faster encoder speeds, and improved cabling for EMI reduction.

Each DMC-41x3 provides two communication channels: a high speed 100BaseT Ethernet connection
and a USB programming port. There is an auxiliary RS-232 port that can be used to communicate to
external devices such as HMI's. The controllers allow for high-speed servo control up to 15 million
encoder counts/sec and step motor control up to 3 million steps per second. Sample rates as low as 62

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-41x3 is available with up to eight axes in a single stand alone unit. The DMC-4113, 4123,
4133, 4143 are one thru four axes controllers and the DMC-4153, 4163, 4173, 4183 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.

Commands are sent in ASCII. Additional software is available for automatic-tuning, trajectory
viewing on a PC screen, and program development using many environments such as Visual Basic, C,
C++ etc. Drivers for Windows XP, Vista and 7 (32 & 64 bit) as well as Linux are available.

AMP-43220/43240 Servo Amplifier (-D3220/-D3240)

The AMP-43240 and AMP-43220 amplifiers reside inside the DMC-41x3 enclosure. The AMP-43240
contains four transconductance, PWM amplifiers for driving brushless or brush-type servo motors (the
AMP-43240 contains 2 amplifiers). Each amplifier drives motors operating at up to 10 Amps
continuous, 20 Amps peak, 20–60 VDC. The gain settings of the amplifier are user-programmable at

0.5 Amp/Volt, 1.0 Amp/Volt and 2.0 Amp/Volt. The switching frequency is 24 kHz. The drive
operates in a Chopper Mode. The amplifier offers protection for over-voltage, under-voltage, over­current, short-circuit and over-temperature. Two AMP-43240s or AMP-43220's can be used in 5- thru
8-axis controllers.

AMP-43520/43540 Servo Amplifier (-D3520/-D3540)

The AMP-43540 and AMP-43520 amplifies reside inside the DMC-41x3 enclosure. The AMP-43540
contains four sinusoidally commutated, PWM amplifiers for driving brushless servo motors (the AMP­43520 contains 2 amplifiers). Each amplifier drives motors operating at up to 8 Amps continuous, 15
Amps peak, 20–60 VDC. The gain settings of the amplifier are user-programmable at 0.4 Amp/Volt,

0.8 Amp/Volt and 1.6 Amp/Volt. The switching frequency is 33 kHz. The amplifier offers protection
for over-voltage, under-voltage, over-current, short-circuit and over-temperature. Two AMP-43540s or
AMP-43520's can be used for 5- thru 8-axis controllers.

Chapter 2 Installation

Pre-Installation

Operating Environment

The location for use of the DMC-41x3, AMP-432x0 and AMP-435x0 must meet the following
requirements.

Description Units Specification

Ambient Temperature C 0 to +40

Altitude feet 10,000

Humidity RH 20-95% (non-condensing)

Mounting Location

The DMC-41x3 motion controller must be mounted on a flat surface using the 4 mounting holes found
on the metal base-plate. The grating found on the side of the metal must not be obstructed in order
provide proper air flow for adequate heat dissipation. The dimensions for a 1-4 axis controller are
smaller than that of a 4-8 axis controller, these dimensions and the mounting hole locations are found
in Appendices A3 and A4.

Additional Mounting Consideration when using the AMP-43xx0

When operating a DMC-41x3- D3xx0-D3xx0 or a DMC-41x3-D3xx0, special mounting
considerations must be made if the total continuous current output for the controller is greater than 15A
for a 1-4 axis controller and greater than 30A for a 5-8 axis controller. In this case, the controller base
must be mounted to an addition heat sink.

When the application requires that the DMC-41x3-D3xx0-D3xx0 be mounted to a heat sink, the heat
sink must be sized such that the base of the DMC-41x3 be kept at a temperature of 65O C or below.
This works out to a thermal resistance of 0.2O C/W at full continuous power. Full continuous power is
defined as a 100% duty cycle with all 8 axis running 10Amps continuous current (80 Amps total), with
a 60VDC bus.

Elements Needed for Installation

1. Isolated DC power supply

a. Ratings found in Appendix A1

2. Power Supply Cable

a. Cable from DC power supply to power input for AMP-43xx0.

b. DMC-4183 controller requires 2 cables.

3. PC or laptop with Ethernet and/or USB ports

4. GalilTools, or GalilTools-Lite software package

5. Ethernet Cable

a. Recommended shielded Cat 5 STP cable. Straight-through or Cross-over.

6. Male Type A – Male Type B USB cable

7. Molex pin Crimp Tool

8. Additional cables may be required for connection to motors, external amplifiers, digital or
analog I/O, and other devices. See the full DMC-41x3 User Manual for further information.

9. Disconnect switch or circuit breaker for AC power to DC Power Supply

Unpacking the Controller

Caution: The DMC-41x3 motion controller and included internal amplifier include electrostatic

sensitive components. Observe standard precautions for handling ESD sensitive devices
when handling the controller.

1. Verify that the following components have been shipped along the motion controller.

• Connectors and mating pins for motor power and amplifier power.

o Qty 4 – 4 pin molex connectors for EACH internal amplifier

o Qty 1 – 6 pin molex connector for EAH internal amplifier

• Galil Software Installation CD

Note: Connectors and/or software installation CD may not be shipped to existing OEM

customers.

2. Check that no visible damage has occurred to the controller, or internal amplifiers. If any
damage has occurred to the controller, or the components shipped with the controller, contact
Galil Motion Control immediately. Contact information can be found in the beginning of this
manual.

3. Verify the controller that has been shipped to you is in fact the controller that you have
ordered from Galil or your authorized Galil distributor. To do this, check the labeling on the
controller and compare it to the part number that was ordered.

Figure 1: Label for DMC-41x3

Figure 2: Label for DMC-41x3-D3220

Figure 3: Label for DMC-41x3-D3240

Figure 4: Label for DMC-41x3-D3520

Figure 5: Label for DMC-41x3-D3540