Galil Motion Control DMC-4040, DMC-4080 User Manual

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DMC-40x0

Manual Rev. 1.0w

USER MANUAL

Galil Motion Control, Inc.

270 Technology Way

Rocklin, California

916.626.0101

support@galil.com

galil.com

01/2017

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. It is recommended that the user download the latest version of the Command Reference and User Manual from the Galil Website.

http://www.galilmc.com/support/manuals.php

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 ABC, the DMC-4020 uses the axes denoted as AB, and the DMC-4010 uses the A-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. DMC4060 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 X, Y, Z, W.

Machinery in motion can be dangerous!

WARNING

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 iii

Chapter 1 Overview 1

Chapter 2 Getting Started 10

Chapter 3 Connecting Hardware 33

Introduction ................................................................................................................... 1

Part Numbers ................................................................................................................ 2

Overview of Motor Types ............................................................................................. 5

Overview of External Amplifiers .................................................................................. 6

Galil Internal Amplifiers and Drivers ........................................................................... 6

Functional Elements ...................................................................................................... 7

Layout ........................................................................................................................... 10

Power Connections ....................................................................................................... 12

Dimensions ................................................................................................................... 13

Elements You Need ....................................................................................................... 15

Installing the DMC, Amplifiers, and Motors ................................................................ 16

Overview ....................................................................................................................... 33

Overview of Optoisolated Inputs .................................................................................. 33

Optoisolated Input Electrical Information .................................................................... 36

High Power Optoisolated Outputs ................................................................................ 39

TTL Inputs and Outputs ................................................................................................ 40

Analog Inputs ................................................................................................................ 42

Extended I/O ................................................................................................................. 42

External Amplifier Interface ......................................................................................... 43

Chapter 4 Software Tools and Communication 50

Introduction ................................................................................................................... 50

Controller Response to Commands .............................................................................. 50

Unsolicited Messages Generated by Controller ............................................................ 51

Serial Communication Ports ......................................................................................... 51

Ethernet Configuration .................................................................................................. 53

Modbus ......................................................................................................................... 55

Data Record .................................................................................................................. 58

GalilSuite (Windows and Linux) .................................................................................. 64

Creating Custom Software Interfaces ........................................................................... 65

Chapter 5 Command Basics 67

Introduction ................................................................................................................... 67

Command Syntax - ASCII ............................................................................................ 67

Controller Response to DATA ...................................................................................... 68

Interrogating the Controller .......................................................................................... 69

Chapter 6 Programming Motion 71

Overview ....................................................................................................................... 71

Independent Axis Positioning ....................................................................................... 72

Independent Jogging ..................................................................................................... 74

Position Tracking .......................................................................................................... 75

Linear Interpolation Mode ............................................................................................ 79

Vector Mode: Linear and Circular Interpolation Motion .............................................. 82

Electronic Gearing ........................................................................................................ 89

Electronic Cam .............................................................................................................. 92

PVT Mode ..................................................................................................................... 97

Contour Mode ............................................................................................................... 100

DMC-40x0 Contents ▫ ii

Virtual Axis ................................................................................................................... 104

Stepper Motor Operation .............................................................................................. 105

Stepper Position Maintenance Mode (SPM) ................................................................. 107

Dual Loop (Auxiliary Encoder) .................................................................................... 110

Motion Smoothing ....................................................................................................... 112

Homing ......................................................................................................................... 114

High Speed Position Capture (The Latch Function) .................................................... 116

Chapter 7 Application Programming 117

Overview ....................................................................................................................... 117

Program Format ............................................................................................................ 117

Executing Programs - Multitasking .............................................................................. 119

Debugging Programs .................................................................................................... 120

Program Flow Commands ............................................................................................ 121

Mathematical and Functional Expressions ................................................................... 136

Variables ........................................................................................................................ 139

Operands ....................................................................................................................... 140

Arrays ............................................................................................................................ 141

Input of Data (Numeric and String) .............................................................................. 144

Output of Data (Numeric and String) ........................................................................... 146

Hardware I/O ................................................................................................................ 150

Extended I/O of the DMC-40x0 Controller .................................................................. 154

Example Applications ................................................................................................... 156

Using the DMC Editor to Enter Programs .................................................................... 160

Chapter 8 Hardware & Software Protection 162

Introduction ................................................................................................................... 162

Hardware Protection ..................................................................................................... 162

Software Protection ....................................................................................................... 163

Chapter 9 Troubleshooting 167

Overview ....................................................................................................................... 167

Chapter 10 Theory of Operation 170

Overview ....................................................................................................................... 170

Operation of Closed-Loop Systems .............................................................................. 172

System Modeling .......................................................................................................... 173

System Analysis ............................................................................................................ 177

System Design and Compensation ................................................................................ 179

Appendices 182

Electrical Specifications ................................................................................................ 182

Performance Specifications .......................................................................................... 184

Ordering Options .......................................................................................................... 185

Power Connector Part Numbers .................................................................................... 192

Input Current Limitations ............................................................................................. 193

Serial Cable Connections .............................................................................................. 194

Configuring the Amplifier Enable Circuit .................................................................... 196

Signal Descriptions ....................................................................................................... 206

List of Other Publications ............................................................................................. 208

Training Seminars ......................................................................................................... 208

Contacting Us ................................................................................................................ 209

WARRANTY ................................................................................................................ 210

Integrated Components 211

Overview ....................................................................................................................... 211

A1 – AMP-430x0 (-D3040,-D3020) 213

Description .................................................................................................................... 213

Electrical Specifications ................................................................................................ 214

Operation ....................................................................................................................... 215

Error Monitoring and Protection ................................................................................... 217

DMC-40x0 Contents ▫ iii

A2 – AMP-43140 (-D3140) 219

Description .................................................................................................................... 219

Electrical Specifications ................................................................................................ 220

Operation ....................................................................................................................... 221

A3 – AMP-43240 (-D3240) 222

Description .................................................................................................................... 222

Electrical Specifications ................................................................................................ 223

Operation ....................................................................................................................... 224

Error Monitoring and Protection ................................................................................... 225

A4 – AMP-435x0 (-D3540,-D3520) 228

Description .................................................................................................................... 228

Electrical Specifications ................................................................................................ 229

Operation ....................................................................................................................... 230

Error Monitoring and Protection ................................................................................... 233

A5 – AMP-43640 (-D3640) 235

Introduction ................................................................................................................... 235

Electrical Specifications ................................................................................................ 236

Operation ....................................................................................................................... 238

A6 – AMP-43740 (-D3740) 241

Description .................................................................................................................... 241

Electrical Specifications ................................................................................................ 242

Operation ....................................................................................................................... 243

Error Monitoring and Protection ................................................................................... 245

A7 – SDM-440x0 (-D4040,-D4020) 247

Description .................................................................................................................... 247

Electrical Specifications ................................................................................................ 248

Operation ....................................................................................................................... 249

A8 – SDM-44140 (-D4140) 251

Description .................................................................................................................... 251

Electrical Specifications ................................................................................................ 252

Operation ....................................................................................................................... 253

Error Monitoring and Protection ................................................................................... 254

A9 – CMB-41012 (-C012) 255

Description .................................................................................................................... 255

Connectors for CMB-41012 Interconnect Board ......................................................... 256

A10 – CMB-41022 (-C022) 259

Description .................................................................................................................... 259

Connectors for CMB-41022 Interconnect Board ......................................................... 260

A11 – ICM-42000 (-I000) 264

Description .................................................................................................................... 264

Connectors for ICM-42000 Interconnect Board ........................................................... 265

A12 – ICM-42100 (-I100) 268

Description .................................................................................................................... 268

Connectors for ICM-42100 Interconnect Board ........................................................... 269

Theory of Operation ...................................................................................................... 272

A13 – ICM-42200 (-I200) 275

Description .................................................................................................................... 275

Connectors for ICM-42200 Interconnect Board ........................................................... 276

DMC-40x0 Contents ▫ iv

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 100 BaseT 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, contouring and a PVT Mode. 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 optoisolated digital inputs (16 inputs for DMC-4050 thru DMC-4080), 8 high power optically isolated outputs (16 outputs for DMC-4050 thru DMC-4080), and 8 analog inputs for interface to joysticks, sensors, and pressure transducers. The DMC-40x0 also has an additional 32 I/O at 3.3V logic. Further I/O is available if the auxiliary encoders are not being used (2 inputs / each axis). Dedicated optoisolated inputs are provided for forward and reverse limits, abort, home, and definable input interrupts.

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.

Chapter 1 Overview ▫ 1 DMC-40x0 User Manual

Part Numbers

The DMC-40x0 is modular by nature, meaning that a customer must specify several components in order to create a full part number. The user must specify the main control board (DMC), the communication board (CMB), and the interconnect module (ICM) to have a complete unit. The user can also specify an optional internal amplifier (AMP or SDM). How these models stack up internally is shown in Figure 1.1 for 1-4 axis models.

Figure 1.1: Abstract internal layout of the DMC-40x0 for 1-4 axis models

For 5-8 axis models, the user must also specify an additional ICM and optional internal amplifier type for axis 5-8 as shown in Figure 1.2.

Figure 1.2: Abstract internal layout of the DMC-40x0 for 5-8 axis models

Each module has it's own set of part numbers and configuration options that make the full part number of a DMC40x0 unit. The DMC has the part number format “DMC-40X0(Y),” the CMB is “-CXXX(Y),” the ICM is “-IXXX(Y),” and the AMP/SDM is “-DXXX(Y),” where X designates different module options and Y designates different configuration options for these modules. The full DMC-40x0 part number would be the full string of individual module part numbers combined as shown for 1-4 and 5-8 axis models in Figure 1.3.

Chapter 1 Overview ▫ 2 DMC-40x0 User Manual

Figure 1.3: Layout of a complete DMC-40x0 part number

The placement of ICM and AMP/SDM options is extremely important for 5-8 axis models. Reading left to right, the first ICM (Axis 1-4) will be placed in the ICM (1) spot in Figure 1.2 and the second ICM (Axis 5-8) will be placed in the ICM (2) spot. This also follows for AMP/SDM placement.

If the part number is not readily available, you can determine the information by using the 'ID' command. Issuing an 'ID' command when connected to the controller will return your controller's internal hardware configuration.

The CMB and ICM module options effect the pin-outs of the DMC-40x0.

WARNING

Use Table 1.2 and Table 1.3 below to determine your CMB and ICM part numbers then refer to the

appropriate documentation for your pin-outs before connecting any hardware.

DMC, “DMC-40X0(Y)” Options

Option Type Options

X 1,2,3,4,5,6,7, and 8 Number of control axis N/A

Y DIN DIN Rail Mount DMC, “DMC-40X0(Y)” Controller Board

12V Power Controller with 12 VDC

-16bit 16-bit analog inputs

4-20mA 4-20mA analog inputs

ISCNTL Isolate Controller Power

TRES Encoder terminating resistors

ETL ETL certification

MO Motor off jumper installed

Table 1.1: Controller board, DMC, “DMC-40X0(Y)” options

Chapter 1 Overview ▫ 3 DMC-40x0 User Manual

Brief Description Documentation

Options, starting on pg 185.

CMB, “-CXXX(Y)” Options

Option Type Options Brief Description Documentation

XXX 012 Default communication board A9 – CMB-41012 (-C012), pg 255

022 Dual-Ethernet communication board A10 – CMB-41022 (-C022), pg 259

Y 5V SSI Feedback 5V – Configure Extended I/O for 5V logic, pg

187

P422 RS-422 on Main and Aux serial port RS-422 – Serial Port Serial Communication, pg

P1422 RS-422 on Main serial port only

187

P2422 RS-422 on Aux serial port only

Table 1.2: Communication board, CMB “-CXXX(Y)” options

ICM, “-IXXX(Y)” Options

Option Type Options Brief Description Documentation

XXX 000 Default interconnect board A11 – ICM-42000 (-I000), pg 264

100 Sine/Cosine feedback interconnect board A12 – ICM-42100 (-I100), pg 268

200 26-pin encoder connecter interconnect board A13 – ICM-42200 (-I200),pg 275

Y SSI SSI Feedback ICM, “-IXXX(Y)” Interconnect Board Options,

BiSS BiSS Feedback

DIFF Differential ±10 motor command outputs

STEP Differential STEP/DIR outputs

starting on pg 188

Table 1.3: Interconnect module, ICM “-IXXX(Y)” options

AMP/SDM, “-DXXXX(Y)” Options

Option Type Options Brief Description Documentation

XXXX 3020/3040 500 W trapazoidal servo drive

2 and 4-axis models

3140 20 W brush-type only drive A2 – AMP-43140 (-D3140), pg 219

3240 750 W trapazoidal servo drive A3 – AMP-43240 (-D3240), pg 222

3520/3540 600 W sinusoidal servo drive

2 and 4-axis models

3640 20 W sinusoidal servo drive A5 – AMP-43640 (-D3640), pg 235

4040/4020 1.4 A with 1/16 microstepping drive A7 – SDM-440x0 (-D4040,-D4020), pg 247

4140 3 A with 1/64 microstepping drive A8 – SDM-44140 (-D4140), pg 251

Y 100mA 100mA current

-D3140 option only

SSR Solid state relay

HALLF Filtered hall sensors

ISAMP Isolates power between amplifiers

Two banks of AMP/SDMs required

A1 – AMP-430x0 (-D3040,-D3020), pg 213

A4 – AMP-435x0 (-D3540,-D3520), pg 228

AMP/SDM, “-DXXXX(Y)” Internal Amplifier Options,

starting on pg 190

Not available for all amplifier options, see the

proper documentation in Ordering Options.

Table 1.4: Amplifier options, AMP/SDM “-DXXXX(Y)”

Chapter 1 Overview ▫ 4 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 and ceramic motors - 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.

Chapter 1 Overview ▫ 5 DMC-40x0 User Manual

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.

Galil Internal 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. Instead of having to route a +/-10V motor command signal, or STEP/DIR to some external box, all the wiring is taken care of internally. In addition, Galil's internal amplifiers reside inside the same box as the controller, ICM, and communication board (see Part Numbers, pg 2) saving real estate space and the hassle of configuring a separate device.

A full list of amplifier specifications and details can be found in the Integrated Components, starting on pg 211.

Chapter 1 Overview ▫ 6 DMC-40x0 User Manual

Functional Elements

WATCHDOG T IMER RISC BASED

MICROCOMPUT ER

HIGH-SPEED

MOTOR/ENCODE R INTERFACE

FOR

A,B,C,D

I/O INTERFACE

ETHERNET

RS-232 / RS-422

8 UNCOMMITT ED

ANALOG INPUT S

HIGH-SPEED LATCH FOR EACH AXIS

ISOLATED LIMI TS AND

HOME INPUTS

MAIN ENCODE RS

AUXILIARY EN CODERS

+/- 10 VOLT OUTPUT FOR

SERVO MOTO RS

PULSE/DIRE CTION OUTPUT

FOR STEP MOTORS

HIGH SPEED ENC ODER

COMPARE OUT PUT

8 PROGRAMMAB LE,

OPTOISOLATE D

INPUTS

8 PROGRAMMABL E HIGH POWER OPTOISOLATED OUTPUT S 32 Configurable I/O

The DMC-40x0 circuitry can be divided into the following functional groups as shown in Figure 1.4 and discussed below.

Figure 1.4: 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 non-volatile 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 22 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. An additional Ethernet port is available with the CMB-41022, see A10 – CMB-41022 (-C022), pg 259 for details.

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

Chapter 1 Overview ▫ 7 DMC-40x0 User Manual

logic) and unused auxiliary encoder inputs may also be used as additional inputs (2 inputs / each axis). The general

4080

inputs as well as the index pulse 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 Figure 1.5, the DMC-40x0 is part of a motion control system which includes amplifiers, motors and encoders. These elements are described below.

Power Supply

Computer DMC-40x0 Controller

Encoder Motor

Figure 1.5: 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: www.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 http://galilmc.com/products/accelera/dmc40x0.html for more information.

Chapter 1 Overview ▫ 8 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 MA and MB. This type of encoder is known as a quadrature encoder. Quadrature encoders may be either singleended (MA+ and MB+) or differential (MA+, MA-, MB+, and MB-). 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 Ω termination resistors installed on the encoder inputs. See the Ordering Options 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 550 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 A12 – 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.

Chapter 1 Overview ▫ 9 DMC-40x0 User Manual

Chapter 2 Getting Started

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.

DMC-4040

Figure 2.1: Outline of the of the DMC-40x0 1-4 axes model

Chapter 2 Getting Started ▫ 10 DMC-40x0 User Manual

DMC-4080

Figure 2.2: Outline of the of the DMC-40x0, 5-8 axes model

Chapter 2 Getting Started ▫ 11 DMC-40x0 User Manual

Power Connections

2-pin Molex controller power connector.

SDM/AMP Power

Axis A-D

SDM/AMP Power

Axis E-H

Figure 2.3: Power Connector locations for the DMC-40x0

Figure 2.4: Power Connector used when controller is ordered without Galil Amplifiers

For more information on powering your controller see Step 4. Power the Controller, pg 17. For more information regarding connector type and part numbers see Power Connector Part Numbers, pg 192. The power specifications for the controller are provided in Power Requirements, pg 183. and the power specifications for each amplifier are found under their specific section in the appendix, see Integrated Components, pg 211.

Chapter 2 Getting Started ▫ 12 DMC-40x0 User Manual

Dimensions

DMC-4040

Figure 2.5: Dimensions (in inches) of DMC-40x0 (where x= 1, 2, 3, or 4 axis)

Chapter 2 Getting Started ▫ 13 DMC-40x0 User Manual

DMC-4080

Figure 2.6: Dimensions (in inches) of DMC-40x0 (where x= 5, 6, 7, or 8 axis)

Chapter 2 Getting Started ▫ 14 DMC-40x0 User Manual

Elements You Need

For a complete system, Galil recommends the following elements:

1. DMC-40x0, motion controller where the x designates number of axis, 1-8.

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. GalilSuite or GalilSuite Lite (Free) software package

GalilSuite is highly recommended for first time users of the DMC-40x0. It provides step-by-step instructions for system connection, tuning, and analysis.

Chapter 2 Getting Started ▫ 15 DMC-40x0 User Manual

Installing the DMC, Amplifiers, and Motors

Installation of a complete, operational motion control system consists of the following steps:

Step 1. Determine Overall System Configuration, pg 16

Step 2. Install Jumpers on the DMC-40x0, pg 17

Step 3. Install the Communications Software, pg 17

Step 4. Power the Controller, pg 17

Step 5. Establish Communications with Galil Software, pg 18

Step 6. Connecting Encoder Feedback, pg 19 Optional for steppers

Step 7. Setting Safety Features before Wiring Motors, pg 20 Servo motors only

Step 8. Wiring Motors to Galil's Internal Amps, pg 22 Internal amplifiers only

Step 8a. Commutation of 3-phased Brushless Motors, pg 24 Brushless motors only

Step 9. Connecting External Amplifiers and Motors, pg 29 External amplifiers only

Step 10. Tune the Servo System, pg 32 Servo motors only

Electronics are dangerous!

Only a certified electrical technician, electrical engineer, or electrical professional should wire the DMC product and related components. Galil shall not be liable or responsible for any

WARNING

incidental or consequential damages.

All wiring procedures and suggestions mentioned in the following sections should be done with the controller in a powered-off state. Failing to do so can cause harm to the user or to the controller.

The following instructions are given for Galil products only. If wiring an non-Galil device,

NOTE

follow the instructions provided with that product. Galil shall not be liable or responsible for any incidental or consequential damages that occur to a 3rd party device.

Step 1. Determine Overall System Configuration

Before setting up the motion control system, the user must determine the desired motor configuration. The DMC40x0 can control any combination of brushless motors, brushed motors, and stepper motors. Galil has several internal amplifier options that can drive motors directly but can also control external amplifiers using either a ±10V motor command line or PWM/Step and direction lines. There are also several feedback options that the DMC can accept.

See Part Numbers, pg 2 for understanding your complete DMC unit and part number before continuing.

Chapter 2 Getting Started ▫ 16 DMC-40x0 User Manual

Step 2. Install Jumpers on the DMC-40x0

The following jumpers are located in a rectangular cut-out near the power and error lights on the communication board. See A9 – CMB-41012 (-C012), pg 255 or A10 – CMB-41022 (-C022), pg 259 for clarification, depending on the communication board ordered.

Motor Off Jumper

It is recommended to use the MO jumper when connecting motors for the first time. With a jumper installed at the MO location, the controller will boot-up in the “motor off” state, where the amplifier enable signals are toggled to “inhibit/disable”.

RS232 Baud Rate Jumpers

If using the RS232 port for communication, the baud rate is set via jumpers. To set the baud rate, use the jumper settings as found in Baud Rate Selection, pg 52.

Master Reset and Upgrade Jumpers

Jumpers labeled MRST and UPGD are the Master Reset and Upgrade jumpers, respectively.

When the MRST pins are jumpered, the controller will perform a master reset upon a power cycle, the reset input pulled down, or a push-button reset. Whenever the controller has a master reset, all programs, arrays, variables, and motion control parameters stored in EEPROM will be erased and restored back to factory default settings.

The UPGD jumper enables the user to unconditionally update the controller’s firmware. This jumper should not be used without first consulting Galil.

Step 3. Install the Communications Software

After applying power to the controller, a PC is used for programming. Galil's development software enables communication between the controller and the host device. The most recent copy of Galil's development software can be found here:

http://www.galilmc.com/support/software-downloads.php

Step 4. Power the Controller

Dangerous voltages, current, temperatures and energy levels exist in this product and the

WARNING

If the controller was ordered with Galil's internal amplifiers, power to the controller and amplifier is typically supplied through the amplifier's power connector. If the controller is ordered without internal amplifiers, the power will come through a 2-pin connector on the side of the controller. See Power Connections, pg 12 for the location of the power connections of the DMC-40x0. For pin-outs and a list of connectors to make a power cable, see Power Connector Part Numbers, pg 192.

Different options may effect which connections and what bus voltages are appropriate. If using an internal amplifier, the ISCNTL – Isolate Controller Power, pg 186 option will require multiple connections, one to power the controller board and another to power the amplifiers. If using two banks of amplifiers the ISAMP – Isolation of power between each AMP amplifier, pg 190 option will require that the amplifiers are powered independently.

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

Table 2.5 below shows which power connectors are and required for powering the system based upon the options ordered. “X” designates a connection, these connectors are only populated if required.

Chapter 2 Getting Started ▫ 17 DMC-40x0 User Manual

Options Ordered Power Connector Locations

ISCNTL

AMP/SDM

Axis A-D

X X

X X X X

X X

X X X X

X X X X X

X X X X X X X

In this configuration the amplifiers are sharing power. Their bus voltages and grounds must be from the same source to prevent damage

to the controller and amplifiers.

AMP/SDM

Axis E-H

ISAMP

Table 2.5: Available power connectors based upon option ordered

Controller Power

(2-pin Molex on side)

AMP/SDM Power, Axis A-D

(6- or 4-pin Molex)

AMP/SDM Power, Axis E-H

(6- or 4-pin Molex)

NOTE: If the 12V option is ordered, the DMC-40x0 is automatically upgraded to ISCNTL and should be powered accordingly.

The DMC-40x0 power should never be plugged in HOT. Always power down the power supply before installing or removing power connector(s) to/from controller.

NOTE: Any emergency stop or disconnect switches should be installed on the AC input to the DC power supply. Relays and/or other switches should not be installed on the DC line between the Galil and the Power supply. An example system is shown in Figure 2.7 with a DMC-4080-C012-I000-I000-D3040-D3040:

Figure 2.7: Wiring for DMC-4080 with Amplifiers

The green power light indicator should go on when power is applied.

Step 5. Establish Communications with Galil Software

See Ethernet Configuration, pg 53 for details on using Ethernet with the DMC-40x0. To configure your NIC card using Windows to connect to a DMC controller, see this two-minute video:

http://www.galilmc.com/learning/two-minute-display.php?video=connecting-to-ethernet-controller

For connecting using serial, see RS-232 Configuration, pg 51 for proper configuration of the Main DMC-40x0 serial port.

Chapter 2 Getting Started ▫ 18 DMC-40x0 User Manual

See the GalilSuite manual for using the software to communicate:

http://www.galilmc.com/support/manuals/galilsuite/index.html

Step 6. Connecting Encoder Feedback

The type of feedback the unit is capable of depends on the ICM (Interconnect module) chosen and additional options ordered. Table 2.6 shows the different Encoder feedback types available for the DMC-40x0 including which ICM and additional part numbers are required. Note that each feedback type has a different configuration command. See the Command Reference for full details on how to properly configure each axis.

Different feedback types can be used on the same controller. For instance, one axis could be using Standard quadrature and the next could be using SSI on the same ICM board. By default, all axis are configured for Standard quadrature.

Feedback Type

Standard quadrature

Step/Dir

Analog

SSI

BiSS

Sin/Cos, 1 V

position sensor.

pk-pk

None

Other Contact Galil at 1.800.377.6329

All wiring/electrical information regarding using analog inputs can be found in the Analog Inputs, pg 42.

Although stepper systems do not require feedback, Galil supports a feedback sensor on each stepper axis. Servo motors require a

Configuration

Command

– – --

Table 2.6: Configuration commands, ICM/Part numbers required for a given feedback type

ICM/Part Number Required Connection Location

Standard on all units Encoder

Standard on all units

(12-bit Standard. 16-bit optional)

ICM-42000 (-I000) or ICM-42200 (-I200)

with the (SSI) option

ICM-42000 (-I000) or ICM-42200 (-I200)

with the (BiSS) option

ICM-42100 (-I200) Encoder

Analog

Encoder

A note about using encoders and steppers:

When a stepper is used, the auxiliary encoder for the corresponding axis is unavailable for an external connection. If an encoder is used for position feedback, connect the encoder to the main encoder input corresponding to that axis. The commanded position of the stepper can be interrogated with TD and the encoder position can be interrogated with TP.

The following steps provide a general guide for connecting encoders to the DMC unit:

Step A. Wire the encoder

The pin-outs and electrical information for SSI and BiSS options can be found here:

SSI and BiSS – SSI and BiSS Absolute encoder Option, pg 188

The rest of the encoder pin-outs is found under the ICM being used:

ICM-42000

ICM-42000 Encoder 15 pin HD D-Sub Connector (Female), pg 267

ICM-42100

ICM-42100 Encoder 15 pin HD D-Sub Connector (Female), pg 271

Chapter 2 Getting Started ▫ 19 DMC-40x0 User Manual

ICM-42200

ICM-42200 Encoder 26 pin HD D-Sub Connector (Female), pg 277

Step B. Issue the appropriate configuration commands

Find the appropriate configuration commands for your feedback type as shown in Table 2.6, pg 19.

Step C. Verify proper encoder operation

1. Ensure the motor is off my issuing an MO.

2. Check the current position by issuing TP, the value reported back is in the units of counts.

3. Move the motor by hand and re-issue TP. The returned value should have been incremented or decremented from the first TP. If there is no change, check the encoder wiring and settings and retest starting at Step 1.

4. Using the encoder specification sheet, translate a physical distance of the motor into counts read by the controller. For example, a 2000 line encoder means that the controller reads 2000*4= 8000 counts/revolution and a half turn of the motor would be 4000 counts.

5. Issue TP to determine the current motor position, record this value.

6. Move the motor by hand some measured physical distance.

7. Query TP again. Take the absolute difference from the current TP and the TP recorded from Step 5.

8. Determine if the physical distance moved is equal to the expected amount of counts calculated in Step 4, move on to Step 9. Otherwise, check the encoder wiring and settings and retest starting at Step 1.

9. Perform Step 5-8 again, instead moving a physical distance in the opposite direction. If the physical distance correctly translates to the expected amount of counts, the encoder is wired correctly.

Step D. Reverse encoder direction, if necessary

Table 2.7 below provides instructions for how to reverse the direction of feedback by rewiring the encoder to the DMC controller. The direction of standard, quadrature encoders can be be reversed using the CE command.

NOTE

Standard Quadrature

Reversing direction of the feedback may cause a servo motor to runaway, see Step 7. Setting Safety Features before Wiring Motors, pg 20 regarding Runaway Motors.

Feedback Type Directions

Differential Swap channels A+ and A-

Single-ended Swap channels A+ and B+

Sin/Cos, 1 V

SSI or BiSS Follow encoder manufacturers instructions

Analog feedback Cannot change the direction of feedback without external hardware to invert

The polarity of the control loop may still be inverted by either re-wiring the motor or using the MT command, see Step 7.

Setting Safety Features before Wiring Motors, pg 20 regarding positive feedback loops.

pk-pk

Table 2.7: Directions for reversing feedback direction based upon feedback type

Swap signals V0+ and V0-

analog signal.

Step 7. Setting Safety Features before Wiring Motors

This section applies to servo motors only.

Step A. Set Torque Limit

Chapter 2 Getting Started ▫ 20 DMC-40x0 User Manual

TL will limit the output voltage of the ±10V motor command line. This output voltage is either translated into torque or velocity by the amplifier (Galil's internal amplifiers are in torque mode). This command should be used to avoid excessive torque or speed when initially setting up a servo system. The user is responsible for determining the relationship between the motor command line and the amplifier torque/velocity using the documentation of the motor and/or amplifier.

See the TL setting in the Command Reference for more details.

See the AG command in the command reference for current gains of Galil's internal amplifiers. The amplifier gain can also be used to change the ratio of outputting amps of the amplifier per commanded volts of the controller. This is another way to limit the amount of current but can also maintain the resolution of the ±10V motor command line.

Step B. Set the Error Limit

When ER (error limit) and OE (off-on-error) is set, the controller will automatically shut down the motors when excess error (|TE| > ER) has occurred. This is an important safety feature during set up as wrong polarity can cause the motor to run away, see Step C below for more information regarding runaway motors.

NOTE: Off-on-error (OE) requires the amplifier enable signal to be connected from the controller to the amplifier. This is automatic when using Galil's internal amplifiers, see Step 9. Connecting External Amplifiers and Motors, pg 29 for external amplifiers

Step C. Understanding and Correcting for Runaway Motors

A runaway motor is a condition for which the motor is rotating uncontrollably near it's maximum speed in a single direction. This is often caused by one of two conditions:

1. The amplifier enable signal is the incorrect logic required by the amplifier

This is only applicable to external amplifiers only.

If the motor is in a MO state when the motor runs away, the MO command is toggling your amplifier “on/enabled” and needs to be reconfigured. The motor is running away because the controller is registering the axis is in an “inactive” and is not attempting to control it's movement. See Step 9. Connecting External Amplifiers and Motors, pg 29 for configuring the amplifier enable signal.

2. The motor and encoder are in opposite polarity causing a positive feedback loop

Reversed polarity is when a positive voltage on the motor command line results in negative movement of the motor. This will result in a positive feedback loop and a runaway motor.

The following steps can be taken to detect reverse polarity, the A-axis is used as an example:

1. After connecting your servo motor using either Step 8. Wiring Motors to Galil's Internal Amps, pg 22 or Step 9. Connecting External Amplifiers and Motors, pg 29 issue the following commands:

MO A KIA= 0 KPA= 0 KDA= 0 SH A

2. Check your current position by issuing TP A.

3. Set a small, positive voltage on your motor command line using the OF command; use a high enough voltage to get the motor to move. This will cause a runaway-like condition so have an appropriate OE set, see Step B. Example:

OFA= 0.5

4. If the motor has not been disabled by OE, disable it by issuing MO A.

5. Check the position again by using TP A.

Chapter 2 Getting Started ▫ 21 DMC-40x0 User Manual

6. If TP has increased, than the motor command line and encoder are in correct polarity. If TP has decreased than the motor command line is in opposite polarity with the encoder.

If the system has reverse polarity, take the following steps to correct for it:

Brushed Motor

Choose one of the following:

1. Reverse the direction of the motor leads by swapping phase A and phase B

2. Reverse the direction of the encoder, see Step 6. Connecting Encoder Feedback, pg 19

Brushless Motor

Choose one of the following:

1. Reverse direction of the encoder, see Step 6. Connecting Encoder Feedback, pg 19

2. Reverse direction of the motor by swapping any two motor phases (or two hall sensors if using a trapezoidal amplifier). The motor will now have to be re-commutated by using either the Trapezoidal or Sinusoidal method, see Step 8a. Commutation of 3-phased Brushless Motors, pg 24

Non-wiring Options

You can reverse the direction of the motor command line by using the MT command or reverse direction of the feedback by using the CE command (standard quadrature and step/direction feedback only). It is not recommended to correct for polarity using configuration commands as an unexpected condition may arise where these settings are accidentally over-ridden causing a runaway.

See the Command Reference for more details.

Step D. Other Safety Features

This section only provides a brief list of safety features that the DMC can provide. Other features include Encoder Failure Detection (OA, OT, OV) , Automatic Subroutines to create an automated response to events such as limit switches toggling (#LIMSWI), command errors (#POSERR), and amplifier errors (TA, #AMPERR), and more. For a full list of features and how to program each see Chapter 8 Hardware & Software Protection, pg 162.

Step 8. Wiring Motors to Galil's Internal Amps

Table 2.8 below provides a general overview of the connections required for most systems connecting to a DMC internal amplifier and controller system. Following the table is a step-by-step guide on how to do so.

Motor Type Required Connections

Brushless servo motor • Power to controller and internal amplifier

• Motor power leads to internal amplifiers

• Encoder feedback

• Hall sensors (Not required for sinusoidal amplifiers)

Brushed servo motor • Power to controller and internal amplifier

• Motor power leads to internal amplifiers

• Encoder feedback

Stepper motor • Power to controller and internal amplifier

• Motor power leads to internal amplifier

• Encoder feedback (optional)

Table 2.8: Synopsis of connections required to connect a motor to Galil's internal amplifiers

Chapter 2 Getting Started ▫ 22 DMC-40x0 User Manual

Step A. Connect the encoder feedback (optional for steppers)

See Step 6. Connecting Encoder Feedback, pg 19.

Step B. Connect the motor power leads and halls (if required) to the internal amplifiers

Table 2.9 lists each of Galil's internal amplifiers and where to find documentation for pin-outs of the amplifier connections and electrical specifications. In addition it describes the commutation method and whether halls are required.

Amplifier Commutation Halls Required

A1 – AMP-430x0 (-D3040,-D3020), pg 213 Trapezoidal Halls required for brushless motors

A2 – AMP-43140 (-D3140), pg 219 Brushed No

A3 – AMP-43240 (-D3240), pg 222 Trapezoidal Halls required for brushless motors

A4 – AMP-435x0 (-D3540,-D3520), pg 228 Sinusoidal Halls optional for brushless motors

A5 – AMP-43640 (-D3640), pg 235 Sinusoidal Halls optional for brushless motors

A6 – AMP-43740 (-D3740), pg 241 Sinusoidal Halls optional for brushless motors

A7 – SDM-440x0 (-D4040,-D4020), pg 247 N/A, stepper No

A8 – SDM-44140 (-D4140), pg 251 N/A, stepper No

Table 2.9: Amplifier documentation location, commutation, and hall requirements for each internal amplifier.

Pin-outs for the hall signals is found under the ICM being used:

ICM-42000

ICM-42000 Encoder 15 pin HD D-Sub Connector (Female), pg 267

ICM-42100

ICM-42100 Encoder 15 pin HD D-Sub Connector (Female), pg 271

ICM-42200

ICM-42200 Encoder 26 pin HD D-Sub Connector (Female), pg 277

If wiring 3-phased, brushless motors:

NOTE

Skip to the additional instructions provided in Step 8a. Commutation of 3- phased Brushless Motors, pg 24 to find proper commutation.

Step C. Issue the appropriate configuration commands

Table 2.10 provides a brief list of configuration commands that may need to be set depending on your motor type and motor specifications.

Chapter 2 Getting Started ▫ 23 DMC-40x0 User Manual

Command Description

TL, TK

(Also used to ignore halls when the use of external amplifiers is required in lieu of an

(Can also be used to switch capable amplifiers between chopper and inverter mode)

Limits motor command line output in Volts, thus limiting the current in the amplifier

Table 2.10: Sample of motor and amplifier configuration commands

Configures an axis for use with either a stepper or servo motor

Amplifier gain (A/V for servos or A/Phase for steppers)

Will configure an internal servo amplifier for brushed mode

internal)

Configures the current loop update rate

Stepper drive resolution (microstepping configuration)

Configures stepper motor current at holding or “rest” positions

Step D. If using a servo motor, continue to Step 10. Tune the Servo System, pg 32. If using a stepper, continue on to Step E.

Step E. Enable and use your motor

A SH will enable the internal amplifier and a MO will disable the internal amplifier. Once enabled, you can send DMC motion commands to move the motor, see Chapter 6 Programming Motion, pg 71 for details.

Step 8a. Commutation of 3-phased Brushless Motors

If a motor is not correctly commutated it will not function as expected. Commutation is the act of properly getting each of the 3 internal phases of a servo motor to switch at the correct time to allow smooth, 360 degree rotation in both directions. The two most common methods for doing so are trapezoidal commutation (use of Hall sensors) and through position sensor algorithms (sinusoidal commutation, no Halls required).

The following sections provide a brief description and guide on how to perform either commutation method including wiring and configuration commands. These sections are divided into Trapezoidal and Sinusoidal:

Trapezoidal Commutation

The following amplifiers support trapezoidal commutation:

A1 – AMP-430x0 (-D3040,-D3020), pg 213

A3 – AMP-43240 (-D3240), pg 222

Trapezoidal commutation is a time-tested way for determining the motor location within a magnetic cycle; However, interpretation of hall sensor feedback varies between motor manufactures requiring the user to find the correct wiring combination.

Before wiring the motor the user should determine which is easier: Wiring the hall sensors or wiring the motor phases. This method will start with wiring both the halls and motor phases at random then trying each of the 6 wiring combinations of either the halls or the motor phases (not both). For each combination, the user will be asked to check the open-loop velocity in both directions . Some of the wiring combinations will lead to no motion, this is expected. The following directions are given using the A-axis as an example.

1. Wire the 3 motor phase wires and 3 hall sensors randomly. Do not connect the motor to any external mechanics or load, a free spinning motor is required for testing. Take all safety precautions necessary as the motor tests below will result in a runaway condition.

2. Set the PID’s and BR to zero and disable off-on-error (OE) to allow for full rotation of the motor in openloop. Issue the following commands from a Galil terminal program:

KPA= 0

Chapter 2 Getting Started ▫ 24 DMC-40x0 User Manual

KDA= 0 KIA= 0 BRA= 0 OE 0 SH A

3. Place a small offset voltage on the motor command line using the OF command (ex OFA= 0.5). The smallest OF possible to see motion is recommended. If no motion presents itself, increase in small increments until you see motion. If your OF is beyond what is expected to see motion, record “no motion” using one of the tables below (Table 2.12 for swapping motor phases or Table 2.13 for swapping halls) and try the next wiring combination.

Note: To stop the motor from spinning use either the MO A command or issue OFA= 0.

4. Once spinning, check the velocity of the motor with the TV A command. Record this value under “+ Velocity” in either Table 2.12 or Table 2.13.

5. Issue an equal but opposite OF. For example, if you previously issued OFA= 0.5 now issue OFA= -0.5. Record this velocity under “- Velocity.”

6. Issue OFA= 0 or MO A to stop the motors. Power down the controller and amplifiers system and swap 2 wires of the hall sensors or motor power leads—whichever method is being used (Remember, chose one or the other, not both!). Keep track of what cable combinations have been tested (labeling the phases maybe useful) in the example table in Table 2.11, motor phases were recorded based upon their insulation color.

7. Repeat steps 2-6 for every possible wiring combination, there will be six and Table 2.12 or Table 2.13 below should be completely filled out.

8. The correct wiring combination will be the one with the least difference in magnitude between the velocities in the positive and negative direction. In the case where there are two combinations that meet this criteria, choose the combination that has the higher velocities. In the example table shown in Table 2.11, Trial 1 would be the correct choice.

Trial # Phase A Phase B Phase C + Velocity - Velocity

Red White Black 153700 -160000

Red Black White No motion No motion

White Black Red No motion No motion

White Red Black -141000 139000

Black Red White No motion No motion

Black White Red -70000 92000

Table 2.11: Example table showing realistic test results using this commutation method

Chapter 2 Getting Started ▫ 25 DMC-40x0 User Manual

Trial # Phase A Phase B Phase C + Velocity - Velocity

Table 2.12: Table provided for use with swapping motor phases to achieve trapezoidal communication

Trial # Hall A Hall B Hall C + Velocity - Velocity

Table 2.13: Table provided for use with swapping hall leads to achieve trapezoidal communication

9. Check that the motor phases and encoder feedback are in proper polarity to avoid a runaway condition. Do so by watching the different hall transitions by using the QH command and rotating the motor by hand in an MO state. If the motor and encoder polarity are correct than TP A should report a smaller number when QH A reports 1 than when QH A reports 3. If TP A is larger when QH A reports 1 than 3, then the motor is in a positive feedback state and will runaway when sent movement commands; Reverse the encoder feedback as described in Step 6. Connecting Encoder Feedback, pg 19.

10. Issue MO A and set OFA= 0. Set small, and appropriate values of KP A and KD A and verify the motor holds position once a SH A is issued. The motor is now under closed loop control.

11. Double check commutation by issuing a small jog command (JGA=1000; BG A) and verify the motor spins smoothly for more than 360 degrees. If the user monitors QH during the jog movement it should report a number 1-6 transitioning through the following sequence: 1, 3, 2, 6, 4, 5 and repeating.

12. If no runaway occurs, the motor is ready to be tuned. Skip to Step 10. Tune the Servo System, pg 32.

Sinusoidal Commutation

The following amplifiers support sinusoidal commutation:

A4 – AMP-435x0 (-D3540,-D3520), pg 228

A5 – AMP-43640 (-D3640), pg 235

A6 – AMP-43740 (-D3740), pg 241

Galil provides several sinusoidal commutation methods. The following list provides a brief description of how each method works and Table 2.14 discusses the pros and cons of each. Detailed instructions for each method follow on pg 27.

Chapter 2 Getting Started ▫ 26 DMC-40x0 User Manual

BZ Method - The BZ method forces the motor to zero electrical degrees by exciting phases A and B in a two step initialization process . The location of the motor within it's magnetic cycle is known and sinusoidal commutation is initialized.

Commands required: BA, BM, BZ

BX Method - The BX method uses a limited motion algorithm to determine the proper location of the motor within the magnetic cycle. It is expected to move no greater than 10 degrees of the magnetic cycle. The last stage of the BX command will lock the motor into the nearest 15 degree increment.

Commands required: BA, BM, BX

BI/BC Method – The motor initially boots up in a “pseudo-trapezoidal” mode. The BC function monitors the status of the hall sensors and replaces the estimated commutation phase value with a more precise value upon the first hall transition. The motor is then running in a sinusoidally commutated mode and the use of the halls are no longer required.

Commands required: BA, BM, BI, BC

BZ and QH are used to aid in the wiring process and initial set-up for this method.

Note: These list the minimum required commands to provide commutation. There are many more commutation configuration commands available not discussed here. See the Command Reference for details.

Method PRO CON

• Can be used with vertical or unbalanced loads

• Less sensitive to noise than BX

• Does not require halls

• Quick first-time set-up

• Provides the least amount of movement (If no hall sensors are available)

• Does not require halls

• Quick first-time set-up

• No unnecessary movement required

• Best option with a vertical or unbalanced load

BI/BC

Table 2.14: Pros and cons of each commutation method

If your motor has halls, it is recommended to use the BI/BC method.

• Can cause significant motor movement

• Will fail at hard stops

• Not recommended with vertical or unbalanced loads

• Sensitive to noise on feedback lines

• Requires some movement

• Will fail at hard stops

• Requires halls

• Longer first-time set-up due to additional wiring

• Can run away or stall if halls are not wired properly

The following sections discuss how to wire and configure a motor for sinusoidal commutation using the different commutation methods:

BZ/BX Method

The BZ command must move the motor to find zero electrical degrees . This movement is

WARNING

sudden and will cause the system to jerk. Larger applied voltages will cause more severe motor jerk.

The BZ and BX method are wired in the same way. Both BZ and BX require encoder feedback to the controller and the motor phases to the drive.

Chapter 2 Getting Started ▫ 27 DMC-40x0 User Manual

1. Check encoder position with the TP command. Ensure the motor is in an MO state and move the motor

max

[Volts ]=

2 G

manually in the desired positive direction while monitoring TP. If TP reports a smaller, or more negative number, reverse encoder direction, see Step 6. Connecting Encoder Feedback, pg 19.

2. Select which axis will be using sinusoidal commutation by issuing the BA command.

3.Set brushless modulus, using the BM configuration command. BM is the distance, in counts, of a single magnetic cycle of the motor. This can be calculated by dividing counts/revolution of the encoder by the number of pole pairs of the motor. For a linear motor, the number of encoder counts per magnetic phase will need to be calculated from motor and encoder manufacturers information.

4. Try initializing the amplifier using either BZ or BX command. Note that the BZ and BX commands require a single argument which is the user allotted maximum voltage to be applied on the motor command line during the commutation routine. Ensure that the command voltage for BZ or BX is sufficient to move the motor. To do this, use the continuous current rating of the motor (Im in Amps) and AG current gain (G in Amps/Volt) to determine the maximum n parameter.:

A conservative starting point is 0.5 n

but may be increased up to n

max

as needed. NOTE: in order to prevent

max

hitting limits or hard stops during BZ initialization, ensure that the motor is clear to move a BM value in either direction.

a. If the initialization fails and TC 1 returns error codes 114 BZ command runaway or 160 BX failure, turn off the controller and amplifier and swap motor leads A and B and re-perform steps 1-

b. If the initialization fails and TC 1 returns error code 112 BZ timeout, try increasing the hold times with the BZ< o > p command. o defaults to 200 msec while p defaults to 100 msec. Increase either or both of these to allow more time for any induced oscillations to settle.

c. If the initialization fails and TC 1 returns error code 113 No movement in BZ command, try increasing the voltage applied to the amp during initialization (n parameter).

5. Once initialization succeeds, servo the motor (SH) and test commutation by jogging the motor at a slow enough rate to monitor one full electrical cycle, BM/#seconds per electrical cycle. As an example, with a BM of 2000 and a desired 15 seconds per electrical cycle, jog the axis at 133 counts/s,

a. If the motor stalls, cogs, or runs away, turn off the controller and amplifier and swap motor leads A and B and re-perform steps 1-4.

b. If the motor rotates smoothly 360 electrical degrees (use _BDm to monitor electrical position) in both directions, the motor is properly wired and amplifier initialized . Note: Sine amplifier initialization is required each time the controller is booted up.

BI/BC Method

The motor must have hall sensors to work with BI/BC.

NOTE

In addition, the AMP-43640 is a special case that supports hall initialization through it's general inputs, rather than standard hall pins. To query hall state in this case, use _BCm rather than QH. See the BI command for more information.

BI/BC method uses the motors hall sensors to initialize the brushless degrees of the motor.

The halls, motor phases, and encoder feedback must all be wired to the DMC. The hall inputs must be aligned so that hall A aligns with the excitement of motor phase A and B, hall B aligns with the excitement of motor phases B

Chapter 2 Getting Started ▫ 28 DMC-40x0 User Manual

and C, and hall C aligns with the excitement of motor phases C and A. Setting up the motor for BI/BC initialization may require wiring changes to both the motor leads and the hall inputs. The following steps will ensure that the correct configuration is reached:

1. Put the motor in an MO state. Move the motor shaft manually in the direction desired for positive movement.

a. If TP is decreasing, reverse encoder direction. See Step 6. Connecting Encoder Feedback, pg 19.

2. Continue to move the motor in the positive direction by hand, but now monitor the state of QH. QH should change as the motor continues to rotate in the positive direction. QH should return the sequence: 1 3 2 6 4 5.

a. If the order is reversed, swap Hall A and Hall C.

b. If all 6 states are not seen, one of the hall inputs is miswired or not connected.

3. Select which axis will be using sinusoidal commutation by issuing the BA command.

4. Set brushless modulus, using the BM configuration command. BM is the distance, in counts, of a single magnetic cycle of the motor. This can be calculated by dividing counts/revolution of the encoder by the number of pole pairs of the motor. For a linear motor, the number of encoder counts per magnetic phase may need to be calculated from motor and encoder manufacturers information.

5. Initialize the motor for hall commutation BI -1.

6. Test the motor for proper commutation by enabling the motor (SH) and jogging the motor slowly (JG 1000;BG A). If the motor rotates 360 degrees without cogging, running away, or stalling, skip to step 7.

a. If the motor stalls, cogs, or runs away, issue an MO and try initialization using BZ. If the motor stalls, cogs, or runs away, after BZ, turn off the controller and amplifier and swap motor phases A and B and retry steps 3-6.

b. If commutation is still not successful after 6. a., issue the appropriate BA, BM, and BZ commands— but do not servo. Check the hall state with QH. If QH shows either of the two values shown below, then turn off the controller and amplifier and rewire the motor based on the following, and then retry step 3-6.

•If QH m returns 5: Turn off the controller and amplifier and swap motor phases A and B, then B and C

•If QH m returns 6: Turn off the controller and amplifier and swap motor phases A and C, then B and C

7. The motor should now be wired for sine commutation using the BI/BC method. Once BI -1 is issued, the motor is in a pseudo-trapezoidal state, you can enable sine commutation by issuing the BC command and commanding a slow jog move. Once a hall transition is found, the commutation will be in sinusoidal mode.

Step 9. Connecting External Amplifiers and Motors

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.

Table 2.15 below shows a brief synopsis of the connections required, the full step-by-step guide is provided below.

Chapter 2 Getting Started ▫ 29 DMC-40x0 User Manual

Motor Type Connection Requirements

Servo motors

(Brushed and Brushless)

Stepper motor • Power to controller and amplifier

Table 2.15: Synopsis of connections required to connect an external amplifier

• Power to controller and amplifier

• Amplifier enable

• Encoder feedback

• Motor command line

• See amplifier documentation for motor connections

• Amplifier enable

• PWM/Step and direction line

• Encoder feedback (optional)

• See amplifier documentation for motor connections

Step A. Connect the motor to the amplifier

Initially do so 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.

A Note Regarding Commutation

This section applies to 3-phase external amplifiers only.

External amplifiers often will perform either trapezoidal or sinusoidal commutation without the need of a controller. In this case, be sure to use your amplifiers guide to achieve proper commutation.

Although very rare, if an external amplifier requires the controller to perform sinusoidal commutation, an additional ±10 V motor command line may be required from the DMC. In other words, two motor axes are needed to commutate a single external sinusoidal amplifier. See the BA command for what two motor command lines to use in this case. After the two ±10 V motor command lines are wired, the user can use the sinusoidal commutation methods listed above under Sinusoidal Commutation, pg

26.

Step B. Connect the amplifier enable signal

Before making any connections from the amplifier to the controller, verify that the ground level of the amplifier is either floating or at the same potential as earth.

When the amplifier ground is not isolated from the power line or when it has a different

WARNING

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 k 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 defaulted to 5V, high amp enable. (the amplifier enable signal will be high when the controller expects the amplifier to be enabled). It is recommended that if an amplifier requires a different configuration, the controller should be be ordered with the desired configuration. See the ordering options below:

Amplifier Enable Configurations, pg 189

Pin-outs for the amplifier enable signal is found under the ICM being used:

ICM-42000

Chapter 2 Getting Started ▫ 30 DMC-40x0 User Manual

ICM-42000 External Driver (A-D) 44 pin HD D-Sub Connector (Male), pg 266

ICM-42000 External Driver (E-H) 44 pin HD D-Sub Connector (Male), pg 266

ICM-42100

ICM-42100 External Driver (A-D) 44 pin HD D-Sub Connector (Male), pg 270

ICM-42100 External Driver (E-H) 44 pin HD D-Sub Connector (Male), pg 270

ICM-42200

ICM-42200 Encoder 26 pin HD D-Sub Connector (Female), pg 277

For full electrical specifications and wiring diagrams refer to:

External Amplifier Interface, pg 43 ICM-42000 and ICM-42100 Amplifier Enable Circuit, pg 44 ICM-42200 Amplifier Enable Circuit, pg 46

For re-configuring the ICM-42000/ICM-42100 for a different amplifier enable option, see:

Configuring the Amplifier Enable Circuit, pg 196

Once the amplifier enable signal is correctly wired , issuing a MO will disable the amplifier and an SH will enable it.

Step C. Connect the Encoders (optional for stepper systems)

See Step 6. Connecting Encoder Feedback, pg 19.

Step D. Connect the Command Signals

The DMC-40x0 has two ways of controlling amplifiers:

1. Using a motor command line (±10V analog output)

The motor and the amplifier may be configured in torque or velocity mode. In the torque mode, the amplifier gain should be such that a 10V signal generates the maximum required current. In the velocity mode, a command signal of 10V should run the motor at the maximum required speed.

2. Using step (0-5V, PWM) and direction (0-5V toggling line), this is referred to as step/dir for short.

Some external amplifiers may require the use of differential step/direction or motor command lines. These are available upon ordering the (STEP) and (DIFF) options, respectively. See DIFF – Differential analog motor command outputs, pg 188 and STEP – Differential step and direction outputs, pg 188 for more details.

Pin-outs for the command signals are found under the ICM being used:

The full list of ICM pin-outs are provided in Step B, above.

For full electrical specifications refer to:

External Amplifier Interface, pg 43

To configure the command signal type and other configuration commands see Table 2.16 below for a brief synopsis. For a full list of configuration commands see the Command Reference.

Step E. Issue the appropriate configuration Commands

Chapter 2 Getting Started ▫ 31 DMC-40x0 User Manual

Command Description

Table 2.16: Brief listing of most commonly used configuration commands for the motor command and step/dir lines

The motor type command configures what type of control method to use

(switches axis between motor command or step/dir options)

Servo only. Limits the motor command line's continuous output in Volts

Servo only. Limits the motor command line's peak output in Volts

Step F. If using a servo motor, continue to Step 10. Tune the Servo System, pg 32. If using a stepper motor, skip to Step G.

Step G. Enable and use your motor

A SH will enable the external amplifier, once enabled, you can send DMC motion commands to move the motor, see Chapter 6 Programming Motion, pg 71 for details.

Step 10. Tune the Servo System

Adjusting the tuning parameters is required when using servo motors. A given set of default PID's is provided, but are not optimized and should not be used in practice.

For the theory of operation and a full explanation of all the PID and other filter parameters, see Chapter 10 Theory of Operation, pg 170.

For additional tuning resources and step-by-step tuning guides, see the following:

Application Notes

Manual Tuning Methods: http://www.galil.com/download/application-note/note3413.pdf

Manual Tuning using the Velocity Zone method: http://www.galil.com/download/application-note/note5491.pdf

Autotuning Tools in Galil Suite: http://www.galil.com/download/manual/galilsuite/tuner.html

Chapter 2 Getting Started ▫ 32 DMC-40x0 User Manual

Chapter 3 Connecting Hardware

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Overview

The DMC-40x0 provides optoisolated digital inputs for forward limit, reverse limit, home, and abort signals. The controller also has 8 optoisolated, uncommitted inputs (for general use) as well as 8 high power optoisolated outputs and 8 analog inputs configured for voltages between ±10 volts.

Controllers with 5 or more axes have an additional 8 optoisolated inputs and an additional 8 high

power optoisolated outputs.

This chapter describes the inputs and outputs and their proper connection.

Overview of Optoisolated Inputs

Limit Switch Input

The forward limit switch (FLSx) inhibits motion in the forward direction immediately upon activation of the switch. The reverse limit switch (RLSx) inhibits motion in the reverse direction immediately upon activation of the switch. If a limit switch is activated during motion, the controller will make a decelerated stop using the deceleration rate previously set with the SD command. The motor will remain on (in a servo state) after the limit switch has been activated and will hold motor position. The controller can be configured to disable the axis upon the activation of a limit switch, see the OE command in the command reference for further detail.

When a forward or reverse limit switch is activated, the current application program that is running in thread zero will be interrupted and the controller will automatically jump to the #LIMSWI subroutine if one exists. This is a subroutine which the user can include in any motion control program and is useful for executing specific instructions upon activation of a limit switch. Automatic Subroutines for Monitoring Conditions are discussed in Chapter 7 Application Programming.

After a limit switch has been activated, further motion in the direction of the limit switch will not be possible until the logic state of the switch returns back to an inactive state. Any attempt at further motion before the logic state has been reset will result in the following error: “22 - Begin not possible due to limit switch” error.

The operands, _LFx and _LRx, contain the state of the forward and reverse limit switches, respectively (x represents the axis, A, B, C, D etc.). The value of the operand is either a ‘0’ or ‘1’ corresponding to the logic state of the limit switch. Using a terminal program, the state of a limit switch can be printed to the screen with the command, MG_LFx or MG_LRx. This prints the value of the limit switch operands for the ‘x’ axis. The logic state of the limit switches can also be interrogated with the TS command. For more details on TS see the Command Reference.

Chapter 3 Connecting Hardware ▫ 33 DMC-40x0 User Manual

Home Switch Input

Homing inputs are designed to provide mechanical reference points for a motion control application. A transition in the state of a Home input alerts the controller that a particular reference point has been reached by a moving part in the motion control system. A reference point can be a point in space or an encoder index pulse.

The Home input detects any transition in the state of the switch and toggles between logic states 0 and 1 at every transition. A transition in the logic state of the Home input will cause the controller to execute a homing routine specified by the user.

There are three homing routines supported by the DMC-40x0: Find Edge (FE), Find Index (FI), and Standard Home (HM).

The Find Edge routine is initiated by the command sequence: FE A, BG A. The Find Edge routine will cause the motor to accelerate, and then slew at constant speed until a transition is detected in the logic state of the Home input. The direction of the FE motion is dependent on the state of the home switch. High level causes forward motion. The motor will then decelerate to a stop. The acceleration rate, deceleration rate and slew speed are specified by the user, prior to the movement, using the commands AC, DC, and SP. When using the FE command,

it is recommended that a high deceleration value be used so the motor will decelerate rapidly after sensing the Home switch.

The Find Index routine is initiated by the command sequence: FI A, BG A. Find Index will cause the motor to accelerate to the user-defined slew speed (SP) at a rate specified by the user with the AC command and slew until the controller senses a change in the index pulse signal from low to high. The motor then decelerates to a stop at the rate previously specified by the user with the DC command and then moves back to the index pulse and speed HV. Although Find Index is an option for homing, it is not dependent upon a transition in the logic state of the Home input, but instead is dependent upon a transition in the level of the index pulse signal.

The Standard Homing routine is initiated by the sequence of commands HM A, BG A. Standard Homing is a combination of Find Edge and Find Index homing. Initiating the standard homing routine will cause the motor to slew until a transition is detected in the logic state of the Home input. The motor will accelerate at the rate specified by the command, AC, up to the slew speed. After detecting the transition in the logic state on the Home Input, the motor will decelerate to a stop at the rate specified by the command, DC. After the motor has decelerated to a stop, it switches direction and approaches the transition point at the speed of HV counts/sec. When the logic state changes again, the motor moves forward (in the direction of increasing encoder count) at the same speed, until the controller senses the index pulse. After detection, it decelerates to a stop, moves back to the index, and defines this position as 0. The logic state of the Home input can be interrogated with the command MG_HMA. This command returns a 0 or 1 if the logic state is low or high, respectively. The state of the Home input can also be interrogated indirectly with the TS command.

For examples and further information about Homing, see command HM, FI, FE of the Command Reference and the section entitled Homing in the Programming Motion Section of this manual.

Abort Input

The function of the Abort input is to immediately stop the controller upon transition of the logic state.

NOTE: The response of the abort input is significantly different from the response of an activated limit switch. When the abort input is activated, the controller stops generating motion commands immediately, whereas the limit switch response causes the controller to make a decelerated stop.

NOTE: The effect of an Abort input is dependent on the state of the off-on-error function (OE Command) for each axis. If the Off-On-Error function is enabled for any given axis, the motor for that axis will be turned off when the abort signal is generated. This could cause the motor to ‘coast’ to a stop since it is no longer under servo control. If the Off-On-Error function is disabled, the motor will decelerate to a stop as fast as mechanically possible and the motor will remain in a servo state.

Chapter 3 Connecting Hardware ▫ 34 DMC-40x0 User Manual

All motion programs that are currently running are terminated when a transition in the Abort input is detected.

4080

This can be configured with the CN command. For information see the Command Reference, OE and CN.

ELO (Electronic Lock-Out) Input

Used in conjunction with Galil amplifiers, this input allows the user the shutdown the amplifier at a hardware level. For more detailed information on how specific Galil amplifiers behave when the ELO is triggered, see Integrated in the Appendices. If using a 5-8 axis controller with two integrated amplifiers, the ELO input on the A-D connector should be used. If an ELO is sensed both amplifiers will act on it, and shut down at a hardware level.

Reset Input/Reset Button

When the Reset line is triggered the controller will be reset. The reset line and reset button will not master reset the controller unless the MRST jumper is installed during a controller reset.

Uncommitted Digital Inputs

The DMC-40x0 has 8 optoisolated inputs. These inputs can be read individually using the function @IN[x] where x specifies the input number (1 thru 8). These inputs are uncommitted and can allow the user to create conditional statements related to events external to the controller. For example, the user may wish to have the x-axis motor move 1000 counts in the positive direction when the logic state of DI1 goes high.

The Digital inputs can be used as high speed position latch inputs, see High Speed Position Capture (The Latch Function) for more information.

This can be accomplished by connecting a voltage in the range of +5V to +28V into INCOM of the input circuitry from a separate power supply.

Controllers with more than 4 axes have an additional 8 general optoisolated inputs (inputs 9-16). The

INCOM for these inputs is found on the I/O (E-H) D-Sub connector.

An additional 32 I/O are provided at 3.3V (5V option) through the extended I/O. These are not

optoisolated.

Chapter 3 Connecting Hardware ▫ 35 DMC-40x0 User Manual

Optoisolated Input Electrical Information

Electrical Specifications

INCOM/LSCOM Max Voltage 24 V

INCOM/LSCOM Min Voltage 0 V

Minimum current to turn on Inputs 1.2 mA

Minimum current to turn off Inputs once activated (hysteresis) 0.5 mA

Maximum current per input

11 mA

Internal resistance of inputs 2.2 kΩ

See the Input Current Limitations, pg 193 section for more details.

The DMC-40x0's optoisolated inputs are rated to operate with a supply voltage of 5–24 VDC. The optoisolated inputs are powered in banks. For example, INCOM (Bank 0), located on the 44-pin I/O (A-D) D-sub connector, provides power to DI[8:1] (digital inputs), the abort input (ABRT), reset (RST), and electric lock-out (ELO). Table 3.17 shows all the input banks power commons and their corresponding inputs for 1-4 axis controllers and Table 3.18 shows the input banks for 5-8 axis controllers.

Common Signal Common Signal Location Powers Inputs Labeled

INCOM (Bank 0) I/O (A-D) D-Sub Connector DI[8:1], ABRT, RST, ELO LSCOM (Bank 0) I/O (A-D) D-Sub Connector FLSA, RLSA, HOMA

FLSB, RLSB, HOMB FLSC, RLSC, HOMC FLSD, RLSD, HOMD

Table 3.17: 1-4 axis controller INCOM and LSCOM banks and corresponding inputs powered

Common Signal Common Signal Location Powers Inputs

INCOM (Bank 0) I/O (A-D) D-Sub Connector DI[8:1], ABRT, RST, ELO LSCOM (Bank 0) I/O (A-D) D-Sub Connector FLSA, RLSA, HOMA

FLSB, RLSB, HOMB FLSC, RLSC, HOMC

FLSD, RLSD, HOMD INCOM (Bank 1) I/O (E-H) D-Sub Connector DI[16:9] LSCOM (Bank 1) I/O (E-H) D-Sub Connector FLSE, RLSE, HOME

FLSF, RLSF, HOMF

FLSG, RLSG, HOMG

FLSH, RLSH, HOMH

Table 3.18: 5-8 axis controller INCOM and LSCOM banks and corresponding inputs powered

The full pin-outs for each bank can be found in the Integrated Components, pg 211 under the ICM option ordered: A11 – ICM-42000 (-I000), A12 – ICM-42100 (-I100), or A13 – ICM-42200 (-I200).

Chapter 3 Connecting Hardware ▫ 36 DMC-40x0 User Manual

Wiring the Optoisolated Digital Inputs

To take full advantage of optoisolation, an isolated power supply should be used to provide the voltage at the input common connection. Connecting the ground of the isolated power to the ground of the controller will bypass optoisolation and is not recommended if true optoisolation is desired.

If there is not an isolated supply available, the 5 VDC, 12 VDC, and GND controller references may be used to power INCOM/LSCOM. The current supplied by the controller references are limited, see +5, ±12V Power Output Specifications, pg 183 in the Appendices for electrical specifications. Using the controller reference power completely bypasses optoisolation and is not recommended for most applications.

Banks of inputs can be used as either active high or low. Connecting +Vs to INCOM/LSCOM will configure the inputs for active low as current will flow through the diode when the inputs are pulled to the isolated ground. Connecting the isolated ground to INCOM/LSCOM will configure the inputs for active high as current will flow through the diode when the inputs are pulled up to +Vs.

Figure 3.1 - Figure 3.5 are the optoisolated wiring diagrams for powering INCOM/LSCOM (Bank 0) and INCOM/LSCOM (Bank 1) and their corresponding inputs.

Figure 3.1: Digital Inputs 1-8 (DI[8:1])

Figure 3.2: Digital Inputs 9-16 (DI[16:9])

Chapter 3 Connecting Hardware ▫ 37 DMC-40x0 User Manual

Figure 3.3: Limit Switch Inputs for Axes A-D

Figure 3.4: Limit Switch Inputs for Axes E-H

Figure 3.5: ELO, Abort and Reset Inputs

Chapter 3 Connecting Hardware ▫ 38 DMC-40x0 User Manual

High Power Optoisolated Outputs

The DMC-40x0 has different interconnect module options, this section will describe the 500mA optically isolated outputs that are used on the ICM-42x00.

The amount of uncommitted, optoisolated outputs the DMC-40x0 has depends on the number of axis. For instance, 1-4 axis models come with a single bank of 8 outputs, Bank 0 (DO[8:1]). 5-8 axis models come with an additional bank of 8 outputs, Bank 1 (DO[16:9]), for a total of 16 outputs.

The wiring pins for Bank 0 are located on the ICM-42x00 I/O (A-D) 44 pin HD D-sub Connector and the pins for wiring Bank 1 are located on the ICM-42x00 I/O (E-H) 44 pin HD D-sub Connector. See the the Appendix for your ICM: A11 – ICM-42000 (-I000), A12 – ICM-42100 (-I100), or A13 – ICM-42200 (-I200) for pin-outs.

Description

The 500mA sourcing option, referred to as high power sourcing (HSRC), is capable of sourcing up to 500mA per output and up to 3A per bank. The voltage range for the outputs is 12-24 VDC. These outputs are capable of driving inductive loads such as solenoids or relays. The outputs are configured for hi-side (sourcing) only.

Electrical Specifications

Output PWR Max Voltage 24 VDC

Output PWR Min Voltage 12 VDC

Max Drive Current per Output 0.5 A (maximum 3A per Bank)

Wiring the Optoisolated Outputs

The output power supply will be connected to Output PWR (labeled OPWR) and the power supply return will be connected to Output GND (labeled ORET). Note that the load is wired between DO and Output GND. The wiring diagram for Bank 0 is shown in Figure 3.6 and Bank 1 in Figure 3.7. See the “I/O 44 pin HD D-sub Connector” for your specific ICM module in the Appendix for the correct pin-outs.

Figure 3.6: 500mA Sourcing wiring diagrams for Bank 0, DO[8:1]

Chapter 3 Connecting Hardware ▫ 39 DMC-40x0 User Manual

Figure 3.7: 500mA Sourcing wiring diagram for Bank 1, DO[16:9]

TTL Inputs and Outputs

Main Encoder Inputs

The main encoder inputs can be configured for quadrature (default) or pulse and direction inputs. This configuration is set through the CE command. The encoder connections are found on the HD D-sub Encoder connectors and are labeled MA+, MA-, MB+, MB-. The '-' (negative) inputs are the differential inputs to the encoder inputs; if the encoder is a single ended 5V encoder, then the negative input should be left floating. If the encoder is a single ended and outputs a 0-12V signal then the negative input should be tied to the 5V line on the DMC.

When the encoders are setup as step and direction inputs the MA channel will be the step or pulse input, and the MB channel will be the direction input.

The encoder inputs can be ordered with 120Ohm termination resistors installed. See TRES – Encoder Termination Resistors in the Appendix for more information.

Electrical Specifications

Maximum Voltage 12 VDC

Minimum Voltage -12 VDC

Maximum Frequency (Quadrature) 15 MHz

'+' inputs are internally pulled-up to 5V through a 4.7 kΩ resistor

'-' inputs are internally biased to ~1.3V

pulled up to 5V through a 7.1 kΩ resistor

pulled down to GND through a 2.5kΩ resistor

The Auxiliary Encoder Inputs

The auxiliary encoder inputs can be used for general use. For each axis, the controller has one auxiliary encoder and each auxiliary encoder consists of two inputs, channel A and channel B. The auxiliary encoder inputs are mapped to the inputs 81-96. The Aux encoder inputs are not available for any axis that is configured for step and direction outputs (stepper).

Each input from the auxiliary encoder is a differential line receiver and can accept voltage levels between ± 12 volts. The inputs have been configured to accept TTL level signals. To connect TTL signals, simply connect the

Chapter 3 Connecting Hardware ▫ 40 DMC-40x0 User Manual

signal to the + input and leave the - input disconnected. For other signal levels, the - input should be connected to a voltage that is ½ of the full voltage range (for example, connect the - input to 6 volts if the signal is a 0 - 12 volt logic).

Example:

A DMC-4010 has one auxiliary encoder. This encoder has two inputs (channel A and channel B). Channel A input is mapped to input 81 and Channel B input is mapped to input 82. To use this input for 2 TTL signals, the first signal will be connected to AA+ and the second to AB+. AA- and AB- will be left unconnected. To access this input, use the function @IN[81] and @IN[82].

NOTE: The auxiliary encoder inputs are not available for any axis that is configured for stepper motor.

Electrical Specifications

Maximum Voltage 12 VDC

Minimum Voltage -12 VDC

'+' inputs are internally pulled-up to 5V through a 4.7kΩ resistor

'-' inputs are internally biased to ~1.3V

pulled up to 5V through a 7.1kΩ resistor

pulled down to GND through a 2.5kΩ resistor

Output Compare

The output compare signal is a TTL ouput signal and is available on the I/O (A-D) D-Sub connector labeled as CMP. An additional output compare signal is available for 5-8 axes controllers on the I/O (E-H) D-sub connector.

Output compare is controlled by the position of any of the main encoder inputs on the controller. The output can be programmed to produce either a brief, active low pulse (250 nsec) based on an incremental encoder value or to activate once (“one shot”) when an axis position has been passed. When setup for a one shot, the output will stay low until the OC command is called again. For further information, see the command OC in the Command Reference.

NOTE

Output compare is not valid with sampled feedback types such as: SSI, BiSS, Sin/Cos, and Analog

Electrical Specifications

Output Voltage 0 – 5 VDC

Current Output 20 mA Sink/Source

Error Output

The controller provides a TTL signal, ERR, to indicate a controller error condition. When an error condition occurs, the ERR signal will go low and the controller LED will go on. An error occurs because of one of the following conditions:

1. At least one axis has a position error greater than the error limit. The error limit is set by using the command ER.

2. The reset line on the controller is held low or is being affected by noise.

3. There is a failure on the controller and the processor is resetting itself.

4. There is a failure with the output IC which drives the error signal.

The ERR signal is found on the I/O (A-D) D-Sub connector.

Chapter 3 Connecting Hardware ▫ 41 DMC-40x0 User Manual

4080

For controllers with 5-8 axes, the ERR signal is duplicated on the I/O (E-H) D-Sub connector.

For additional information see Error Light (Red LED) in Chapter 9 Troubleshooting.

Electrical Specifications

Output Voltage 0 – 5 VDC

Current Output 20 mA Sink/Source

Analog Inputs

The DMC-40x0 has eight analog inputs configured for the range between -10V and 10V. The inputs are decoded by a 12-bit A/D decoder giving a voltage resolution of approximately .005V. A 16-bit ADC is available as an option (Ex. DMC-4020(-16bit)-C012-I000). The analog inputs are specified as AN[x] where x is a number 1 thru 8.

AQ settings

The analog inputs can be set to a range of ±10V, ±5V, 0-5V or 0-10V, this allows for increased resolution when the full ±10V is not required. The inputs can also be set into a differential mode where analog inputs 2,4,6 and 8 can be set to the negative differential inputs for analog inputs 1,3,5 and 7 respectively. See the AQ command in the command reference for more information.

Electrical Specifications

Input Impedance (12 and 16 bit) –

Unipolar (0-5V, 0-10V) 42kΩ

Bipolar (±5V, ±10V) 31kΩ

Extended I/O

The DMC-40x0 controller offers 32 extended TTL I/O points which can be configured as inputs or outputs in 8 bit increments. Configuration is accomplished with command CO – see Extended I/O of the DMC-40x0 Controller. The I/O points are accessed through the 44 pin D-Sub connector labeled EXTENDED I/O. See the A9 – CMB-41012 (C012) section in the Appendix for a complete pin out of the Extended I/O.

Electrical Specifications (3.3V – Standard)

Inputs

Max Input Voltage 3.4 VDC

Guarantee High Voltage 2.0 VDC

Guarantee Low Voltage 0.8 VDC Inputs are internally pulled up to 3.3V through a 4.7kΩ resistor

Chapter 3 Connecting Hardware ▫ 42 DMC-40x0 User Manual

Outputs

Sink/Source 4mA per output

Electrical Specifications (5V – Option)

Inputs

Max Input Voltage 5.25 VDC Guarantee High Voltage 2.0 VDC Guarantee Low Voltage 0.8 VDC

Inputs are internally pulled up to 5V through a 4.7kΩ resistor

Outputs

Sink/Source 20mA

External Amplifier Interface

External Stepper Control

The controller provides step and direction (STPn, DIRn) outputs for every axis available on the controller. These outputs are typically used for interfacing to external stepper drivers, but they can be configured for a PWM output. See the MT command for more details.

PWM/Step and Sign/Direction Electrical Specifications

Output Voltage 0 – 5 VDC

Current Output 20 mA Sink/Source

External Servo Control

The DMC-40x0 command voltage ranges between ±10V and is output on the motor command line - MCMn (where n is A-H). This signal, along with GND, provides the input to the motor amplifiers. The amplifiers must be sized to drive the motors and load. For best performance, the amplifiers should be configured for a torque (current) mode of operation with no additional compensation. The gain should be set such that a 10 volt input results in the maximum required current.

Motor Command Line Electrical Specifications

Output Voltage ±10 VDC

Motor Command Output Impedance 500 Ω

Amplifier Enable

The DMC-40x0 has an amplifier enable signal - AENn (where n is A-H) which changes under the following conditions:

• The motor-off command MO is given or the watchdog timer activates.

• The OE command (Enable Off-On-Error) is set and the position error exceeds the error limit (set by ER).

• A limit switch is reached (see OE command in the Command Reference for more information).

Chapter 3 Connecting Hardware ▫ 43 DMC-40x0 User Manual

For all versions of the ICM-42x00, the default configuration of the amplifier enable signal is 5V active high amp

Amplifier Enable Circuit

Sinking Output Configuration

(Pin 1 of LTV8441 in Pin 2 of Socket U4)

TTL level Amp

Enable signal

from controller

(SH = 5V, MO = 0V)

TTL level Amp

Enable signal

from controller

(SH = 5V, MO = 0V)

RP2 (470 Ohm)

Pin 1

of socket

Socket U4

RP6 (820 Ohm)

AECOM2

JP2

Amp Enable Output to Drive (AENn)

AECOM2

JP2

AECOM1

JP1

enable (HAEN) sinking. In other words, the AEN signal will be high when the controller expects the amplifier to be enabled. The polarity and the amplitude can be changed by configuring the Amplifier Enable Circuit on the ICM42xx0.

If your amplifier requires a different configuration than the default 5V HAEN sinking 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.

Note: Many amplifiers designate the enable input as ‘inhibit’.

ICM-42000 and ICM-42100 Amplifier Enable Circuit

This section describes how to configure the ICM-42000 and ICM-42100 for different Amplifier Enable configurations. It is advised that the user order the DMC-40x0 with the proper Amplifier enable configuration.

The ICM-42000 and ICM-42100 gives the user a broad range of options with regards to the voltage levels present on the enable signal. The user can choose between High-Amp-Enable (HAEN), Low-Amp-Enable (LAEN), 5V logic, 12V logic, external voltage supplies up to 24V, sinking, or sourcing. Tables 3.19 and 3.20 found below illustrate the settings for jumpers, resistor packs, and the socketed optocoupler IC. Refer to Figures 3.8 and 3.9 for precise physical locations of all components. Note that the resistor pack located at RP2 may be reversed to change the active state of the amplifier enable output. However, the polarity of RP6 must not be changed; a different resistor value may be needed to limit the current to 6 mA. The default value for RP6 is 820 Ω, which works at 5V. When using 24 V, RP6 should be replaced with a 4.7 k resistor pack.

NOTE: For detailed step-by-step instructions on changing the Amplifier Enable configuration on the ICM-42000 or ICM-42100 see the Configuring the Amplifier Enable Circuit section in the Appendices.

Figure 3.8: Amplifier Enable Circuit Sinking Output Configuration

Chapter 3 Connecting Hardware ▫ 44 DMC-40x0 User Manual

Sinking Configuration (pin1 of LTV8441 chip in pin2 of socket U4)

Amplifier Enable Circuit

Sourcing Output Configuration

(Pin 1 of LTV8441 in Pin 1 of Socket U4)

TTL level Amp

Enable signal

from controller

(SH = 5V, MO = 0V)

TTL level Amp

Enable signal

from controller

(SH = 5V, MO = 0V)

5V or GND

RP2 (470 Ohm)

Pin 1

of socket

Pin 1

Socket U4

RP6 (820 Ohm)

Amp Enable Output to Drive (AENn)

AECOM1

AECOM2

JP2

AECOM2

JP2

JP1

Logic State JP1 JP2 RP2 (square pin next to RP2 label is 5V) 5V, HAEN (Default configuration) 5V - AECOM1 GND – AECOM2 Dot on R-pack next to RP2 label 5V, LAEN 5V – AECOM1 GND – AECOM2 Dot on R-pack opposite RP2 label 12V, HAEN +12V – AECOM1 GND – AECOM2 Dot on R-pack next to RP2 label 12V, LAEN +12V – AECOM1 GND – AECOM2 Dot on R-pack opposite RP2 label Isolated 24V, HAEN AEC1 – AECOM1 AEC2 – AECOM2 Dot on R-pack next to RP2 label Isolated 24V, LAEN AEC1 - AECOM1 AEC2 - AECOM2 Dot on R-pack opposite RP2 label

For 24V isolated enable, tie +24V of external power supply to AEC1 at the D-sub, tie common return to AEC2. Replace RP6 with a 4.7 kΩ resistor pack. For Axes A-D, AEC1 and AEC2 are located on the EXTERNAL DRIVER (A-D) D-Sub connector. For Axes E-H, AEC1 and AEC2 are located on the EXTERNAL DRIVER (E-H) D-Sub connector. Note: AEC1 and AEC2 for axes A-D are NOT connected to AEC1 and AEC2 for axes E-H.

Table 3.19: Sinking Configuration

Figure 3.9: Amplifier Enable Circuit Sourcing Output Configuration

Sourcing Configuration (pin1 of LTV8441 chip in pin1 of socket U4) Logic State JP1 JP2 RP2 (square pin next to RP2 label is 5V)

5V, HAEN GND – AECOM1 5V – AECOM2 Dot on R-pack opposite RP2 label 5V, LAEN GND – AECOM1 5V – AECOM2 Dot on R-pack next to RP2 label 12V, HAEN GND – AECOM1 +12V – AECOM2 Dot on R-pack opposite RP2 label 12V, LAEN GND – AECOM1 +12V – AECOM2 Dot on R-pack next to RP2 label Isolated 24V, HAEN AEC1 – AECOM1 AEC2 - AECOM2 Dot on R-pack opposite RP2 label Isolated 24V, LAEN AEC1 - AECOM1 AEC2 – AECOM2 Dot on R-pack next to RP2 label

For 24V isolated enable, tie +24V of external power supply to AEC2 at the D-sub, tie common return to AEC1. Replace RP6 with a 4.7 kΩ resistor pack. For Axes A-D, AEC1 and AEC2 are located on the EXTERNAL DRIVER (A-D) D-Sub connector. For Axes E-H, AEC1 and AEC2 are located on the EXTERNAL DRIVER (E-H) D-Sub connector. Note: AEC1 and AEC2 for axes A-D are NOT connected to AEC1 and AEC2 for axes E-H.

Chapter 3 Connecting Hardware ▫ 45 DMC-40x0 User Manual

Table 3.20: Sourcing Configuration

ICM-42200 Amplifier Enable Circuit

This section describes how to configure the ICM-42200 for different Amplifier Enable outputs. The ICM-42200 is designed to be used with external amplifiers. As a result, the amplifier enable circuit for each axis is individually configurable through jumper settings. The user can choose between High-Amp-Enable (HAEN), Low-Amp-Enable (LAEN), 5V logic, 12V logic, external voltage supplies up to 24V, sinking, or sourcing. Every different configuration is described below with jumper settings and a schematic of the circuit. The default configuration unless specified will be Isolated Supply, HAEN, Sinking.

Chapter 3 Connecting Hardware ▫ 46 DMC-40x0 User Manual

Chapter 3 Connecting Hardware ▫ 47 DMC-40x0 User Manual

Chapter 3 Connecting Hardware ▫ 48 DMC-40x0 User Manual

Chapter 3 Connecting Hardware ▫ 49 DMC-40x0 User Manual

Chapter 4 Software Tools and

Communication

Introduction

The default configuration DMC-40x0, with the default CMB-41012 communication board, has two RS232 ports and 1 Ethernet port. An additional Ethernet port is available with the CMB-41022. The main RS-232 port is the data set and can be configured through the jumpers on the top of the controller. The auxiliary RS-232 port is the data term and can be configured with the software command CC. This configuration can be saved using the Burn (BN) instruction. The Ethernet port(s) is a 10/100BASE-T connection that auto-negotiates the speed and half or full duplex.

The GalilTools software package is available for PC computers running Microsoft Windows® to communicate with the DMC-40x0 controller. This software package has been developed to operate under Windows and Linux, and include all the necessary drivers to communicate to the controller. In addition, GalilTools includes a software development communication library which allows users to create their own application interfaces using programming environments such as C, C++, Visual Basic, and LabVIEW.

The following sections in this chapter are a description of the communications protocol, and a brief introduction to the software tools and communication techniques used by Galil. At the application level, GalilTools is the basic programs that the majority of users will need to communicate with the controller, to perform basic setup, and to develop application code (.dmc programs) that is downloaded to the controller. At the Galil API level, the GalilTools Communication Library is available for users who wish to develop their own custom application programs to communicate to the controller. Custom application programs can utilize API function calls directly to our DLL’s. At the driver level, we provide fundamental hardware interface information for users who desire to create their own drivers.

Controller Response to Commands

Most DMC-40x0 instructions are represented by two characters followed by the appropriate parameters. Each instruction must be terminated by a carriage return. Multiple commands may be concatenated by inserting a semicolon between each command.

Instructions are sent in ASCII, and the DMC-40x0 decodes each ASCII character (one byte) one at a time. It takes approximately 40 μsec for the controller to decode each command.

After the instruction is decoded, the DMC-40x0 returns a response to the port from which the command was generated. If the instruction was valid, the controller returns a colon (:) or the controller will respond with a

Chapter 4 Software Tools and Communication ▫ 50 DMC-40x0 User Manual

question mark (?) if the instruction was not valid. For example, the controller will respond to commands which are sent via the main RS-232 port back through the RS-232 port, and to commands which are sent via the Ethernet port back through the Ethernet port.

For instructions that return data, such as Tell Position (TP), the DMC-40x0 will return the data followed by a carriage return, line feed and : .

It is good practice to check for : after each command is sent to prevent errors. An echo function is provided to enable associating the DMC-40x0 response with the data sent. The echo is enabled by sending the command EO 1 to the controller.

Unsolicited Messages Generated by Controller

When the controller is executing a program, it may generate responses which will be sent via the main RS-232 port or Ethernet ports. This response could be generated as a result of messages using the MG command OR as a result of a command error. These responses are known as unsolicited messages since they are not generated as the direct response to a command.

Messages can be directed to a specific port using the specific Port arguments – see the MG and CF commands in the Command Reference. If the port is not explicitly given or the default is not changed with the CF command, unsolicited messages will be sent to the default port. The default port is the main serial port. When communicating via an Ethernet connection, the unsolicited messages must be sent through a handle that is not the main communication handle from the host. The GalilTools software automatically establishes this second communication handle.

The controller has a special command, CW, which can affect the format of unsolicited messages. This command is used by Galil Software to differentiate response from the command line and unsolicited messages. The command, CW1 causes the controller to set the high bit of ASCII characters to 1 of all unsolicited characters. This may cause characters to appear garbled to some terminals. This function can be disabled by issuing the command, CW2. For more information, see the CW command in the Command Reference.

When handshaking is used (hardware and/or software handshaking) characters which are generated by the controller are placed in a FIFO buffer before they are sent out of the controller. The size of the RS-232 buffer is 512 bytes. When this buffer becomes full, the controller must either stop executing commands or ignore additional characters generated for output. The command CW,1 causes the controller to ignore all output from the controller while the FIFO is full. The command, CW ,0 causes the controller to stop executing new commands until more room is made available in the FIFO. This command can be very useful when hardware handshaking is being used and the communication line between controller and terminal will be disconnected. In this case, characters will continue to build up in the controller until the FIFO is full. For more information, see the CW command in the Command Reference.

Serial Communication Ports

The RS-232 and RS-422 (optional) are located on the CMB (communication board) of the DMC-40x0. Note that the auxiliary port is essentially the same as the main port except inputs and outputs are reversed.

RS-232 Configuration

The pin-outs for the RS-232 ports can be found on either A9 – CMB-41012 (-C012), pg 255 or A10 – CMB-41022 (C022), pg 259 depending on the CMB option ordered.

Chapter 4 Software Tools and Communication ▫ 51 DMC-40x0 User Manual

Configure your PC for 8-bit data, one start-bit, one stop-bit, full duplex and no parity. The baud rate for the RS232 communication can be selected by setting the proper switch configuration on the front panel according to the table below.

Baud Rate Selection

JP1 JUMPER SETTINGS

19.2 38.4

ON ON 9600

ON OFF 19200 OFF ON 38400 OFF OFF 115200

BAUD RATE

Handshaking

The RS232 main port is set for hardware handshaking. Hardware Handshaking uses the RTS and CTS lines. The CTS line will go high whenever the DMC-40x0 is not ready to receive additional characters. The RTS line will inhibit the DMC-40x0 from sending additional characters. Note, the RTS line goes high for inhibit.

Auxiliary RS-232 Port Configuration

The main purpose of the auxiliary RS232 port is to connect to external devices that cannot use DMC code to communicate. It is important to note that the Aux port is not an interpreted port and cannot receive DMC Galil commands directly. Instead, use CI, #COMINT, and the P2 operands to handle received data on this port.

NOTE: If you are connecting the RS-232 auxiliary port to a terminal or any device which is a DATASET, it is necessary to use a connector adapter, which changes a dataset to a dataterm. This cable is also known as a 'null' modem cable.

CC Command

The CC, or Configure Communications command, configures the auxiliary ports properties including: Baud rate, handshaking, enable/disabled port, and echo. See the CC command in the Command Reference for a full description and command syntax.

If the CC command is configured for hardware handshaking it is required to use the RTS and CTS lines. The RTS line will go high whenever the DMC is not ready to receive additional characters. The CTS line will inhibit the DMC from sending additional characters. Note, the CTS line goes high for inhibit.

RS-422 Configuration

The DMC-40x0 can be ordered with the main and/or auxiliary port configured for RS-422 communication. RS-422 communication is a differentially driven serial communication protocol that should be used when long distance serial communication is required in an application.

See RS-422 – Serial Port Serial Communication, pg 187 for pin-outs and details of the RS-422 options.

Chapter 4 Software Tools and Communication ▫ 52 DMC-40x0 User Manual

Ethernet Configuration

Communication Protocols

The Ethernet is a local area network through which information is transferred in units known as packets. Communication protocols are necessary to dictate how these packets are sent and received. The DMC-40x0 supports two industry standard protocols, TCP/IP and UDP/IP. The controller will automatically respond in the format in which it is contacted.

TCP/IP is a "connection" protocol. The master, or client, connects to the slave, or server, through a series of packet handshakes in order to begin communicating. Each packet sent is acknowledged when received. If no acknowledgment is received, the information is assumed lost and is resent.

Unlike TCP/IP, UDP/IP does not require a "connection". If information is lost, the controller does not return a colon or question mark. Because UDP does not provide for lost information, the sender must re-send the packet.

It is recommended that the motion control network containing the controller and any other related devices be placed on a “closed” network. If this recommendation is followed, UDP/IP communication to the controller may be utilized instead of a TCP connection. With UDP there is less overhead, resulting in higher throughput. Also, there is no need to reconnect to the controller with a UDP connection. Because handshaking is built into the Galil communication protocol through the use of colon or question mark responses to commands sent to the controller, the TCP handshaking is not required.

Packets must be limited to 512 data bytes (including UDP/TCP IP Header) or less. Larger packets could cause the controller to lose communication.

NOTE: In order not to lose information in transit, the user must wait for the controller's response before sending the next packet.

Addressing

There are three levels of addresses that define Ethernet devices. The first is the MAC or hardware address. This is a unique and permanent 6 byte number. No other device will have the same MAC address. The DMC-40x0 MAC address is set by the factory and the last two bytes of the address are the serial number of the board. To find the Ethernet MAC address for a DMC-40x0 unit, use the TH command. A sample is shown here with a unit that has a serial number of 3:

Sample MAC Ethernet Address: 00-50-4C-20-04-AF

The second level of addressing is the IP address. This is a 32-bit (or 4 byte) number that usually looks like this:

192.168.15.1. The IP address is constrained by each local network and must be assigned locally. Assigning an IP address to the DMC-40x0 controller can be done in a number of ways.

The first method for setting the IP address is using a DHCP server. The DH command controls whether the DMC40x0 controller will get an IP address from the DHCP server. If the unit is set to DH1 (default) and there is a DHCP server on the network, the controller will be dynamically assigned an IP address from the server. Setting the board to DH0 will prevent the controller from being assigned an IP address from the server.

The second method to assign an IP address is to use the BOOT-P utility via the Ethernet connection. The BOOT-P functionality is only enabled when DH is set to 0. Either a BOOT-P server on the internal network or the Galil software may be used. When opening the Galil Software, it will respond with a list of all DMC-40x0’s and other controllers on the network that do not currently have IP addresses. The user must select the board and the software will assign the specified IP address to it. This address will be burned into the controller (BN) internally to save the IP address to the non-volatile memory.

Chapter 4 Software Tools and Communication ▫ 53 DMC-40x0 User Manual

NOTE: if multiple boards are on the network – use the serial numbers to differentiate them.

Be sure that there is only one BOOT-P or DHCP server running. If your network has DHCP or BOOT-P running, it may automatically assign an IP address to the DMC-40x0 controller

CAUTION

The third method for setting an IP address is to send the IA command through the RS-232 port. (Note: The IA command is only valid if DH0 is set). The IP address may be entered as a 4 byte number delimited by commas (industry standard uses periods) or a signed 32 bit number (e.g. IA 124,51,29,31 or IA 2083724575). Type in BN to save the IP address to the DMC-40x0 non-volatile memory.

NOTE: Galil strongly recommends that the IP address selected is not one that can be accessed across the Gateway. The Gateway is an application that controls communication between an internal network and the outside world.

The third level of Ethernet addressing is the UDP or TCP port number. The Galil board does not require a specific port number. The port number is established by the client or master each time it connects to the DMC-40x0 board. Typical port numbers for applications are:

Port 23: Telnet Port 502: Modbus

upon linking it to the network. In order to ensure that the IP address is correct, please contact your system administrator before connecting the I/O board to the Ethernet network.

Communicating with Multiple Devices

The DMC-40x0 is capable of supporting multiple masters and slaves. The masters may be multiple PC's that send commands to the controller. The slaves are typically peripheral I/O devices that receive commands from the controller.

NOTE: The term "Master" is equivalent to the internet "client". The term "Slave" is equivalent to the internet "server".

An Ethernet handle is a communication resource within a device. The DMC-40x0 can have a maximum of 8 Ethernet handles open at any time. When using TCP/IP, each master or slave uses an individual Ethernet handle. In UDP/IP, one handle may be used for all the masters, but each slave uses one. (Pings and ARPs do not occupy handles.) If all 8 handles are in use and a 9th master tries to connect, it will be sent a "reset packet" that generates the appropriate error in its windows application.

NOTE: There are a number of ways to reset the controller. Hardware reset (push reset button or power down controller) and software resets (through Ethernet or RS232 by entering RS).

When the Galil controller acts as the master, the IH command is used to assign handles and connect to its slaves. The IP address may be entered as a 4 byte number separated with commas (industry standard uses periods) or as a signed 32 bit number. A port number may also be specified, but if it is not, it will default to 1000. The protocol (TCP/IP or UDP/IP) to use must also be designated at this time. Otherwise, the controller will not connect to the slave. (Ex. IHB=151,25,255,9<179>2 This will open handle #2 and connect to the IP address 151.25.255.9, port 179, using TCP/IP)

Which devices receive what information from the controller depends on a number of things. If a device queries the controller, it will receive the response unless it explicitly tells the controller to send it to another device. If the command that generates a response is part of a downloaded program, the response will route to whichever port is specified as the default (unless explicitly told to go to another port with the CF command). To designate a specific destination for the information, add {Eh} to the end of the command. (Ex. MG{EC}"Hello" will send the message "Hello" to handle #3. TP,,?{EF} will send the z axis position to handle #6.)

Chapter 4 Software Tools and Communication ▫ 54 DMC-40x0 User Manual

Multicasting

A multicast may only be used in UDP/IP and is similar to a broadcast (where everyone on the network gets the information) but specific to a group. In other words, all devices within a specified group will receive the information that is sent in a multicast. There can be many multicast groups on a network and are differentiated by their multicast IP address. To communicate with all the devices in a specific multicast group, the information can be sent to the multicast IP address rather than to each individual device IP address. All Galil controllers belong to a default multicast address of 239.255.19.56. The controller's multicast IP address can be changed by using the IA> u command.

Using Third Party Software

Galil supports DHCP, ARP, BOOT-P, and Ping which are utilities for establishing Ethernet connections. DHCP is a protocol used by networked devices (clients) to obtain the parameters necessary for operation in an Internet Protocol network. ARP is an application that determines the Ethernet (hardware) address of a device at a specific IP address. BOOT-P is an application that determines which devices on the network do not have an IP address and assigns the IP address you have chosen to it. Ping is used to check the communication between the device at a specific IP address and the host computer.

The DMC-40x0 can communicate with a host computer through any application that can send TCP/IP or UDP/IP packets. A good example of this is Telnet, a utility that comes with most Windows systems.

Modbus

An additional protocol layer is available for speaking to I/O devices. Modbus is an RS-485 protocol that packages information in binary packets that are sent as part of a TCP/IP packet. In this protocol, each slave has a 1 byte slave address. The DMC-40x0 can use a specific slave address or default to the handle number. The port number for Modbus is 502. The DMC-40x0 can fill the role of either a Modbus master or Modbus slave.

The Modbus protocol has a set of commands called function codes. The DMC-40x0 supports the 10 major function codes as a Modbus Master:

Function Code Definition

01 Read Coil Status (Read Bits) 02 Read Input Status (Read Bits) 03 Read Holding Registers (Read Words) 04 Read Input Registers (Read Words) 05 Force Single Coil (Write One Bit) 06 Preset Single Register (Write One Word) 07 Read Exception Status (Read Error Code) 15 Force Multiple Coils (Write Multiple Bits) 16 Preset Multiple Registers (Write Words) 17 Report Slave ID

The DMC-40x0 supports 2 major function codes as a Modbus Slave:

Function Code Definition

03 Read Holding Registers (Read Words) 16 Preset Multiple Registers (Write Words)

A Modbus master has the ability to read and write array data on the DMC-40x0¹ acting as a slave (up to 1000 elements are available). Each element is accessible as a 16-bit unsigned integer (Modbus register 1xxx) or as a 32-

Chapter 4 Software Tools and Communication ▫ 55 DMC-40x0 User Manual

bit floating point number (Modbus registers 2xxx). The ability to write to the slaves array table is enabled by setting the ME command (ME is not needed to read array data). See the DMC-40x0 Command Reference for further details.

¹ Only DMC-40x0 firmware revisions Rev 1.2d and later support Modbus slave capability via the ME command.

The DMC-40x0 provides three levels of Modbus communication. The first level allows the user to create a raw packet and receive raw data. It uses the MBh command with a function code of –1. The format of the command is

MBh = -1,len,array[] where len is the number of bytes

array[] is the array with the data

The second level incorporates the Modbus structure. This is necessary for sending configuration and special commands to an I/O device. The formats vary depending on the function code that is called. For more information refer to the Command Reference.

The third level of Modbus communication uses standard Galil commands. Once the slave has been configured, the commands that may be used are @IN[], @AN[], SB, CB, OB, and AO. For example, AO 2020,8.2 would tell I/O number 2020 to output 8.2 volts.

If a specific slave address is not necessary, the I/O number to be used can be calculated with the following:

I/O Number = (HandleNum*1000) + ((Module-1)*4) + (BitNum-1)

Where HandleNum is the handle number from 1 (A) to 8 (H). Module is the position of the module in the rack from 1 to 16. BitNum is the I/O point in the module from 1 to 4.

Modbus Examples

Example #1

DMC-4040 connected as a Modbus master to a RIO-47120 via Modbus. The DMC-4040 will set or clear all 16 of the RIO’s digital outputs

1. Begin by opening a connection to the RIO which in our example has IP address 192.168.1.120

IHB=192,168,1,120<502>2 (Issued to DMC-4040)

2. Dimension an array to store the commanded values. Set array element 0 equal to 170 and array element 1 equal to 85. (array element 1 configures digital outputs 15-8 and array element 0 configures digital outputs 7-0)

DM myarray[2] myarray[0] = 170 (which is 10101010 in binary) myarray[1] = 85 (which is 01010101in binary)

3. a) Send the appropriate MB command. Use function code 15. Start at output 0 and set/clear all 16 outputs based on the data in myarray[]

MBB=,15,0,16,myarray[]

3. b) Set the outputs using the SB command.

SB2001;SB2003;SB2005;SB2007;SB2008;SB2010;SB2012;SB2014;

Results:

Both steps 3a and 3b will result in outputs being activated as below. The only difference being that step 3a will set and clear all 16 bits where as step 3b will only set the specified bits and will have no affect on the others.

Chapter 4 Software Tools and Communication ▫ 56 DMC-40x0 User Manual

Bit Number Status Bit Number Status

0 0 8 1 1 1 9 0 2 0 10 1 3 1 11 0 4 0 12 1 5 1 13 0 6 0 14 1 7 1 15 0

Example #2

DMC-4040 connected as a Modbus master to a 3rd party PLC. The DMC-4040 will read the value of analog inputs 3 and 4 on the PLC located at addresses 40006 and 40008 respectively. The PLC stores values as 32-bit floating point numbers which is common.

1. Begin by opening a connection to the PLC which has an IP address of 192.168.1.10 in our example

IHB=192,168,1,10<502>2

2. Dimension an array to store the results

DM myanalog[4]

3. Send the appropriate MB command. Use function code 4 (as specified per the PLC). Start at address

40006. Retrieve 4 modbus registers (2 modbus registers per 1 analog input, as specified by the PLC)

MBB=,4,40006,4,myanalog[]

Results:

Array elements 0 and 1 will make up the 32 bit floating point value for analog input 3 on the PLC and array elements 2 and 3 will combine for the value of analog input 4.

myanalog[0]=16412=0x401C myanalog[1]=52429=0xCCCD myanalog[2]=49347=0xC0C3 myanalog[3]=13107=0x3333

Analog input 3 = 0x401CCCCD = 2.45V

Analog input 4 = 0xC0C33333 = -6.1V

Example #3

DMC-4040 connected as a Modbus master to a hydraulic pump. The DMC-4040 will set the pump pressure by writing to an analog output on the pump located at Modbus address 30000 and consisting of 2 Modbus registers forming a 32 bit floating point value.

1. Begin by opening a connection to the pump which has an IP address of 192.168.1.100 in our example

IHB=192,168,1,100<502>2

2. Dimension and fill an array with values that will be written to the PLC

DM pump[2] pump[0]=16531=0x4093 pump[1]=13107=0x3333

Chapter 4 Software Tools and Communication ▫ 57 DMC-40x0 User Manual

3. Send the appropriate MB command. Use function code 16. Start at address 30000 and write to 2 registers

General Controller Information and Status

ADDR

TYPE

ITEM

ADDR

TYPE

ITEM

1st Byte of Header

30-31

Reserved01UB

2nd Byte of Header

32-33

Reserved

3rd Byte of Header

34-35

Reserved

4th Byte of Header

36-37

Reserved

04-05

sample number

38-39

Reserved06UB

general input block 0 (inputs 1-8)

40-41

Reserved07UB

general input block 1 (inputs 9-16)

42UBEthernet Handle A Status

general input block 2 (inputs 17-24)

43UBEthernet Handle B Status

general input block 3 (inputs 25-32)

44UBEthernet Handle C Status

general input block 4 (inputs 33-40)

45UBEthernet Handle D Status

general input block 5 (inputs 41-48)

46UBEthernet Handle E Status

general input block 6 (inputs 49-56)

47UBEthernet Handle F Status

general input block 7 (inputs 57-64)

48UBEthernet Handle G Status

general input block 8 (inputs 65-72)

49UBEthernet Handle H Status

general input block 9 (inputs 73-80)

50UBerror code

general output block 0 (outputs 1-8)

51UBthread status – see bit field map below

general output block 1 (outputs 9-16)

52-55

Amplifier Status

general output block 2 (outputs 17-24)

56-59

Segment Count for Contour Mode

general output block 3 (outputs 25-32)

60-61

Buffer space remaining – Contour Mode

general output block 4 (outputs 33-40)

62-63

segment count of coordinated move for S plane

using the data in the array pump[]

MBB=,16,30000,2,pump[]

Results:

Analog output will be set to 0x40933333 which is 4.6V

Data Record

The DMC-40x0 can provide a binary block of status information with the use of the QR and DR commands. These commands, along with the QZ command can be very useful for accessing complete controller status. The QR command will return 4 bytes of header information and specific blocks of information as specified by the command arguments:

QR ABCDEFGHST

Each argument corresponds to a block of information according to the Data Record Map below. If no argument is given, the entire data record map will be returned. Note that the data record size will depend on the number of axes.

Data Record Map Key

Acronym Meaning

UB Unsigned byte

UW Unsigned word

SW Signed word

SL Signed long

UL Unsigned long

21 UB general output block 5 (outputs 41-48) 64-65 UW coordinated move status for S plane – see bit field map

22 UB general output block 6 (outputs 49-56) 66-69 SL distance traveled in coordinated move for S plane

Chapter 4 Software Tools and Communication ▫ 58 DMC-40x0 User Manual

below

general output block 7 (outputs 57-64)

70-71

Buffer space remaining – S Plane

general output block 8 (outputs 65-72)

72-73

segment count of coordinated move for T plane

25 UB general output block 9 (outputs 73-80) 74-75 UW Coordinated move status for T plane – see bit field map

below

28-29

Reserved

80-81

Buffer space remaining – T Plane

26-27 SW Reserved 76-79 SL distance traveled in coordinated move for T plane

Chapter 4 Software Tools and Communication ▫ 59 DMC-40x0 User Manual

Axis Information

ADDR

TYPE

ITEM

ADDR

TYPE

ITEM

85UBA axis stop code

229UBE axis stop code

86-89SLA axis reference position

230-233

E axis reference position

90-93SLA axis motor position

234-237

E axis motor position

94-97SLA axis position error

238-241

E axis position error

98-101

A axis auxiliary position

242-245

E axis auxiliary position

102-105

A axis velocity

246-249

E axis velocity

106-109

A axis torque

250-253

E axis torque

112UBA Hall Input Status

256UBE Hall Input Status

113UBReserved

257UBReserved

114-117

A User defined variable (ZA)

258-261

E User defined variable (ZE)

121UBB axis stop code

265UBF axis stop code

122-125

B axis reference position

266-269

F axis reference position

126-129

B axis motor position

270-273

F axis motor position

130-133

B axis position error

274-277

F axis position error

134-137

B axis auxiliary position

278-281

F axis auxiliary position

138-141

B axis velocity

282-285

F axis velocity

142-145

B axis torque

286-289

F axis torque

148UBB Hall Input Status

292UBF Hall Input Status

149UBReserved

293UBReserved

150-153

B User defined variable (ZB)

294-297

F User defined variable (ZF)

157UBC axis stop code

301UBG axis stop code

158-161

C axis reference position

302-305

G axis reference position

162-165

C axis motor position

306-309

G axis motor position

166-169

C axis position error

310-313

G axis position error

170-173

C axis auxiliary position

314-317

G axis auxiliary position

174-177

C axis velocity

318-321

G axis velocity

178-181

C axis torque

322-325

G axis torque

184UBC Hall Input Status

328UBG Hall Input Status

185UBReserved

329UBReserved

186-189

C User defined variable (ZC)

330-333

G User defined variable (ZG)

193UBD axis stop code

337UBH axis stop code

194-197

D axis reference position

338-341

H axis reference position

198-201

D axis motor position

342-345

H axis motor position

202-205

D axis position error

346-349

H axis position error

206-209

D axis auxiliary position

350-353

H axis auxiliary position

210-213

D axis velocity

354-357

H axis velocity

214-217

D axis torque

358-361

H axis torque

220UBD Hall Input Status

364UBH Hall Input Status

82-83 UW A axis status – see bit field map below 226-227 UW E axis status – see bit field map below

84 UB A axis switches – see bit field map below 228 UB E axis switches – see bit field map below

110-111 SW or UW 1A axis analog input 254-255 SW or UW 1E axis analog input

118-119 UW B axis status – see bit field map below 262-263 UW F axis status – see bit field map below

120 UB B axis switches – see bit field map below 264 UB F axis switches – see bit field map below

146-147 SW or UW 1B axis analog input 290-291 SW or UW 1F axis analog input

154-155 UW C axis status – see bit field map below 298-299 UW G axis status – see bit field map below

156 UB C axis switches – see bit field map below 300 UB G axis switches – see bit field map below

182-183 SW or UW 1C axis analog input 326-327 SW or UW 1G axis analog input

190-191 UW D axis status – see bit field map below 334-335 UW H axis status – see bit field map below

192 UB D axis switches – see bit field map below 336 UB H axis switches – see bit field map below

218-219 SW or UW 1D axis analog input 362-363 SW or UW 1H axis analog input

Chapter 4 Software Tools and Communication ▫ 60 DMC-40x0 User Manual

221UBReserved

365UBReserved

222-225

D User defined variable (ZD)

366-369

H User defined variable (ZH)

Will be either a Signed Word or Unsigned Word depending upon AQ setting. See AQ in the Command Reference for more information.

Chapter 4 Software Tools and Communication ▫ 61 DMC-40x0 User Manual

Data Record Bit Field Maps

Header Information - Byte 0, 1 of Header:

BIT 15 BIT 14 BIT 13 BIT 12 BIT 11 BIT 10 BIT 9 BIT 8

1 N/A N/A N/A N/A

I Block Present in Data Record

BIT 7 BIT 6 BIT 5 BIT 4 BIT 3 BIT 2 BIT 1 BIT 0

H Block Present

in Data Record

G Block Present

in Data Record

F Block Present

in Data Record

E Block Present

in Data Record

D Block Present

in Data Record

C Block Present

in Data Record

Bytes 2, 3 of Header:

Bytes 2 and 3 make a word which represents the Number of bytes in the data record, including the header.

Byte 2 is the low byte and byte 3 is the high byte

NOTE: The header information of the data records is formatted in little endian (reversed network byte order).

Thread Status (1 Byte)

BIT 7 BIT 6 BIT 5 BIT 4 BIT 3 BIT 2 BIT 1 BIT 0

Thread 7

Running

Thread 6

Running

Thread 5

Running

Thread 4

Running

Thread 3 Running

Thread 2

Running

Coordinated Motion Status for S or T Plane (2 Byte)

BIT 15 BIT 14 BIT 13 BIT 12 BIT 11 BIT 10 BIT 9 BIT 8

Move in

Progress

N/A N/A N/A N/A N/A N/A N/A

T Block Present

in Data Record

B Block Present

in Data Record

Thread 1

Running

S Block Present

in Data Record

A Block Present

in Data Record

Thread 0

Running

BIT 7 BIT 6 BIT 5 BIT 4 BIT 3 BIT 2 BIT 1 BIT 0

N/A N/A

Motion is

slewing

Motion is

stopping due to

ST or Limit

Switch

Motion is

making final

deceleration

N/A N/A N/A

Axis Status (1 Word)

BIT 15 BIT 14 BIT 13 BIT 12 BIT 11 BIT 10 BIT 9 BIT 8

Move in

Progress

Mode of

Motion PA or PR

Mode of

Motion PA only

(FE) Find Edge

in Progress

Home (HM) in

Progress

1st Phase of HM

complete

2nd Phase of HM

complete or FI

command

issued

BIT 7 BIT 6 BIT 5 BIT 4 BIT 3 BIT 2 BIT 1 BIT 0

Negative

Direction Move

Mode of

Motion

Contour

Motion is

slewing

Motion is

stopping due to

ST of Limit

Switch

Motion is

making final

deceleration

Latch is armed

3rd Phase of

HM in Progress

Axis Switches (1 Byte)

BIT 7 BIT 6 BIT 5 BIT 4 BIT 3 BIT 2 BIT 1 BIT 0

Latch Occurred

State of Latch

Input

N/A N/A

State of

Forward Limit

State of Reverse

Limit

State of Home

Input

Mode of

Motion Coord.

Motion

Motor Off

Stepper Mode

Chapter 4 Software Tools and Communication ▫ 62 DMC-40x0 User Manual

Amplifier Status (4 Bytes)

BIT 31 BIT 30 BIT 29 BIT 28 BIT 27 BIT 26 BIT 25 BIT 24

N/A N/A N/A N/A N/A N/A

ELO Active

(Axis E-H)

ELO Active

(Axis A-D)

BIT 23 BIT 22 BIT 21 BIT 20 BIT 19 BIT 18 BIT 17 BIT 16

Peak Current

H-axis

Peak Current

G-axis

Peak Current

F-axis

Peak Current

E-axis

Peak Current

D-axis

Peak Current

C-axis

Peak Current

B-axis

Peak current

A-axis

BIT 15 BIT 14 BIT 13 BIT 12 BIT 11 BIT 10 BIT 9 BIT 8

Hall Error

H-axis

Hall Error

G-axis

Hall Error

F-axis

Hall Error

E-axis

Hall Error

D-axis

Hall Error

C-axis

Hall Error

B-axis

Hall Error

A-axis

BIT 7 BIT 6 BIT 5 BIT 4 BIT 3 BIT 2 BIT 1 BIT 0

Under Voltage

Axis (E-H)

Over Temp.

Axis (E-H)

Over Voltage

Axis (E-H)

Over Current

Axis (E-H)

Under Voltage

Axis (A-D)

Over Temp.

Axis (A-D)

Over Voltage

Axis (A-D)

Over Current

Axis (A-D)

Notes Regarding Velocity and Torque Information

The velocity information that is returned in the data record is 64 times larger than the value returned when using the command TV (Tell Velocity). See command reference for more information about TV.

The Torque information is represented as a number in the range of ±32767. Maximum negative torque is -32767. Maximum positive torque is 32767. Zero torque is 0.

QZ Command

The QZ command can be very useful when using the QR command, since it provides information about the controller and the data record. The QZ command returns the following 4 bytes of information.

BYTE # INFORMATION

0 Number of axes present 1 number of bytes in general block of data record 2 number of bytes in coordinate plane block of data record 3 Number of Bytes in each axis block of data record

Chapter 4 Software Tools and Communication ▫ 63 DMC-40x0 User Manual

GalilSuite (Windows and Linux)

GalilSuite is Galil's latest set of development tools for the latest generation of Galil controllers. It is highly recommended for all first-time purchases of Galil controllers as it provides easy set-up, tuning and analysis. GalilSuite replaces GalilToolS with an improved user-interface, real-time scopes, advanced tuning methods, and communications utilities.

Supported Controllers

•DMC40x0

•DMC41x3

•DMC30010

•DMC21x3/2

•RIO47xxx

•DMC18x6 - PCI Driver required, separate installer

•DMC18x0 - PCI Driver required, separate installer

•DMC18x2* - PCI Driver required, separate installer

Contact Galil for other hardware products

Supported Operating Systems**

•Microsoft Windows 8

•Microsoft Windows 7

•Microsoft Windows XP SP3

•Scope, Watch, and Viewer support require an Ethernet or PCI connection and controller firmware

supporting the DR command

* No Scope, Watch, or Viewer support. ** Contact Galil for other OS options.

The GalilSuitecontains the following tools:

Tool Description

Launcher Launcher Tool with the ability to create custom profiles to manage controller connections

Terminal For sending and receiving Galil commands

Editor To easily create and work on multiple Galil programs simultaneously

Viewer To see a complete status of all controllers on a single screen

Scope For viewing and manipulating data for multiple controllers real-time

Watch For simplified debugging of any controller on the system and a display of I/O and motion status

Tuner With up to four methods for automatic and manual PID tuning of servo systems

Configuration For modifying controller settings, backup/restore and firmware download

The latest version of GalilSuite can be downloaded here:

http://www.galilmc.com/support/software-downloads.php

For information on using GalilSuite see the user manual:

http://www.galilmc.com/support/manuals.php

Chapter 4 Software Tools and Communication ▫ 64 DMC-40x0 User Manual

Creating Custom Software Interfaces

Galil provides programming tools so that users can develop their own custom software interfaces to a Galil controller. For new applications, Galil recommends the GalilTools Communication Libraries.

HelloGalil – Quick Start to PC programming

For programmers developing Windows applications that communicate with a Galil controller, the HelloGalil library of quick start projects immediately gets you communicating with the controller from the programming language of your choice. In the "Hello World" tradition, each project contains the bare minimum code to demonstrate communication to the controller and simply prints the controller's model and serial numbers to the screen Figure

4.1.

Figure 4.1: Sample program output

http://www.galilmc.com/support/hello_galil.html

Galil Communication Libraries

The Galil Communication Library (Galil class) provides methods for communication with a Galil motion controller over Ethernet, RS-232 or PCI buses. It consists of a native C++ Library and a similar COM interface which extends compatibility to Windows programming languages (e.g. VB, C#, etc).

A Galil object (usually referred to in sample code as "g") represents a single connection to a Galil controller.

For Ethernet controllers, which support more than one connection, multiple objects may be used to communicate with the controller. An example of multiple objects is one Galil object containing a TCP handle to a DMC-40x0 for commands and responses, and one Galil object containing a UDP handle for unsolicited messages from the controller. If recordsStart() is used to begin the automatic data record function, the library will open an additional UDP handle to the controller (transparent to the user).

The library is conceptually divided into six categories:

1. Connecting and Disconnecting - functions to establish and discontinue communication with a controller.

2. Basic Communication - The most heavily used functions for command-and-response and unsolicited messages.

3. Programs - Downloading and uploading embedded programs.

4. Arrays - Downloading and uploading array data.

5. Advanced - Lesser-used calls.

6. Data Record - Access to the data record in both synchronous and asynchronous modes.

Chapter 4 Software Tools and Communication ▫ 65 DMC-40x0 User Manual

C++ Library (Windows and Linux)

Both Full and Lite versions of GalilTools ship with a native C++ communication library. The Linux version (libGalil.so) is compatible with g++ and the Windows version (Galil1.dll) with Visual C++ 2008. Contact Galil if another version of the C++ library is required. See the getting started guide and the hello.cpp example in /lib.

COM (Windows)

To further extend the language compatibility on Windows, a COM (Component Object Model) class built on top of the C++ library is also provided with Windows releases. This COM wrapper can be used in any language and IDE supporting COM (Visual Studio 2005, 2008, etc). The COM wrapper includes all of the functionality of the base C++ class. See the getting started guide and the hello.* examples in \lib for more info.

For more information on the GalilTools Communications Library, see the online user manual.

http://www.galilmc.com/support/manuals/galiltools/library.html

Chapter 4 Software Tools and Communication ▫ 66 DMC-40x0 User Manual

Chapter 5 Command Basics

Introduction

The DMC-40x0 provides over 100 commands for specifying motion and machine parameters. Commands are included to initiate action, interrogate status and configure the digital filter. These commands are sent in ASCII.

The DMC-40x0 instruction set is BASIC-like and easy to use. Instructions consist of two uppercase letters that correspond phonetically with the appropriate function. For example, the instruction BG begins motion, and ST stops the motion.

Commands can be sent "live" over the communications port for immediate execution by the DMC-40x0, or an entire group of commands can be downloaded into the DMC-40x0 memory for execution at a later time. Combining commands into groups for later execution is referred to as Applications Programming and is discussed in the following chapter.

This section describes the DMC-40x0 instruction set and syntax. A summary of commands as well as a complete listing of all DMC-40x0 instructions is included in the Command Reference.

Command Syntax - ASCII

DMC-40x0 instructions are represented by two ASCII upper case characters followed by applicable arguments. A space may be inserted between the instruction and arguments. A semicolon or <return> is used to terminate the instruction for processing by the DMC-40x0 command interpreter.

NOTE: If you are using a Galil terminal program, commands will not be processed until an <return> command is given. This allows the user to separate many commands on a single line and not begin execution until the user gives the <return> command.

NOTE

For example, the command

PR 4000 <return> Position relative

Implicit Notation

PR is the two character instruction for position relative. 4000 is the argument which represents the required position value in counts. The <return> terminates the instruction. The space between PR and 4000 is optional.

Chapter 5 Command Basics ▫ 67 DMC-40x0 User Manual

All DMC commands are two-letters sent in upper case!

For specifying data for the A,B,C and D axes, commas are used to separate the axes. If no data is specified for an

4080

axis, a comma is still needed as shown in the examples below. If no data is specified for an axis, the previous value is maintained.

To view the current values for each command, type the command followed by a ? for each axis requested.

PR 1000 PR ,2000 PR ,,3000 PR ,,,4000 PR 2000, 4000,6000, 8000 PR ,8000,,9000 PR ?,?,?,? PR ,?

Specify A only as 1000 Specify B only as 2000 Specify C only as 3000 Specify D only as 4000 Specify A,B,C and D Specify B and D only Request A,B,C,D values Request B value only

Explicit Notation

The DMC-40x0 provides an alternative method for specifying data. Here data is specified individually using a single axis specifier such as A, B, C or D. An equals sign is used to assign data to that axis. For example:

Instead of data, some commands request action to occur on an axis or group of axes. For example, ST AB stops motion on both the A and B axes. Commas are not required in this case since the particular axis is specified by the appropriate letter A, B, C or D. If no parameters follow the instruction, action will take place on all axes. Here are some examples of syntax for requesting action:

PRA=1000 ACB=200000

BG A BG B BG ABCD BG BD BG

Specify a position relative movement for the A axis of 1000 Specify acceleration for the B axis as 200000

Begin A only Begin B only Begin all axes Begin B and D only Begin all axes

For controllers with 5 or more axes, the axes are referred to as A,B,C,D,E,F,G,H. The specifiers X,Y,Z,W and A,B,C,D may be used interchangeably.

BG ABCDEFGH

BG D

Begin all axes

Begin D only

Coordinated Motion with more than 1 axis

When requesting action for coordinated motion, the letter S or T is used to specify the coordinated motion. This allows for coordinated motion to be setup for two separate coordinate systems. Refer to the CA command in the Command Reference for more information on specifying a coordinate system. For example:

BG S BG TD

Begin coordinated sequence, S Begin coordinated sequence, T, and D axis

Controller Response to DATA

The DMC-40x0 returns a : for valid commands and a ? for invalid commands.

For example, if the command BG is sent in lower case, the DMC-40x0 will return a ?.

:bg ?

When the controller receives an invalid command the user can request the error code. The error code will specify the reason for the invalid command response. To request the error code type the command TC1. For example:

invalid command, lower case DMC-40x0 returns a ?

Chapter 5 Command Basics ▫ 68 DMC-40x0 User Manual

?TC1

1 Unrecognized command

Tell Code command Returned response

There are many reasons for receiving an invalid command response. The most common reasons are: unrecognized command (such as typographical entry or lower case), command given at improper time (such as during motion), or a command out of range (such as exceeding maximum speed). A complete listing of all codes is listed in the TC command in the Command Reference section.

Interrogating the Controller

Interrogation Commands

The DMC-40x0 has a set of commands that directly interrogate the controller. When the command is entered, the requested data is returned in decimal format on the next line followed by a carriage return and line feed. The format of the returned data can be changed using the Position Format (PF), Variable Format (VF) and Leading Zeros (LZ) command. See Chapter 7 Application Programming and the Command Reference.

Summary of Interrogation Commands

RP RL

^R^V

SC TA TB TC TD TE TI TP TR TS TT TV

Report Command Position Report Latch Firmware Revision Information Stop Code Tell Amplifier Error Tell Status Tell Error Code Tell Dual Encoder Tell Error Tell Input Tell Position Trace Tell Switches Tell Torque Tell Velocity

For example, the following example illustrates how to display the current position of the X axis:

TP A

TP AB

0,0

Tell position A

Controllers Response

Tell position A and B

Controllers Response

Interrogating Current Commanded Values.

Most commands can be interrogated by using a question mark (?) as the axis specifier. Type the command followed by a ? for each axis requested.

PR ?,?,?,?

PR ,?

The controller can also be interrogated with operands.

Chapter 5 Command Basics ▫ 69 DMC-40x0 User Manual

Request A,B,C,D values

Request B value only

Operands

Most DMC-40x0 commands have corresponding operands that can be used for interrogation. Operands must be used inside of valid DMC expressions. For example, to display the value of an operand, the user could use the command:

MG ‘operand’ where ‘operand’ is a valid DMC operand

All of the command operands begin with the underscore character (_). For example, the value of the current position on the A axis can be assigned to the variable ‘V’ with the command:

V=_TPA

The Command Reference denotes all commands which have an equivalent operand as "Operand Usage". Also, see description of operands in Chapter 7 Application Programming.

Command Summary

For a complete command summary, see Command Reference manual.

http://www.galilmc.com/support/manuals.php

Chapter 5 Command Basics ▫ 70 DMC-40x0 User Manual

Chapter 6 Programming Motion

4080

Overview

The DMC-40x0 provides several modes of motion, including independent positioning and jogging, coordinated motion, electronic cam motion, and electronic gearing. Each one of these modes is discussed in the following sections.

The DMC-4010 are single axis controllers and use X-axis motion only. Likewise, the DMC-4020 use X and Y, the DMC-4030 use X,Y, and Z, and the DMC-4040 use X,Y,Z, and W. The DMC-4050 use A,B,C,D, and E. The DMC-4060 use A,B,C,D,E, and F. The DMC-4070 use A,B,C,D,E,F, and G. The DMC-4080 use the axes A,B,C,D,E,F,G, and H.

The example applications described below will help guide you to the appropriate mode of motion.

For controllers with 5 or more axes, the specifiers, ABCDEFGH, are used. XYZ and W may be interchanged with ABCD.

EXAMPLE APPLICATION MODE OF MOTION COMMANDS

Absolute or relative positioning where each axis is independent and follows prescribed velocity profile. Velocity control where no final endpoint is prescribed. Motion stops on Stop command. Absolute positioning mode where absolute position targets may be sent to the controller while the axis is in motion. Motion Path described as incremental position points versus time. Motion Path described as incremental position, velocity and delta time 2 to 8 axis coordinated motion where path is described by linear segments. 2-D motion path consisting of arc segments and linear segments, such as engraving or quilting. Third axis must remain tangent to 2-D motion path, such as knife cutting. Electronic gearing where slave axes are scaled to master axis which can move in both directions. Master/slave where slave axes must follow a master such as conveyer speed.

Independent Axis Positioning

Independent Jogging

Position Tracking

Contour Mode

PVT Mode

Linear Interpolation Mode

Vector Mode: Linear and Circular Interpolation Motion

Coordinated motion with Tangent Motion:

Electronic Gearing

Electronic Gearingwith Ramped Gearing

PA, PR, SP, AC, DC

JG, AC, DC, ST

PA, AC, DC, SP, PT

CM, CD, DT

PV, BT

LM, LI, LE, VS,VR, VA, VD

VM, VP, CR, VS,VR, VA, VD, VE

VM, VP, CR, VS,VA,VD, TN, VE

GA, GD, _GP, GR, GM (if gantry)

GA, GD, _GP, GR

Chapter 6 Programming Motion ▫ 71 DMC-40x0 User Manual

Moving along arbitrary profiles or mathematically prescribed profiles such as sine or cosine trajectories. Teaching or Record and Play Back Contour Mode with Teach (Record and Play-

Backlash Correction Dual Loop (Auxiliary Encoder) Following a trajectory based on a master encoder position Smooth motion while operating in independent axis positioning Smooth motion while operating in vector or linear interpolation positioning Smooth motion while operating with stepper motors Gantry - two axes are coupled by gantry Example - Gantry Mode

Contour Mode

Back)

Electronic Cam

Independent Motion Smoothing

Motion Smoothing

Using the KS Command (Step Motor Smoothing):

CM, CD, DT

CM, CD, DT, RA, RD, RC

DV EA, EM, EP, ET, EB, EG, EQ IT

GR, GM

Independent Axis Positioning

In this mode, motion between the specified axes is independent, and each axis follows its own profile. The user specifies the desired absolute position (PA) or relative position (PR), slew speed (SP), acceleration ramp (AC), and deceleration ramp (DC), for each axis. On begin (BG), the DMC-40x0 profiler generates the corresponding trapezoidal or triangular velocity profile and position trajectory. The controller determines a new command position along the trajectory every sample period until the specified profile is complete. Motion is complete when the last position command is sent by the DMC-40x0 profiler. Note: The actual motor motion may not be complete when the profile has been completed, however, the next motion command may be specified.

The Begin (BG) command can be issued for all axes either simultaneously or independently. XYZ or W axis specifiers are required to select the axes for motion. When no axes are specified, this causes motion to begin on all axes.

The speed (SP) and the acceleration (AC) can be changed at any time during motion, however, the deceleration (DC) and position (PR or PA) cannot be changed until motion is complete. Remember, motion is complete when the profiler is finished, not when the actual motor is in position. The Stop command (ST) can be issued at any time to decelerate the motor to a stop before it reaches its final position.

An incremental position movement (IP) may be specified during motion as long as the additional move is in the same direction. Here, the user specifies the desired position increment, n. The new target is equal to the old target plus the increment, n. Upon receiving the IP command, a revised profile will be generated for motion towards the new end position. The IP command does not require a begin. Note: If the motor is not moving, the IP command is equivalent to the PR and BG command combination.

Command Summary - Independent Axis

COMMAND DESCRIPTION

PR x,y,z,w PA x,y,z,w SP x,y,z,w AC x,y,z,w DC x,y,z,w BG XYZW ST XYZW IP x,y,z,w IT x,y,z,w AM XYZW MC XYZW

Specifies relative distance Specifies absolute position Specifies slew speed Specifies acceleration rate Specifies deceleration rate Starts motion Stops motion before end of move Changes position target Time constant for independent motion smoothing Trippoint for profiler complete Trippoint for “in position”

Chapter 6 Programming Motion ▫ 72 DMC-40x0 User Manual

The lower case specifiers (x,y,z,w) represent position values for each axis.

The DMC-40x0 also allows use of single axis specifiers such as PRY=2000

Operand Summary - Independent Axis

OPERAND DESCRIPTION

_ACx _DCx _SPx _PAx

_PRx

Example - Absolute Position Movement

PA 10000,20000 AC 1000000,1000000 DC 1000000,1000000 SP 50000,30000 BG XY

Example - Multiple Move Sequence

Required Motion Profiles:

X-Axis 500 counts Position

Return acceleration rate for the axis specified by ‘x’ Return deceleration rate for the axis specified by ‘x’ Returns the speed for the axis specified by ‘x’ Returns current destination if ‘x’ axis is moving, otherwise returns the current commanded position if in a move. Returns current incremental distance specified for the ‘x’ axis

Specify absolute X,Y position Acceleration for X,Y Deceleration for X,Y Speeds for X,Y Begin motion

20000 count/sec Speed

500000 counts/sec

2 Acceleration

Y-Axis 1000 counts Position

10000 count/sec Speed

500000 counts/sec

2 Acceleration

Z-Axis 100 counts Position

5000 counts/sec Speed

500000 counts/sec Acceleration

This example will specify a relative position movement on X, Y and Z axes. The movement on each axis will be separated by 20 msec. Figure 6.1 shows the velocity profiles for the X,Y and Z axis.

#A PR 2000,500,100 SP 20000,10000,5000 AC 500000,500000,500000 DC 500000,500000,500000 BG X WT 20 BG Y WT 20 BG Z EN

Begin Program Specify relative position movement of 2000, 500 and 100 counts for X,Y and Z axes. Specify speed of 20000, 10000, and 5000 counts / sec Specify acceleration of 500000 counts / sec2 for all axes Specify deceleration of 500000 counts / sec2 for all axes Begin motion on the X axis Wait 20 msec Begin motion on the Y axis Wait 20 msec Begin motion on Z axis End Program

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Figure 6.1: Velocity Profiles of XYZ

VELOCITY (COUNTS/SEC)

20000

10000

5000

15000

40 60

TIME (ms)

100

X axis velocity profile

Y axis velocity profile

Z axis velocity profile

Notes on Figure 6.1: The X and Y axis have a ‘trapezoidal’ velocity profile, while the Z axis has a ‘triangular’ velocity profile. The X and Y axes accelerate to the specified speed, move at this constant speed, and then decelerate such that the final position agrees with the command position, PR. The Z axis accelerates, but before the specified speed is achieved, must begin deceleration such that the axis will stop at the commanded position. All 3 axes have the same acceleration and deceleration rate, hence, the slope of the rising and falling edges of all 3 velocity profiles are the same.

Independent Jogging

The jog mode of motion is very flexible because speed, direction and acceleration can be changed during motion. The user specifies the jog speed (JG), acceleration (AC), and the deceleration (DC) rate for each axis. The direction of motion is specified by the sign of the JG parameters. When the begin command is given (BG), the motor accelerates up to speed and continues to jog at that speed until a new speed or stop (ST) command is issued. If the jog speed is changed during motion, the controller will make a accelerated (or decelerated) change to the new speed.

An instant change to the motor position can be made with the use of the IP command. Upon receiving this command, the controller commands the motor to a position which is equal to the specified increment plus the current position. This command is useful when trying to synchronize the position of two motors while they are moving.

Note that the controller operates as a closed-loop position controller while in the jog mode. The DMC-40x0 converts the velocity profile into a position trajectory and a new position target is generated every sample period. This method of control results in precise speed regulation with phase lock accuracy.

Command Summary - Jogging

COMMAND DESCRIPTION

AC x,y,z,w BG XYZW DC x,y,z,w IP x,y,z,w IT x,y,z,w JG ±x,y,z,w ST XYZW

Parameters can be set with individual axes specifiers such as JGY=2000 (set jog speed for Y axis to 2000).

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Specifies acceleration rate Begins motion Specifies deceleration rate Increments position instantly Time constant for independent motion smoothing Specifies jog speed and direction Stops motion

Operand Summary - Independent Axis

OPERAND DESCRIPTION

_ACx _DCx _SPx _TVx

Example - Jog in X only

Jog X motor at 50000 count/s. After X motor is at its jog speed, begin jogging Z in reverse direction at 25000 count/s.

#A AC 20000,,20000 DC 20000,,20000 JG 50000,,-25000 BG X AS X BG Z EN

Example - Joystick Jogging

The jog speed can also be changed using an analog input such as a joystick. Assume that for a 10 Volt input the speed must be 50000 counts/sec.

#JOY JG0 BGX #B V1 =@AN[1] VEL=V1*50000/10 JG VEL JP #B

Return acceleration rate for the axis specified by ‘x’ Return deceleration rate for the axis specified by ‘x’ Returns the jog speed for the axis specified by ‘x’ Returns the actual velocity of the axis specified by ‘x’ (averaged over 0.25 sec)

Specify X,Z acceleration of 20000 counts / sec Specify X,Z deceleration of 20000 counts / sec Specify jog speed and direction for X and Z axis Begin X motion Wait until X is at speed Begin Z motion

Label Set in Jog Mode Begin motion Label for loop Read analog input Compute speed Change JG speed Loop

Position Tracking

The Galil controller may be placed in the position tracking mode to support changing the target of an absolute position move on the fly. New targets may be given in the same direction or the opposite direction of the current position target. The controller will then calculate a new trajectory based upon the new target and the acceleration, deceleration, and speed parameters that have been set. The motion profile in this mode is trapezoidal. There is not a set limit governing the rate at which the end point may be changed, however at the standard TM rate, the controller updates the position information at the rate of 1msec. The controller generates a profiled point every other sample, and linearly interpolates one sample between each profiled point. Some examples of applications that may use this mode are satellite tracking, missile tracking, random pattern polishing of mirrors or lenses, or any application that requires the ability to change the endpoint without completing the previous move.

The PA command is typically used to command an axis or multiple axes to a specific absolute position. For some applications such as tracking an object, the controller must proceed towards a target and have the ability to change the target during the move. In a tracking application, this could occur at any time during the move or at regularly scheduled intervals. For example if a robot was designed to follow a moving object at a specified distance and the path of the object wasn’t known the robot would be required to constantly monitor the motion of the object that it was following. To remain within a specified distance it would also need to constantly update the position target it is moving towards. Galil motion controllers support this type of motion with the position tracking mode. This mode will allow scheduled or random updates to the current position target on the fly. Based on the new target the controller will either continue in the direction it is heading, change the direction it is moving, or decelerate to a stop.

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The position tracking mode shouldn’t be confused with the contour mode. The contour mode allows the user to generate custom profiles by updating the reference position at a specific time rate. In this mode, the position can be updated randomly or at a fixed time rate, but the velocity profile will always be trapezoidal with the parameters specified by AC, DC, and SP. Updating the position target at a specific rate will not allow the user to create a custom profile.

The following example will demonstrate the possible different motions that may be commanded by the controller in the position tracking mode. In this example, there is a host program that will generate the absolute position targets. The absolute target is determined based on the current information the host program has gathered on the object that it is tracking. The position tracking mode does allow for all of the axes on the controller to be in this mode, but for the sake of discussion, it is assumed that the robot is tracking only in the X dimension.

The controller must be placed in the position tracking mode to allow on the fly absolute position changes. This is performed with the PT command. To place the X axis in this mode, the host would issue PT1 to the controller if both X and Y axes were desired the command would be PT 1,1. The next step is to begin issuing PA command to the controller. The BG command isn’t required in this mode, the SP, AC, and DC commands determine the shape of the trapezoidal velocity profile that the controller will use.

Example - Motion 1:

The host program determines that the first target for the controller to move to is located at 5000 encoder counts. The acceleration and deceleration should be set to 150,000 counts/sec2 and the velocity is set to 50,000 counts/sec. The command sequence to perform this is listed below.

#EX1 PT 1;' Place the X axis in Position tracking mode AC 150000;' Set the X axis acceleration to 150000 counts/sec2 DC 150000;' Set the X axis deceleration to 150000 counts/sec2 SP 50000;' Set the X axis speed to 50000 counts/sec PA 5000;' Command the X axis to absolute position 5000 encoder counts EN

The output from this code can be seen in Figure 6.2, a screen capture from the GalilTools scope.

Figure 6.2: Position vs Time (msec) - Motion 1

Example - Motion 2:

The previous step showed the plot if the motion continued all the way to 5000, however partway through the motion, the object that was being tracked changed direction, so the host program determined that the actual target position should be 2000 counts at that time. Figure 6.2 shows what the position profile would look like if the move was allowed to complete to 5000 counts. The position was modified when the robot was at a position of 4200 counts (Figure 6.3). Note that the robot actually travels to a distance of almost 5000 counts before it turns around. This is a function of the deceleration rate set by the DC command. When a direction change is

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commanded, the controller decelerates at the rate specified by the DC command. The controller then ramps the velocity in up to the value set with SP in the opposite direction traveling to the new specified absolute position. Figure 6.3 the velocity profile is triangular because the controller doesn’t have sufficient time to reach the set speed of 50000 counts/sec before it is commanded to change direction.

The below code is used to simulate this scenario:

#EX2 PT 1;' Place the X axis in Position tracking mode AC 150000;' Set the X axis acceleration to 150000 counts/sec2 DC 150000;' Set the X axis deceleration to 150000 counts/sec2 SP 50000;' Set the X axis speed to 50000 counts/sec PA 5000;' Command the X axis to abs position 5000 encoder counts MF 4200 PA 2000;' Change end point position to position 2000 EN

Figure 6.3: Position and Velocity vs Time (msec) for Motion 2

Example - Motion 3:

In this motion, the host program commands the controller to begin motion towards position 5000, changes the target to -2000, and then changes it again to 8000. Figure 6.4 shows the plot of position vs. time and velocity vs. time. Below is the code that is used to simulate this scenario:

#EX3 PT 1;' Place the X axis in Position tracking mode AC 150000;' Set the X axis acceleration to 150000 counts/sec2 DC 150000;' Set the X axis deceleration to 150000 counts/sec2 SP 50000;' Set the X axis speed to 50000 counts/sec PA 5000;' Command the X axis to abs position 5000 encoder counts WT 300 PA -2000;' Change end point position to -2000 WT 200 PA 8000;' Change end point position to 8000 EN

Figure 6.5 demonstrates the use of motion smoothing (IT) on the velocity profile in this mode. The jerk in the system is also affected by the values set for AC and DC.

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Figure 6.4: Position and Velocity vs Time (msec) for Motion 3

Figure 6.5: Position and Velocity vs Time (msec) for Motion 3 with IT 0.1

Note the controller treats the point where the velocity passes through zero as the end of one move, and the beginning of another move. IT is allowed, however it will introduce some time delay.

Trippoints

Most trippoints are valid for use while in the position tracking mode. There are a few exceptions to this; the AM and MC commands may not be used while in this mode. It is recommended that MF, MR, or AP be used, as they involve motion in a specified direction, or the passing of a specific absolute position.

Command Summary – Position Tracking Mode

COMMAND DESCRIPTION

AC n,n,n,n,n,n,n,n AP n,n,n,n,n,n,n,n DC n,n,n,n,n,n,n,n MF n,n,n,n,n,n,n,n

MR n,n,n,n,n,n,n,n

PT n,n,n,n,n,n,n,n PA n,n,n,n,n,n,n,n SP n,n,n,n,n,n,n,n

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Acceleration settings for the specified axes Trippoint that holds up program execution until an absolute position has been reached Deceleration settings for the specified axes Trippoint to hold up program execution until n number of counts have passed in the forward direction. Only one axis at a time may be specified. Trippoint to hold up program execution until n number of counts have passed in the reverse direction. Only one axis at a time may be specified. Command used to enter and exit the Trajectory Modification Mode Command Used to specify the absolute position target Speed settings for the specified axes

Linear Interpolation Mode

The DMC-40x0 provides a linear interpolation mode for 2 or more axes. In linear interpolation mode, motion between the axes is coordinated to maintain the prescribed vector speed, acceleration, and deceleration along the specified path. The motion path is described in terms of incremental distances for each axis. An unlimited number of incremental segments may be given in a continuous move sequence, making the linear interpolation mode ideal for following a piece-wise linear path. There is no limit to the total move length.

The LM command selects the Linear Interpolation mode and axes for interpolation. For example, LM YZ selects only the Y and Z axes for linear interpolation.

When using the linear interpolation mode, the LM command only needs to be specified once unless the axes for linear interpolation change.

Specifying Linear Segments

The command LI x,y,z,w or LI a,b,c,d,e,f,g,h specifies the incremental move distance for each axis. This means motion is prescribed with respect to the current axis position. Up to 511 incremental move segments may be given prior to the Begin Sequence (BGS) command. Once motion has begun, additional LI segments may be sent to the controller.

The clear sequence (CS) command can be used to remove LI segments stored in the buffer prior to the start of the motion. To stop the motion, use the instructions STS or AB. The command, ST, causes a decelerated stop. The command, AB, causes an instantaneous stop and aborts the program, and the command AB1 aborts the motion only.

The Linear End (LE) command must be used to specify the end of a linear move sequence. This command tells the controller to decelerate to a stop following the last LI command. If an LE command is not given, an Abort AB1 must be used to abort the motion sequence.

It is the responsibility of the user to keep enough LI segments in the DMC-40x0 sequence buffer to ensure continuous motion. If the controller receives no additional LI segments and no LE command, the controller will stop motion instantly at the last vector. There will be no controlled deceleration. LM? or _LM returns the available spaces for LI segments that can be sent to the buffer. 511 returned means the buffer is empty and 511 LI segments can be sent. A zero means the buffer is full and no additional segments can be sent. As long as the buffer is not full, additional LI segments can be sent at PC bus speeds.

The instruction _CS returns the segment counter. As the segments are processed, _CS increases, starting at zero. This function allows the host computer to determine which segment is being processed.

Additional Commands

The commands VS n, VA n, and VD n are used to specify the vector speed, acceleration and deceleration. The DMC40x0 computes the vector speed based on the axes specified in the LM mode. For example, LM XYZ designates linear interpolation for the X,Y and Z axes. The vector speed for this example would be computed using the equation:

VS2=XS2+YS2+ZS2, where XS, YS and ZS are the speed of the X,Y and Z axes.

The controller always uses the axis specifications from LM, not LI, to compute the speed.

IT is used to set the S-curve smoothing constant for coordinated moves. The command AV n is the ‘After Vector’ trippoint, which halts program execution until the vector distance of n has been reached.

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An Example of Linear Interpolation Motion:

#LMOVE DP 0,0 LMXY LI 5000,0 LI 0,5000 LE VS 4000 BGS AV 4000 VS 1000 AV 5000 VS 4000 EN

In this example, the XY system is required to perform a 90 turn. In order to slow the speed around the corner, we  use the AV 4000 trippoint, which slows the speed to 1000 count/s. Once the motors reach the corner, the speed is increased back to 4000 counts / s.

label Define position of X and Y axes to be 0 Define linear mode between X and Y axes. Specify first linear segment Specify second linear segment End linear segments Specify vector speed Begin motion sequence Set trippoint to wait until vector distance of 4000 is reached Change vector speed Set trippoint to wait until vector distance of 5000 is reached Change vector speed Program end

Specifying Vector Speed for Each Segment

The instruction VS has an immediate effect and, therefore, must be given at the required time. In some applications, such as CNC, it is necessary to attach various speeds to different motion segments. This can be done by two functions: < n and > m

For example:LI x,y,z,w < n >m

The first command, < n, is equivalent to commanding VSn at the start of the given segment and will cause an acceleration toward the new commanded speeds, subjects to the other constraints.

The second function, > m, requires the vector speed to reach the value m at the end of the segment. Note that the function > m may start the deceleration within the given segment or during previous segments, as needed to meet the final speed requirement, under the given values of VA and VD.

Note, however, that the controller works with one > m command at a time. As a consequence, one function may be masked by another. For example, if the function >100000 is followed by >5000, and the distance for deceleration is not sufficient, the second condition will not be met. The controller will attempt to lower the speed to 5000, but will reach that at a different point.

As an example, consider the following program.

#ALT DP 0,0 LMXY LI 4000,0 <4000 >1000 LI 1000,1000 < 4000 >1000 LI 0,5000 < 4000 >1000 LE BGS EN

Label for alternative program Define Position of X and Y axis to be 0 Define linear mode between X and Y axes. Specify first linear segment with a vector speed of 4000 and end speed 1000 Specify second linear segment with a vector speed of 4000 and end speed 1000 Specify third linear segment with a vector speed of 4000 and end speed 1000 End linear segments Begin motion sequence Program end

Changing Feed Rate:

The command VR n allows the feed rate, VS, to be scaled between 0 and 10 with a resolution of .0001. This command takes effect immediately and causes VS to be scaled. VR also applies when the vector speed is specified with the ‘<’ operator. This is a useful feature for feed rate override. VR does not ratio the accelerations. For example, VR .5 results in the specification VS 2000 to be divided in half.

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Command Summary - Linear Interpolation

VS VZ VW 

2 2

COMMAND DESCRIPTION

LM xyzw LM abcdefgh

LM?

LI x,y,z,w < n LI a,b,c,d,e,f,g,h < n

VS n VA n VD n VR n BGS CS LE LE? AMS AV n IT

Specify axes for linear interpolation (same) controllers with 5 or more axes Returns number of available spaces for linear segments in DMC-40x0 sequence buffer. Zero means buffer full. 511 means buffer empty. Specify incremental distances relative to current position, and assign vector speed n. Specify vector speed Specify vector acceleration Specify vector deceleration Specify the vector speed ratio Begin Linear Sequence Clear sequence Linear End- Required at end of LI command sequence Returns the length of the vector (resets after 2147483647) Trippoint for After Sequence complete Trippoint for After Relative Vector distance, n S curve smoothing constant for vector moves

Operand Summary - Linear Interpolation

OPERAND DESCRIPTION

_AV _CS _LE _LM

_VPm

Return distance traveled Segment counter - returns number of the segment in the sequence, starting at zero. Returns length of vector (resets after 2147483647) Returns number of available spaces for linear segments in DMC-40x0 sequence buffer. Zero means buffer full. 511 means buffer empty. Return the absolute coordinate of the last data point along the trajectory. (m=X,Y,Z or W or A,B,C,D,E,F,G or H)

To illustrate the ability to interrogate the motion status, consider the first motion segment of our example, #LMOVE, where the X axis moves toward the point X=5000. Suppose that when X=3000, the controller is interrogated using the command ‘MG _AV’. The returned value will be 3000. The value of _CS, _VPX and _VPY will be zero.

Now suppose that the interrogation is repeated at the second segment when Y=2000. The value of _AV at this point is 7000, _CS equals 1, _VPX=5000 and _VPY=0.

Example - Linear Move

Make a coordinated linear move in the ZW plane. Move to coordinates 40000,30000 counts at a vector speed of 100000 counts/sec and vector acceleration of 1000000 counts/sec2.

LM ZW LI,,40000,30000 LE VS 100000 VA 1000000 VD 1000000 BGS

Note that the above program specifies the vector speed, VS, and not the actual axis speeds VZ and VW. The axis speeds are determined by the controller from:

Specify axes for linear interpolation Specify ZW distances Specify end move Specify vector speed Specify vector acceleration Specify vector deceleration Begin sequence

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The result is shown in Figure 6.6: Linear Interpolation.

POSITION Z

40000

FEEDRATE

0.1

0.5

0.6

4000

36000

30000

27000

3000

VELOCITY

Z-AXIS

VELOCITY

W-AXIS

POSITION W

TIME (sec)

Figure 6.6: Linear Interpolation

Example - Multiple Moves

This example makes a coordinated linear move in the XY plane. The Arrays VX and VY are used to store 750 incremental distances which are filled by the program #LOAD.

#LOAD DM VX [750],VY [750] COUNT=0 N=0 #LOOP VX [COUNT]=N VY [COUNT]=N N=N+10 COUNT=COUNT+1 JP #LOOP,COUNT<750 #A LM XY COUNT=0 #LOOP2;JP#LOOP2,_LM=0 JS#C,COUNT=500 LI VX[COUNT],VY[COUNT] COUNT=COUNT+1 JP #LOOP2,COUNT<750 LE AMS MG “DONE” EN #C;BGS;EN

Load Program Define Array Initialize Counter Initialize position increment LOOP Fill Array VX Fill Array VY Increment position Increment counter Loop if array not full Label Specify linear mode for XY Initialize array counter If sequence buffer full, wait Begin motion on 500th segment Specify linear segment Increment array counter Repeat until array done End Linear Move After Move sequence done Send Message End program Begin Motion Subroutine

Vector Mode: Linear and Circular Interpolation Motion

The DMC-40x0 allows a long 2-D path consisting of linear and arc segments to be prescribed. Motion along the path is continuous at the prescribed vector speed even at transitions between linear and circular segments. The

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DMC-40x0 performs all the complex computations of linear and circular interpolation, freeing the host PC from this time intensive task.

The coordinated motion mode is similar to the linear interpolation mode. Any pair of two axes may be selected for coordinated motion consisting of linear and circular segments. In addition, a third axis can be controlled such that it remains tangent to the motion of the selected pair of axes. Note that only one pair of axes can be specified for coordinated motion at any given time.

The command VM m,n,p where ‘m’ and ‘n’ are the coordinated pair and p is the tangent axis (Note: the commas which separate m,n and p are not necessary). For example, VM XWZ selects the XW axes for coordinated motion and the Z-axis as the tangent.

Specifying the Coordinate Plane

The DMC-40x0 allows for 2 separate sets of coordinate axes for linear interpolation mode or vector mode. These two sets are identified by the letters S and T.

To specify vector commands the coordinate plane must first be identified. This is done by issuing the command CAS to identify the S plane or CAT to identify the T plane. All vector commands will be applied to the active coordinate system until changed with the CA command.

Specifying Vector Segments

The motion segments are described by two commands; VP for linear segments and CR for circular segments. Once a set of linear segments and/or circular segments have been specified, the sequence is ended with the command VE. This defines a sequence of commands for coordinated motion. Immediately prior to the execution of the first coordinated movement, the controller defines the current position to be zero for all movements in a sequence. Note: This ‘local’ definition of zero does not affect the absolute coordinate system or subsequent coordinated motion sequences.

The command, VP x,y specifies the coordinates of the end points of the vector movement with respect to the starting point. Non-sequential axis do not require comma delimitation. The command, CR r,q,d define a circular arc with a radius r, starting angle of q, and a traversed angle d. The notation for q is that zero corresponds to the positive horizontal direction, and for both q and d, the counter-clockwise (CCW) rotation is positive.

Up to 511 segments of CR or VP may be specified in a single sequence and must be ended with the command VE. The motion can be initiated with a Begin Sequence (BGS) command. Once motion starts, additional segments may be added.

The Clear Sequence (CS) command can be used to remove previous VP and CR commands which were stored in the buffer prior to the start of the motion. To stop the motion, use the instructions STS or AB1. ST stops motion at the specified deceleration. AB1 aborts the motion instantaneously.

The Vector End (VE) command must be used to specify the end of the coordinated motion. This command requires the controller to decelerate to a stop following the last motion requirement. If a VE command is not given, an Abort (AB1) must be used to abort the coordinated motion sequence.

It is the responsibility of the user to keep enough motion segments in the DMC-40x0 sequence buffer to ensure continuous motion. If the controller receives no additional motion segments and no VE command, the controller will stop motion instantly at the last vector. There will be no controlled deceleration. LM? or _LM returns the available spaces for motion segments that can be sent to the buffer. 511 returned means the buffer is empty and 511 segments can be sent. A zero means the buffer is full and no additional segments can be sent. As long as the buffer is not full, additional segments can be sent at PC bus speeds.

The operand _CS can be used to determine the value of the segment counter.

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Additional commands

The commands VS n, VA n and VD n are used for specifying the vector speed, acceleration, and deceleration.

IT is the s curve smoothing constant used with coordinated motion.

Specifying Vector Speed for Each Segment:

The vector speed may be specified by the immediate command VS. It can also be attached to a motion segment with the instructions

VP x,y < n >m

CR r, ɵ,δ< n >m

The first command, <n, is equivalent to commanding VSn at the start of the given segment and will cause an acceleration toward the new commanded speeds, subjects to the other constraints.

Changing Feed Rate:

The command VR n allows the feed rate, VS, to be scaled between 0 and 10 with a resolution of .0001. This command takes effect immediately and causes VS scaled. VR also applies when the vector speed is specified with the ‘<’ operator. This is a useful feature for feed rate override. VR does not ratio the accelerations. For example, VR 0.5 results in the specification VS 2000 to be divided by two.

Compensating for Differences in Encoder Resolution:

By default, the DMC-40x0 uses a scale factor of 1:1 for the encoder resolution when used in vector mode. If this is not the case, the command, ES can be used to scale the encoder counts. The ES command accepts two arguments which represent the number of counts for the two encoders used for vector motion. The smaller ratio of the two numbers will be multiplied by the higher resolution encoder. For more information, see ES command in the Command Reference.

Trippoints:

The AV n command is the After Vector trippoint, which waits for the vector relative distance of n to occur before executing the next command in a program.

Tangent Motion:

Several applications, such as cutting, require a third axis (i.e. a knife blade), to remain tangent to the coordinated motion path. To handle these applications, the DMC-40x0 allows one axis to be specified as the tangent axis. The VM command provides parameter specifications for describing the coordinated axes and the tangent axis.

VM m,n,p

m,n specifies coordinated axes p specifies tangent axis such as X,Y,Z,W p=N turns off tangent axis

Before the tangent mode can operate, it is necessary to assign an axis via the VM command and define its offset and scale factor via the TN m,n command. m defines the scale factor in counts/degree and n defines the tangent position that equals zero degrees in the coordinated motion plane. The operand _TN can be used to return the initial position of the tangent axis.

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Example:

Assume an XY table with the Z-axis controlling a knife. The Z-axis has a 2000 quad counts/rev encoder and has been initialized after power-up to point the knife in the +Y direction. A 180° circular cut is desired, with a radius of 3000, center at the origin and a starting point at (3000,0). The motion is CCW, ending at (-3000,0). Note that the 0° position in the XY plane is in the +X direction. This corresponds to the position -500 in the Z-axis, and defines the offset. The motion has two parts. First, X,Y and Z are driven to the starting point, and later, the cut is performed. Assume that the knife is engaged with output bit 0.

#EXAMPLE VM XYZ TN 2000/360,-500 CR 3000,0,180 VE CB0 PA 3000,0,_TN BG XYZ AM XYZ SB0 WT50 BGS AMS CB0 MG “ALL DONE” EN

Example program XY coordinate with Z as tangent 2000/360 counts/degree, position -500 is 0 degrees in XY plane 3000 count radius, start at 0 and go to 180 CCW End vector Disengage knife Move X and Y to starting position, move Z to initial tangent position Start the move to get into position When the move is complete Engage knife Wait 50 msec for the knife to engage Do the circular cut After the coordinated move is complete Disengage knife

End program

Command Summary - Coordinated Motion Sequence

COMMAND DESCRIPTION

VM m,n

VP m,n CR r,ɵ,δ<n>m

VS s,t VA s,t VD s,t VR s,t BGST CSST AV s,t AMST TN m,n ES m,n IT s,t LM?

CAS or CAT

Specifies the axes for the planar motion where m and n represent the planar axes and p is the tangent axis. Return coordinate of last point, where m=X,Y,Z or W. Specifies arc segment where r is the radius,  is the starting angle and  is the travel angle. Positive direction is CCW. Specify vector speed or feed rate of sequence. Specify vector acceleration along the sequence. Specify vector deceleration along the sequence. Specify vector speed ratio Begin motion sequence, S or T Clear sequence, S or T Trippoint for After Relative Vector distance. Holds execution of next command until Motion Sequence is complete. Tangent scale and offset. Ellipse scale factor. S curve smoothing constant for coordinated moves Return number of available spaces for linear and circular segments in DMC-40x0 sequence buffer. Zero means buffer is full. 511 means buffer is empty. Specifies which coordinate system is to be active (S or T)

Operand Summary - Coordinated Motion Sequence

OPERAND DESCRIPTION

_VPM _AV _LM

_CS _VE

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The absolute coordinate of the axes at the last intersection along the sequence. Distance traveled. Number of available spaces for linear and circular segments in DMC-40x0 sequence buffer. Zero means buffer is full. 511 means buffer is empty. Segment counter - Number of the segment in the sequence, starting at zero. Vector length of coordinated move sequence.

When AV is used as an operand, _AV returns the distance traveled along the sequence.

Vs Vx Vy 

2 2

C (-4000,3000)

R = 1500

B (-4000,0)

D (0,3000)

A (0,0)

The operands _VPX and _VPY can be used to return the coordinates of the last point specified along the path.

Example:

Traverse the path shown in Figure 6.7. Feed rate is 20000 counts/sec. Plane of motion is XY

VM XY VS 20000 VA 1000000 VD 1000000 VP -4000,0 CR 1500,270,-180 VP 0,3000 CR 1500,90,-180 VE BGS

The resulting motion starts at the point A and moves toward points B, C, D, A. Suppose that we interrogate the controller when the motion is halfway between the points A and B.

The value of _AV is 2000

The value of _CS is 0

_VPX and _VPY contain the absolute coordinate of the point A

Suppose that the interrogation is repeated at a point, halfway between the points C and D. The value of _AV is 4000+1500 +2000=10,712

Specify motion plane Specify vector speed Specify vector acceleration Specify vector deceleration Segment AB Segment BC Segment CD Segment DA End of sequence Begin Sequence

The value of _CS is 2

_VPX,_VPY contain the coordinates of the point C

Figure 6.7: The Required Path

Vector Mode - Mathematical Analysis

The terms of coordinated motion are best explained in terms of the vector motion. The vector velocity, Vs, which is also known as the feed rate, is the vector sum of the velocities along the X and Y axes, Vx and Vy.

The vector distance is the integral of Vs, or the total distance traveled along the path. To illustrate this further, suppose that a string was placed along the path in the X-Y plane. The length of that string represents the distance traveled by the vector motion.

The vector velocity is specified independently of the path to allow continuous motion. The path is specified as a collection of segments. For the purpose of specifying the path, define a special X-Y coordinate system whose origin is the starting point of the sequence. Each linear segment is specified by the X-Y coordinate of the final point

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expressed in units of resolution, and each circular arc is defined by the arc radius, the starting angle, and the



 

360

L Xk Ykk





2 2

L Rk k k  2 360



D Lk



1

10000 20000

20000

10000

C D

angular width of the arc. The zero angle corresponds to the positive direction of the X-axis and the CCW direction of rotation is positive. Angles are expressed in degrees, and the resolution is 1/256th of a degree. For example, the path shown in Figure A.8 is specified by the instructions:

VP 0,10000 CR 10000, 180, -90

VP 20000, 20000

Figure A.8: X-Y Motion Path

The first line describes the straight line vector segment between points A and B. The next segment is a circular arc, which starts at an angle of 180° and traverses -90°. Finally, the third line describes the linear segment between points C and D. Note that the total length of the motion consists of the segments:

A-B Linear 10000 units

B-C Circular

= 15708

C-D Linear 10000

Total 35708 counts

In general, the length of each linear segment is

Where Xk and Yk are the changes in X and Y positions along the linear segment. The length of the circular arc is

The total travel distance is given by

The velocity profile may be specified independently in terms of the vector velocity and acceleration.

For example, the velocity profile corresponding to the path of Figure A.8 may be specified in terms of the vector speed and acceleration.

VS 100000 VA 2000000

The resulting vector velocity is shown in Figure A.9.

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The acceleration time, Ta, is given by

  

100000

2000000

0 05.

T st a

  

0 407.

0.05 0.357

10000

Velocity

time (s)

0.407T

(a)

(b)

(c)

time

The slew time, Ts, is given by

Figure A.9: Vector Velocity Profile

    

35708

T s

100000

. .

0 0 307

The total motion time, Tt, is given by:

The velocities along the X and Y axes are such that the direction of motion follows the specified path, yet the vector velocity fits the vector speed and acceleration requirements.

For example, the velocities along the X and Y axes for the path shown in Figure A.8 are given in Figure A.10.

Figure A.10 shows the vector velocity. It also indicates the position point along the path starting at A and ending at D. Between the points A and B, the motion is along the Y axis. Therefore,

Vy = Vs

and

Vx = 0

Between the points B and C, the velocities vary gradually and finally, between the points C and D, the motion is in the X direction.

Figure A.10: Vector Axes Velocities

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Electronic Gearing

This mode allows up to 8 axes to be electronically geared to some master axes. The masters may rotate in both directions and the geared axes will follow at the specified gear ratio. The gear ratio may be different for each axis and changed during motion.

The command GAX yzw or GA ABCDEFGH specifies the master axes. GR x,y,z,w specifies the gear ratios for the slaves where the ratio may be a number between ±127.9999 with a fractional resolution of .0001. There are two modes: standard gearing and gantry mode. The gantry mode (enabled with the command GM) allows the gearing to stay enabled even if a limit is hit or an ST command is issued. GR 0,0,0,0 turns off gearing in both modes.

The command GM x,y,z,w select the axes to be controlled under the gantry mode. The parameter 1 enables gantry mode, and 0 disables it.

GR causes the specified axes to be geared to the actual position of the master. The master axis is commanded with motion commands such as PR, PA or JG.

When the master axis is driven by the controller in the jog mode or an independent motion mode, it is possible to define the master as the command position of that axis, rather than the actual position. The designation of the commanded position master is by the letter, C. For example, GACX indicates that the gearing is the commanded position of X.

An alternative gearing method is to synchronize the slave motor to the commanded vector motion of several axes performed by GAS. For example, if the X and Y motor form a circular motion, the Z axis may move in proportion to the vector move. Similarly, if X,Y and Z perform a linear interpolation move, W can be geared to the vector move.

Electronic gearing allows the geared motor to perform a second independent or coordinated move in addition to the gearing. For example, when a geared motor follows a master at a ratio of 1:1, it may be advanced an additional distance with PR, or JG, commands, or VP, or LI.

Ramped Gearing

In some applications, especially when the master is traveling at high speeds, it is desirable to have the gear ratio ramp gradually to minimize large changes in velocity on the slave axis when the gearing is engaged. For example if the master axis is already traveling at 500,000 counts/sec and the slave will be geared at a ratio of 1:1 when the gearing is engaged, the slave will instantly develop following error, and command maximum current to the motor. This can be a large shock to the system. For many applications it is acceptable to slowly ramp the engagement of gearing over a greater time frame. Galil allows the user to specify an interval of the master axis over which the gearing will be engaged. For example, the same master X axis in this case travels at 500,000 counts/sec, and the gear ratio is 1:1, but the gearing is slowly engaged over 30,000 counts of the master axis, greatly diminishing the initial shock to the slave axis. Figure 6.Error: Reference source not found below shows the velocity vs. time profile for instantaneous gearing. Figure 6.14 shows the velocity vs. time profile for the gradual gearing engagement.

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Figure 6.11: Velocity counts/sec vs. Time (msec) Instantaneous Gearing Engagement

Figure 6.12: Velocity (counts/sec) vs. Time (msec) Ramped Gearing

The slave axis for each figure is shown on the bottom portion of the figure; the master axis is shown on the top portion. The shock to the slave axis will be significantly less in Figure 6.14 than in Figure 6.Error: Reference source not found. The ramped gearing does have one consequence. There isn’t a true synchronization of the two axes, until the gearing ramp is complete. The slave will lag behind the true ratio during the ramp period. If exact position synchronization is required from the point gearing is initiated, then the position must be commanded in addition to the gearing. The controller keeps track of this position phase lag with the _GP operand. The following example will demonstrate how the command is used.

Example – Electronic Gearing Over a Specified Interval

Objective Run two geared motors at speeds of 1.132 and -.045 times the speed of an external master. Because the master is traveling at high speeds, it is desirable for the speeds to change slowly.

Solution: Use a DMC-4030 controller where the Z-axis is the master and X and Y are the geared axes. We will implement the gearing change over 6000 counts (3 revolutions) of the master axis.

MO Z GA Z, Z GD 6000,6000 GR 1.132,-.045

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Turn Z off, for external master Specify Z as the master axis for both X and Y. Specify ramped gearing over 6000 counts of the master axis. Specify gear ratios

Question: What is the effect of the ramped gearing?

Answer: Below, in the example titled Electronic Gearing, gearing would take effect immediately. From the start of gearing if the master traveled 6000 counts, the slaves would travel 6792 counts and 270 counts.

Using the ramped gearing, the slave will engage gearing gradually. Since the gearing is engaged over the interval of 6000 counts of the master, the slave will only travel ~3396 counts and ~135 counts respectively. The difference between these two values is stored in the _GPn operand. If exact position synchronization is required, the IP command is used to adjust for the difference.

Command Summary - Electronic Gearing

COMMAND DESCRIPTION

GA n

GD a,b,c,d,e,f,g,h _GPn

GR a,b,c,d,e,f,g,h GM a,b,c,d,e,f,g,h MR x,y,z,w MF x,y,z,w

Specifies master axes for gearing where: n = X,Y,Z or W or A,B,C,D,E,F,G,H for main encoder as master n = CX,CY,CZ, CW or CA, CB,CC,CD,CE,CF,CG,CH for commanded position. n = DX,DY,DZ or DW or DA, DB, DC, DD, DE, DF,DG,DH for auxiliary encoders n = S or T for gearing to coordinated motion. Sets the distance the master will travel for the gearing change to take full effect. This operand keeps track of the difference between the theoretical distance traveled if gearing changes took effect immediately, and the distance traveled since gearing changes take effect over a specified interval. Sets gear ratio for slave axes. 0 disables electronic gearing for specified axis. X = 1 sets gantry mode, 0 disables gantry mode Trippoint for reverse motion past specified value. Only one field may be used. Trippoint for forward motion past specified value. Only one field may be used.

Example - Simple Master Slave

Master axis moves 10000 counts at slew speed of 100000 counts/sec. Y is defined as the master. X,Z,W are geared to master at ratios of 5,-.5 and 10 respectively.

GA Y,,Y,Y GR 5,,-.5,10 PR ,10000 SP ,100000 BGY

Specify master axes as Y Set gear ratios Specify Y position Specify Y speed Begin motion

Example - Electronic Gearing

Objective: Run two geared motors at speeds of 1.132 and -0.045 times the speed of an external master. The master is driven at speeds between 0 and 1800 RPM (2000 counts/rev encoder).

Solution: Use a DMC-4030 controller, where the Z-axis is the master and X and Y are the geared axes.

MO Z GA Z, Z GR 1.132,-.045

Turn Z off, for external master Specify Z as the master axis for both X and Y. Specify gear ratios

Now suppose the gear ratio of the X-axis is to change on-the-fly to 2. This can be achieved by commanding:

GR 2

Specify gear ratio for X axis to be 2

Example - Gantry Mode

In applications where both the master and the follower are controlled by the DMC-40x0 controller, it may be desired to synchronize the follower with the commanded position of the master, rather than the actual position. This eliminates the coupling between the axes which may lead to oscillations.

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For example, assume that a gantry is driven by two axes, X,Y, on both sides. This requires the gantry mode for strong coupling between the motors. The X-axis is the master and the Y-axis is the follower. To synchronize Y with the commanded position of X, use the instructions:

GA, CX GR,1 GM,1 PR 3000 BG X

Specify the commanded position of X as master for Y. Set gear ratio for Y as 1:1 Set gantry mode Command X motion Start motion on X axis

You may also perform profiled position corrections in the electronic gearing mode. Suppose, for example, that you need to advance the slave 10 counts. Simply command

IP ,10

Specify an incremental position movement of 10 on Y axis.

Under these conditions, this IP command is equivalent to:

PR,10 BGY

Specify position relative movement of 10 on Y axis Begin motion on Y axis

Often the correction is quite large. Such requirements are common when synchronizing cutting knives or conveyor belts.

Example - Synchronize two conveyor belts with trapezoidal velocity correction

GA,X GR,2 PR,300 SP,5000 AC,100000 DC,100000 BGY

Define X as the master axis for Y. Set gear ratio 2:1 for Y Specify correction distance Specify correction speed Specify correction acceleration Specify correction deceleration Start correction

Electronic Cam

The electronic cam is a motion control mode which enables the periodic synchronization of several axes of motion. Up to 7 axes can be slaved to one master axis. The master axis encoder must be input through a main encoder port.

The electronic cam is a more general type of electronic gearing which allows a table-based relationship between the axes. It allows synchronizing all the controller axes. For example, the DMC-4080 controllers may have one master and up to seven slaves.

To illustrate the procedure of setting the cam mode, consider the cam relationship for the slave axis Y, when the master is X. Such a graphic relationship is shown in Figure 6.13.

Step 1. Selecting the master axis

The first step in the electronic cam mode is to select the master axis. This is done with the instruction

EAp where p = X,Y,Z,W,E,F,G,H

p is the selected master axis

For the given example, since the master is x, we specify EAX

Step 2. Specify the master cycle and the change in the slave axis (or axes).

In the electronic cam mode, the position of the master is always expressed modulo one cycle. In this example, the position of x is always expressed in the range between 0 and 6000. Similarly, the slave position is also redefined such that it starts at zero and ends at 1500. At the end of a cycle when the master is 6000 and the slave is 1500,

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the positions of both x and y are redefined as zero. To specify the master cycle and the slave cycle change, we use the instruction EM.

EM x,y,z,w

where x,y,z,w specify the cycle of the master and the total change of the slaves over one cycle.

The cycle of the master is limited to 8,388,607 whereas the slave change per cycle is limited to 2,147,483,647. If the change is a negative number, the absolute value is specified. For the given example, the cycle of the master is 6000 counts and the change in the slave is 1500. Therefore, we use the instruction:

EM 6000,1500

Step 3. Specify the master interval and starting point.

Next we need to construct the ECAM table. The table is specified at uniform intervals of master positions. Up to 256 intervals are allowed. The size of the master interval and the starting point are specified by the instruction:

EP m,n

where m is the interval width in counts, and n is the starting point.

For the given example, we can specify the table by specifying the position at the master points of 0, 2000, 4000 and

6000. We can specify that by

EP 2000,0

Step 4. Specify the slave positions.

Next, we specify the slave positions with the instruction

ET[n]=x,y,z,w

where n indicates the order of the point.

The value, n, starts at zero and may go up to 256. The parameters x,y,z,w indicate the corresponding slave position. For this example, the table may be specified by

ET[0]=,0 ET[1]=,3000 ET[2]=,2250 ET[3]=,1500

This specifies the ECAM table.

Step 5. Enable the ECAM

To enable the ECAM mode, use the command

EB n

where n=1 enables ECAM mode and n=0 disables ECAM mode.

Step 6. Engage the slave motion

To engage the slave motion, use the instruction

EG x,y,z,w

where x,y,z,w are the master positions at which the corresponding slaves must be engaged.

If the value of any parameter is outside the range of one cycle, the cam engages immediately. When the cam is engaged, the slave position is redefined, modulo one cycle.

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Step 7. Disengage the slave motion

Master X4000

2250

2000 6000

3000

1500

To disengage the cam, use the command

EQ x,y,z,w

where x,y,z,w are the master positions at which the corresponding slave axes are disengaged.

Figure 6.13: Electronic Cam Example

This disengages the slave axis at a specified master position. If the parameter is outside the master cycle, the stopping is instantaneous.

To illustrate the complete process, consider the cam relationship described by

the equation:

Y = 0.5 * X + 100 sin (0.18*X)

where X is the master, with a cycle of 2000 counts.

The cam table can be constructed manually, point by point, or automatically by a program. The following program includes the set-up.

The instruction EAX defines X as the master axis. The cycle of the master is

2000. Over that cycle, Y varies by 1000. This leads to the instruction EM 2000,1000.

Suppose we want to define a table with 100 segments. This implies increments of 20 counts each. If the master points are to start at zero, the required instruction is EP 20,0.

The following routine computes the table points. As the phase equals 0.18X and X varies in increments of 20, the phase varies by increments of 3.6 . The program then computes the values of Y according to the equation and  assigns the values to the table with the instruction ET[N] = ,Y.

INSTRUCTION INTERPRETATION

#SETUP EAX EM 2000,1000 EP 20,0 N = 0 #LOOP P = N3.6 S = @SIN [P]*100 Y = N*10+S ET [N] =, Y N = N+1 JP #LOOP, N<=100 EN

Label Select X as master Cam cycles Master position increments Index Loop to construct table from equation Note 3.6 = 0.18 * 20 Define sine position Define slave position Define table

Repeat the process

Now suppose that the slave axis is engaged with a start signal, input 1, but that both the engagement and disengagement points must be done at the center of the cycle: X = 1000 and Y = 500. This implies that Y must be driven to that point to avoid a jump.

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This is done with the program:

INSTRUCTION INTERPRETATION

#RUN EB1 PA,500 SP,5000 BGY AM AI1 EG,1000 AI - 1 EQ,1000 EN

Label Enable cam starting position Y speed Move Y motor After Y moved Wait for start signal Engage slave Wait for stop signal Disengage slave End

Command Summary - Electronic CAM

Command Description

EA p

EB n EC n EG x,y,z,w EM x,y,z,w EP m,n EQ m,n ET[n] EW EY

Specifies master axes for electronic cam where: p = X,Y,Z or W or A,B,C,D,E,F,G,H for main encoder as master or M or N a for virtual axis master Enables the ECAM ECAM counter - sets the index into the ECAM table Engages ECAM Specifies the change in position for each axis of the CAM cycle Defines CAM table entry size and offset Disengages ECAM at specified position Defines the ECAM table entries Widen Segment (see Application Note #2444) Set ECAM cycle count

Operand Summary - Electronic CAM

Command Description

_EB _EC _EGx _EM _EP _EQx _EY

Contains State of ECAM Contains current ECAM index Contains ECAM status for each axis Contains size of cycle for each axis Contains value of the ECAM table interval Contains ECAM status for each axis Set ECAM cycle count

Example - Electronic CAM

The following example illustrates a cam program with a master axis, Z, and two slaves, X and Y.

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Galil Motion Control DMC-4040, DMC-4080 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Contents

Chapter 1 Overview

Introduction

Part Numbers

DMC, “DMC-40X0(Y)” Options

CMB, “-CXXX(Y)” Options

ICM, “-IXXX(Y)” Options

AMP/SDM, “-DXXXX(Y)” Options

Overview of Motor Types

Standard Servo Motor with ±10 Volt Command Signal

Brushless Servo Motor with Sinusoidal Commutation

Stepper Motor with Step and Direction Signals

Overview of External Amplifiers

Amplifiers in Current Mode

Amplifiers in Velocity Mode

Stepper Motor Amplifiers

Galil Internal Amplifiers and Drivers

Functional Elements

Microcomputer Section

Motor Interface

Communication

General I/O

System Elements

Amplifier (Driver)

Motor

Encoder

Sinusoidal Encoders

Watch Dog Timer

Chapter 2 Getting Started

Layout

DMC-4040

DMC-4080

Power Connections

Dimensions

DMC-4040

DMC-4080

Elements You Need

Installing the DMC, Amplifiers, and Motors

Step 1. Determine Overall System Configuration

Step 2. Install Jumpers on the DMC-40x0

Motor Off Jumper

RS232 Baud Rate Jumpers

Master Reset and Upgrade Jumpers

Step 3. Install the Communications Software

Step 4. Power the Controller

Step 5. Establish Communications with Galil Software

Step 6. Connecting Encoder Feedback

Step 7. Setting Safety Features before Wiring Motors

Step 8. Wiring Motors to Galil's Internal Amps

Step 8a. Commutation of 3-phased Brushless Motors

Trapezoidal Commutation

Sinusoidal Commutation

BZ/BX Method

BI/BC Method

Step 9. Connecting External Amplifiers and Motors

Step 10. Tune the Servo System

Chapter 3 Connecting Hardware

Overview

Overview of Optoisolated Inputs

Limit Switch Input

Home Switch Input

Abort Input

ELO (Electronic Lock-Out) Input

Reset Input/Reset Button

Uncommitted Digital Inputs

Optoisolated Input Electrical Information

Electrical Specifications

Wiring the Optoisolated Digital Inputs

High Power Optoisolated Outputs

Description

Electrical Specifications

Wiring the Optoisolated Outputs

TTL Inputs and Outputs

Main Encoder Inputs

Electrical Specifications

The Auxiliary Encoder Inputs