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Galil DMC-1700, DMC-1800 user manual Troubleshooting, Overview, Installation

Models: DMC-1800 DMC-1700

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Chapter 9 Troubleshooting

Chapter 9 Troubleshooting

Overview

The following discussion may help you get your system to work.

Potential problems have been divided into groups as follows:

1.Installation

2.Communication

3.Stability and Compensation

4.Operation

The various symptoms along with the cause and the remedy are described in the following tables.

Installation

SYMPTOM	DIAGNOSIS		CAUSE

Motor runs away with no	Adjusting offset causes the	1.	Amplifier has an
connections from	motor to change speed.	internal offset.
controller to amplifier
input.
		2.	Damaged amplifier.

Motor is enabled even	The SH command disables	1.	The amplifier
when MO command is	the motor	requires the -LAEN
given		option on the
		Interconnect Module
Unable to read the	No auxiliary encoder	1.	Auxiliary Encoder
auxiliary encoders.	inputs are working	Cable is not connected

REMEDY

Adjust amplifier offset. Amplifier offset may also be compensated by use of the offset configuration on the controller (see the OF command).

Replace amplifier.

Contact Galil

Connect Auxiliary Encoder cable

DMC-1700/1800

Chapter 9 Troubleshooting • 181

Image 189

Galil DMC-1700, DMC-1800 user manual Troubleshooting, Overview, Installation

Contents

By Galil Motion Control, Inc DMC-1700/1800USER MANUAL Manual Rev. 1.2m1X80 Using This ManualContents ContentsChapter 1 Overview Chapter 2 Getting StartedChapter 3 Connecting Hardware Chapter 5 Command BasicsChapter 4 - Software Tools and Communications Chapter 6 Programming Motion Chapter 7 Application Programming Chapter 8 Hardware & Software Protection Chapter 9 TroubleshootingChapter 10 Theory of Operation AppendicesIndex Introduction Chapter 1 OverviewOverview of Motor Types Stepper Motor with Step and Direction SignalsDMC-1700/1800Functional Elements Brushless Servo Motor with Sinusoidal CommutationMotor Interface Microcomputer SectionCommunication General I/OMotor System ElementsAmplifier Driver EncoderWatch Dog Timer 6 • Chapter 1 Overview THIS PAGE LEFT BLANK INTENTIONALLYJ5 4 JP5 JP4 JP9 Chapter 2 Getting StartedJP3 J1 JP8 J6J88 • Chapter 2 Getting Started Elements You Need Step 1. Determine Overall Motor Configuration Installing the DMC-1700/1800Standard Servo Motor Operation Sinusoidal CommutationMaster Reset and Upgrade Jumpers Step 2. Install Jumpers on the DMC-1700/1800Stepper Motor Operation Opto Isolation JumpersDRQ 1 DACK DRQ 0 DACKOptional IRQ Interrupt Jumpers Optional Motor Off JumpersConfiguring the Address Jumpers on the DMC-1700 Step 3. Install the Communications SoftwareUsing Win98SE, ME, NT4.0, 2000, and XP Using DOSDMC-1700Install Step 4. Install the DMC-1700/1800in the PCDMC-1800Install Using Galil Software for DOS DMC-1700onlyonly 1.On the first dialog, select Add/Troubleshoot 2.Let the Hardware Wizard try to detect a new Plug and Play device 18 • Chapter 2 Getting Started Automatically Assigned resources in Win 98 SE 20 Chapter 2 Getting Started Device Manager in Win 98 SEChanging the Resources in Win 98 SE Edit Input/Output Range in Win 98 SE 22 Chapter 2 Getting Started Using Galil Software for Windows NTOnce in the Galil Registry, click New Controller under Non-PnPTools. Select the appropriate controller from the pull down menu and adjust the timeout as seen fit. Click Next to continue Sending Test Commands to the Terminal Notes on Configuring Sinusoidal CommutationBAXZ 1X80 Step 7. Make Connections to Amplifier and EncoderStep D. Verify proper encoder operation Check the Polarity of the Feedback Loop Step 8a. Connect Standard Servo MotorsInverting the Loop Polarity DC Servo Motor DC Power SupplyDMC-1700/1800 Chapter 2 Getting Started •30 • Chapter 2 Getting Started Step 8b. Connect Sinusoidal Commutation Motors If Hall Sensors are Available If Hall Sensors are Not AvailableIf Hall Sensors are Not Available If Hall Sensors are Available Step 8C. Connect Step MotorsStep 9. Tune the Servo System Example 1 - System Set-up Design ExamplesExample 2 - Profiled Move TE X CRExample 3 - Multiple Axes Example 4 - Independent MovesExample 5 - Position Interrogation Example 6 - Absolute Position after a few seconds, commandExample 7 - Velocity Control Example 8 - Operation Under Torque LimitExample 9 - Interrogation Example 11 - Using the On-BoardEditorExample 10 - Operation in the Buffer Mode The instructionExample 12 - Motion Programs with Loops To start the program, commandExample 13 - Motion Programs with Trippoints Example 14 - Control VariablesExample 16 - Circular Interpolation Example 15 - Linear InterpolationInstruction Interpretation4000,4000 0,4000R=2000 4000,042 • Chapter 2 Getting Started THIS PAGE LEFT BLANK INTENTIONALLYUsing Optoisolated Inputs Chapter 3 Connecting HardwareLimit Switch Input OverviewHome Switch Input 44 • Chapter 3 Connecting HardwareAbort Input Uncommitted Digital Inputs Wiring the Optoisolated Inputs1X80 17X8Using an Isolated Power Supply Analog Inputs Amplifier InterfaceBypassing the Opto-Isolation TTL Outputs TTL InputsDMC-1700/1800 ICM-1900/29001X80 THIS PAGE LEFT BLANK INTENTIONALLY 50 • Chapter 3 Connecting HardwareChapter 4 - Software Tools and Communications DMC-1700/1800Chapter 4 - Software Tools and Communications • Figure 4.1 - Software Communications Hierarchy Figure 4.2 - Galil SmartTERM Galil SmartTERMDownload Array DMC Data Record Display DMC Program Editor WindowFigure 4.3 - Data Record Display for a DMC-1840 Setting Communications Parameters and Methods Communication Settings for ISA and PCIGalil Registry Editor Figure 4.4 - Galil Registry EditorAdvanced communications settings are available under the Communications Method tab to allow different methods of communications to be utilized shown in Fig 4.6. The version 7 and higher drivers and .DLL’s allow for three different methods of communications: Interrupt, Stall, and Delay Interrupt Communications Method Stall Thread and Delay Thread MethodsData Record Cache Depth Data Record Refresh RateFigure 4.8 - DMC-1800Data Record Parameters Figure 4.7 - DMC-1700Data Record ParametersFigure 4.9- WSDK Main Screen Windows Servo Design Kit WSDKActiveX Toolkit Creating Custom Software InterfacesDMCWin Programmers Toolkit Galil Communications API with C/C++Galil Communications API with Visual Basic End Sub DOS, Linux, and QNX tools Enabling Event Interrupts EI commandController Event Interrupts and User Interrupts LinuxServicing Interrupts User Interrupts UI commandCommunications with the DMC-1700 Hardware Level Communications for ISA and PCISimplified Communications Procedure Communication with DMC-1700Control Register N+1 Reading the Data Record using the Polling FIFO Interrupt Service for the DMC-1700Communications with the DMC-1800 Polling FIFO Mode Read ProcedureSecondary FIFO Registers OperationPCI Device Identification Simplified Communication ProcedureDEVICE ID VENDOR IDHalf Full Flag FIFO Control Register at N+4Reading the Data Record from the Secondary FIFO Enabling and Reading IRQ’sDMA / Secondary FIFO / DPRAM Memory Map Reset Register at N+8general output block 6 outputs 128-131 DMC-1700/1800Chapter 4 - Software Tools and Communications • Axis Switch Information 1 Byte General Status Information 1 ByteAxis Status Information 1 Word Page THIS PAGE LEFT BLANK INTENTIONALLY Chapter 5 Command Basics Command Syntax - ASCIIIntroduction Command Syntax - Binary Coordinated Motion with more than 1 axis1X80 Header Format Binary Command FormatDatafields Format A7 02 00 05 03 E8 FE 0CExample Binary command tableSummary of Interrogation Commands Interrogation CommandsController Response to DATA Interrogating the ControllerCommand Summary Interrogating Current Commanded ValuesOperands V=_TPX1X80 Chapter 6 Programming MotionDMC-1700/1800 Chapter 6 Programming Motion •86 • Chapter 6 Programming Motion Command Summary - Independent Axis Independent Axis PositioningOperand Summary - Independent Axis Example - Multiple Move Sequence Example - Absolute Position MovementRequired Motion Profiles 88 • Chapter 6 Programming MotionVELOCITY Command Summary - JoggingCOUNTS/SEC 20000Operand Summary - Independent Axis Position TrackingExample - Jog in X only Example - Joystick JoggingCOMMAND 92 Chapter 6 Programming Motion Example - MotionExample Motion Figure 3 Velocity vs Time msec MotionFigure 4 Position vs. Time msec Motion 94 • Chapter 6 Programming Motion Trip PointsCommand Summary - Position Tracking Mode Linear Interpolation ModeSpecifying Linear Segments Additional Commands An Example of Linear Interpolation MotionSpecifying Vector Speed for Each Segment Operand Summary - Linear Interpolation Command Summary - Linear InterpolationChanging Feedrate DMC-1700/1800VS = VZ 2 + VW Example - Linear MoveFigure 6.2 - Linear Interpolation Example - Multiple MovesDMC-1700/1800 Chapter 6 Programming Motion •Specifying the Coordinate Plane Specifying Vector Segments100 • Chapter 6 Programming Motion Additional commands Specifying Vector Speed for Each SegmentChanging Feedrate Tangent Motion TrippointsExample 102 Chapter 6 Programming MotionCommand Summary - Coordinated Motion Sequence Operand Summary - Coordinated Motion SequenceExample C -4000,3000D 0,3000 R = Electronic GearingB -4000,0 A 0,0Ramped Gearing Turn Z off, for external master MO ZGA Z, Z Specify Z as the master axis for both X and YExample - Simple Master Slave Command Summary - Electronic GearingExample - Electronic Gearing Example - Gantry ModeElectronic Cam EM 6000,1500 EM x,y,z,wEP m,n EP 2000,02000 3000 2250 15004000 6000command Command Summary - Electronic CAMINSTRUCTION INTERPRETATIONOperand Summary - Electronic CAM commandExample - Electronic CAM descriptionSpecifying Contour Segments Contour ModePOSITION Additional CommandsCOUNTS TIME msω= ΑΒ 1 − cos2π Β Χ= ATB − 2Aπ sin2π B Command Summary - Contour ModeGeneral Velocity Profiles Generating an Array - An ExampleContour Mode Example Record and Playback Example Teach Record and Play-BackDMC-1700/1800 Chapter 6 Programming Motion •Virtual Axis ECAM Master ExampleSinusoidal Motion Example Stepper Motor Operation Monitoring Generated Pulses vs Commanded PulsesSpecifying Stepper Motor Operation Stepper Motor SmoothingCommand Summary - Stepper Motor Operation Using an Encoder with Stepper MotorsOperand Summary - Stepper Motor Operation Motion Complete TrippointError Limit Stepper Position Maintenance Mode SPMInternal Controller Commands user can query QS = TD − TP ⋅ YA ⋅ YB YCCorrection Example: SPM Mode SetupFull-SteppingDrive, X axis Half-SteppingDrive, X axisExample Error Correction DMC-1700/1800Chapter 6 Programming Motion • 124 • Chapter 6 Programming Motion Example: Friction CorrectionCE Additional Commands for the Auxiliary Encoder Using the CE CommandDual Loop Auxiliary Encoder DE 0,500,-30,300Continuous Dual Loop - Example Backlash CompensationSampled Dual Loop - Example V1= _DEXUsing the IT and VT Commands Motion SmoothingExample - Smoothing ACCELERATION VELOCITY ACCELERATION VELOCITY Using the KS Command Step Motor SmoothingStage HomingStage StageInstruction Example: HomingInterpretation 130 • Chapter 6 Programming MotionSWITCH High Speed Position Capture The Latch Function Command Summary - Homing OperationOperand Summary - Homing Operation Example Find EdgeFast Update Rate Mode DMA channel Pole PL Analog Feedback AFDual Velocity DV Peak Torque Limit TK Notch Filter NB, NF, NZ Second field of EIChapter 7 Application Programming Using the DMC-1700/1800Editor to Enter ProgramsOverview Using Labels in Programs Edit Mode CommandsProgram Format Valid labelsUsing the command, NO or Apostrophe ‘ Special LabelsCommenting Programs Executing Programs - Multitasking XQ #A, nHX n Error Code Command Trace CommandsStop Code Command RAM Memory Interrogation CommandsProgram Flow Commands OperandsDebugging Example Event Triggers & Trippoints DMC-1700and DMC-1800Event Triggers CommandFunction 142 • Chapter 7 Application ProgrammingEvent Trigger - Multiple Move Sequence Event Trigger ExamplesEvent Trigger - Set Output after Distance Event Trigger - Repetitive Position TriggerEvent Trigger - Start Motion on Input Event Trigger - Set output when At speedEvent Trigger - Change Speed along Vector Path 144 • Chapter 7 Application ProgrammingDefine Output Waveform Using AT Conditional JumpsEvent Trigger - Multiple Move with Wait Logical operators Command Format - JP and JSConditional Statements Multiple Conditional StatementsUsing the JP Command Using If, Else, and Endif CommandsExample Using JP command Using the IF and ENDIF CommandsCommand Format - IF, ELSE and ENDIF Using the ELSE CommandExample using IF, ELSE and ENDIF Nesting IF Conditional StatementsStack Manipulation SubroutinesAuto-StartRoutine Automatic Subroutines for Monitoring ConditionsExample - Limit Switch Example - Position ErrorNotes regarding the #LIMSWI Routine Example - Input Interrupt Example - Motion Complete TimeoutDMC-1700/1800 Chapter 7 Application Programming •Example - Command Error w/Multitasking Example - Command ErrorMathematical and Functional Expressions Mathematical OperatorsBit-WiseOperators 154 • Chapter 7 Application Programming FunctionsProgrammable Variables VariablesPOSX Assigning Values to VariablesExample - Using Variables for Joystick OperandsDisplaying the value of variables at the terminal Special Operands Keywords ArraysDefining Arrays Examples of Internal VariablesAssignment of Array Entries Using a Variable to Address Array ElementsCommand Summary - Automatic Data Capture Automatic Data Capture into ArraysData Types for Recording Input of Data Deallocating Array SpaceOperand Summary - Automatic Data Capture Example - Recording into An ArraySending Messages Output of Data Numeric and StringCut-to-LengthExample Inputting String VariablesFormatting Messages Using the MG Command to Configure TerminalsMG STR S3 The Final Value isDisplaying Variables and Arrays Interrogation CommandsSummary of Message Functions MG ^07 ^255PF m.n Example - Using the LZ commandConverting to User Units Formatting Variables and Array ElementsLocal Formatting of Variables VF m.nDigital Outputs Hardware I/ODigital Inputs Example - Start Motion on SwitchInput Interrupt Function Example - Turn on output after moveAnalog Inputs Examples - Input InterruptExample - Position Follower Point-to-Point Example - Position Follower Continuous Move Wire Cutter4000/2π = 637 count/inch INSTRUCTION1 inch = 40,000 counts X-YTable ControllerCR 80000,270,-360 Speed Control by Joystick Speed = 20000 x VIN DMC-1700/1800Chapter 7 Application Programming • Backlash Compensation by Sampled Dual-Loop Position Control by JoystickINSTRUCTION FUNCTIONExample motion program INSTRUCTIONFUNCTION 176 • Chapter 7 Application Programming THIS PAGE LEFT BLANK INTENTIONALLYIntroduction Chapter 8 Hardware & Software ProtectionHardware Protection Output Protection LinesProgrammable Position Limits Software ProtectionOff-On-Error Automatic Error RoutineLimit Switch Routine 180 • Chapter 8 Hardware & Software Protection Chapter 9 Troubleshooting InstallationOverview SYMPTOM SYMPTOM182 • Chapter 9 Troubleshooting DIAGNOSISChapter 9 Troubleshooting • SYMPTOMDIAGNOSIS CAUSETHIS PAGE LEFT BLANK INTENTIONALLY 184 • Chapter 9 TroubleshootingCOMPUTER Chapter 10 Theory of OperationCONTROLLER DRIVERLEVEL Figure 10.3 - Velocity and Position Profiles Operation of Closed-LoopSystemsCONTROLLER System ModelingVoltage Drive Motor-AmplifierPV = KV Kt SSTm + 1STe + = RJT1 = J/Ka Kt Kg Velocity LoopVOLTAGE SOURCE CURRENT SOURCEVELOCITY LOOP KZ − A Digital Filter1 − B Z − BSystem Analysis Encoder Digital FilterDz = 1030 z-0.95/Z The Analytical Method System Design and Compensationα= 76 - 180 - 6 = PM = 180 + α =Kd = 10/32768 = MotorG = 82.4 + 0.2744s Gs = P + sDP = 4 ∗ KP 4 ∗ KD = D/TDMC-1700/1800 Equivalent Filter FormElectrical Specifications AppendicesServo Control Stepper ControlPower Performance SpecificationsJ5-DMC-1740/1840 A-DAXES J1 DMC-1740/1840 A-DAXES MAIN100-PINHIGH DENSITY AUXILIARY ENCODERS; 26-PINIDCJ6 DMC-1780/1880 J8 DMC-1780/1880J7 DMC-1780/1880 E-HAXES MAINOutputs Pin-OutDescription for DMC-1700/1800PWM/STEP OUT Sign/Direction Error Inputs Standard Addresses Setting Addresses for the DMC-1700JPR A8 AddressJPR A7 JPR A6JPR A8 AddressJPR A7 JPR A6Communications Jumpers Plug and Play Addresses210 • Appendices Accessories and OptionsPC/AT Interrupts and Their Vectors ICM-1900Interconnect ModuleThese occur on the first Features MOCMDX DMC-1700/1800Appendices • 214 • Appendices Figure A.1 – ICM-1900Dimensions AMP-19X0Mating Power AmplifiersFeatures SpecificationsMounting: Keyholes --¼” ∅ Gain: 1 amp/V ICM-2900Interconnect ModuleBlock 4 PIN LabelRLSZ DMC-1700/1800Appendices • 218 • Appendices Figure A.2 – Opto Output Circuit FROM CONTROLLERICM-1900 / ICM-2900 CONNECTIONS Accessing extended I/O CO nOP m,a,b,c,d OP 7,,,,7 Connector DescriptionJ6 50-PINIDC MG @IN17222 • Appendices J8 50-PINIDC SignalBlock Bit @INnDescription Figure A.3 – IOM-1964Layout OverviewFigure A.4 – CB-50-80and CB-50-100Bracket Layout Configuring Hardware BanksDigital Inputs Figure A.5 – IOM-1964Chip Configuration LayoutFigure A.8 – Output Sinking and Sourcing Diagram Figure A.7 – Input Sinking and Sourcing DiagramFigure A.6 – Opto Input Circuit Input CircuitHigh Power Digital Outputs Figure A.9 - High Current Output CircuitFigure A.10 – Typical Load Connection Figure A.11 – Output Circuit Diagram Output CommandStandard Digital Outputs ResultHigh Power Digital Outputs Electrical SpecificationsOutput Command Digital InputsScrew Terminal Listing Relevant DMC CommandsREV A+B REV CI/O64 DMC-1700/1800Appendices • Coordinated Motion - Mathematical Analysis Vs = Vx 2 + Vy234 • Appendices Page time s VelocityLk = Xk 2 + Yk 100000Vy = Vs DMC-1700/DMC-1000ComparisonVx = timeList of Other Publications MOTION CONTROL MADE EASY Training SeminarsADVANCED MOTION CONTROL PRODUCT WORKSHOPContacting Us WARRANTYInternet address: support@galilmc.com COPYRIGHTIndex Compensation Gear Ratio 104–7 Gearing 85–86, 104–8 Quit Stop