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Galil DMC-1800, DMC-1700 user manual This Page Left Blank Intentionally, 184 • Troubleshooting

Models: DMC-1800 DMC-1700

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184 • Chapter 9 Troubleshooting

DMC-1700/1800

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Galil DMC-1800, DMC-1700 user manual This Page Left Blank Intentionally, 184 • Troubleshooting

Contents

DMC-1700/1800 By Galil Motion Control, IncUSER MANUAL Manual Rev. 1.2mUsing This Manual 1X80Contents 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 9 Troubleshooting Chapter 8 Hardware & Software ProtectionChapter 10 Theory of Operation AppendicesIndex Chapter 1 Overview IntroductionStepper Motor with Step and Direction Signals Overview of Motor TypesDMC-1700/1800Functional Elements Brushless Servo Motor with Sinusoidal CommutationMicrocomputer Section Motor InterfaceCommunication General I/OSystem Elements MotorAmplifier Driver EncoderWatch Dog Timer THIS PAGE LEFT BLANK INTENTIONALLY 6 • Chapter 1 OverviewChapter 2 Getting Started J5 4 JP5 JP4 JP9JP3 J1 JP8 J6J88 • Chapter 2 Getting Started Elements You Need Installing the DMC-1700/1800 Step 1. Determine Overall Motor ConfigurationStandard Servo Motor Operation Sinusoidal CommutationStep 2. Install Jumpers on the DMC-1700/1800 Master Reset and Upgrade JumpersStepper Motor Operation Opto Isolation JumpersDRQ 0 DACK DRQ 1 DACKOptional IRQ Interrupt Jumpers Optional Motor Off JumpersStep 3. Install the Communications Software Configuring the Address Jumpers on the DMC-1700Using Win98SE, ME, NT4.0, 2000, and XP Using DOSStep 4. Install the DMC-1700/1800in the PC DMC-1700InstallDMC-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 Using Galil Software for Windows NT 22 Chapter 2 Getting StartedOnce 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 Step 7. Make Connections to Amplifier and Encoder 1X80Step D. Verify proper encoder operation Step 8a. Connect Standard Servo Motors Check the Polarity of the Feedback LoopInverting the Loop Polarity DC Power Supply DC Servo MotorDMC-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 Step 8C. Connect Step Motors If Hall Sensors are AvailableStep 9. Tune the Servo System Design Examples Example 1 - System Set-upExample 2 - Profiled Move TE X CRExample 3 - Multiple Axes Example 4 - Independent MovesExample 5 - Position Interrogation after a few seconds, command Example 6 - Absolute PositionExample 7 - Velocity Control Example 8 - Operation Under Torque LimitExample 11 - Using the On-BoardEditor Example 9 - InterrogationExample 10 - Operation in the Buffer Mode The instructionTo start the program, command Example 12 - Motion Programs with LoopsExample 13 - Motion Programs with Trippoints Example 14 - Control VariablesExample 15 - Linear Interpolation Example 16 - Circular InterpolationInstruction Interpretation0,4000 4000,4000R=2000 4000,0THIS PAGE LEFT BLANK INTENTIONALLY 42 • Chapter 2 Getting StartedChapter 3 Connecting Hardware Using Optoisolated InputsLimit Switch Input OverviewHome Switch Input 44 • Chapter 3 Connecting HardwareAbort Input Wiring the Optoisolated Inputs Uncommitted Digital Inputs1X80 17X8Using an Isolated Power Supply Analog Inputs Amplifier InterfaceBypassing the Opto-Isolation TTL Inputs TTL OutputsDMC-1700/1800 ICM-1900/29001X80 50 • Chapter 3 Connecting Hardware THIS PAGE LEFT BLANK INTENTIONALLYChapter 4 - Software Tools and Communications DMC-1700/1800Chapter 4 - Software Tools and Communications • Figure 4.1 - Software Communications Hierarchy Galil SmartTERM Figure 4.2 - Galil SmartTERMDownload Array DMC Program Editor Window DMC Data Record DisplayFigure 4.3 - Data Record Display for a DMC-1840 Communication Settings for ISA and PCI Setting Communications Parameters and MethodsGalil 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 Stall Thread and Delay Thread Methods Interrupt Communications MethodData Record Cache Depth Data Record Refresh RateFigure 4.7 - DMC-1700Data Record Parameters Figure 4.8 - DMC-1800Data Record ParametersWindows Servo Design Kit WSDK Figure 4.9- WSDK Main ScreenCreating Custom Software Interfaces ActiveX ToolkitDMCWin Programmers Toolkit Galil Communications API with C/C++Galil Communications API with Visual Basic End Sub Enabling Event Interrupts EI command DOS, Linux, and QNX toolsController Event Interrupts and User Interrupts LinuxUser Interrupts UI command Servicing InterruptsHardware Level Communications for ISA and PCI Communications with the DMC-1700Simplified Communications Procedure Communication with DMC-1700Control Register N+1 Interrupt Service for the DMC-1700 Reading the Data Record using the Polling FIFOPolling FIFO Mode Read Procedure Communications with the DMC-1800Secondary FIFO Registers OperationSimplified Communication Procedure PCI Device IdentificationDEVICE ID VENDOR IDFIFO Control Register at N+4 Half Full FlagReading the Data Record from the Secondary FIFO Enabling and Reading IRQ’sReset Register at N+8 DMA / Secondary FIFO / DPRAM Memory Mapgeneral 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 Binary Command Format Header FormatDatafields Format A7 02 00 05 03 E8 FE 0CBinary command table ExampleInterrogation Commands Summary of Interrogation CommandsController Response to DATA Interrogating the ControllerInterrogating Current Commanded Values Command SummaryOperands V=_TPXChapter 6 Programming Motion 1X80DMC-1700/1800 Chapter 6 Programming Motion •86 • Chapter 6 Programming Motion Command Summary - Independent Axis Independent Axis PositioningOperand Summary - Independent Axis Example - Absolute Position Movement Example - Multiple Move SequenceRequired Motion Profiles 88 • Chapter 6 Programming MotionCommand Summary - Jogging VELOCITYCOUNTS/SEC 20000Position Tracking Operand Summary - Independent AxisExample - Jog in X only Example - Joystick JoggingCOMMAND Example - Motion 92 Chapter 6 Programming MotionExample Motion Figure 3 Velocity vs Time msec MotionFigure 4 Position vs. Time msec Motion Trip Points 94 • Chapter 6 Programming MotionCommand Summary - Position Tracking Mode Linear Interpolation ModeSpecifying Linear Segments Additional Commands An Example of Linear Interpolation MotionSpecifying Vector Speed for Each Segment Command Summary - Linear Interpolation Operand Summary - Linear InterpolationChanging Feedrate DMC-1700/1800Example - Linear Move VS = VZ 2 + VWExample - Multiple Moves Figure 6.2 - Linear InterpolationDMC-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 Trippoints Tangent MotionExample 102 Chapter 6 Programming MotionCommand Summary - Coordinated Motion Sequence Operand Summary - Coordinated Motion SequenceExample Electronic Gearing C -4000,3000D 0,3000 R =B -4000,0 A 0,0Ramped Gearing MO Z Turn Z off, for external masterGA Z, Z Specify Z as the master axis for both X and YCommand Summary - Electronic Gearing Example - Simple Master SlaveExample - Electronic Gearing Example - Gantry ModeElectronic Cam EM x,y,z,w EM 6000,1500EP m,n EP 2000,03000 2250 1500 20004000 6000Command Summary - Electronic CAM commandINSTRUCTION INTERPRETATIONcommand Operand Summary - Electronic CAMExample - Electronic CAM descriptionContour Mode Specifying Contour SegmentsAdditional Commands POSITIONCOUNTS TIME msCommand Summary - Contour Mode ω= ΑΒ 1 − cos2π Β Χ= ATB − 2Aπ sin2π BGeneral Velocity Profiles Generating an Array - An ExampleContour Mode Example Teach Record and Play-Back Record and Playback ExampleDMC-1700/1800 Chapter 6 Programming Motion •Virtual Axis ECAM Master ExampleSinusoidal Motion Example Monitoring Generated Pulses vs Commanded Pulses Stepper Motor OperationSpecifying Stepper Motor Operation Stepper Motor SmoothingUsing an Encoder with Stepper Motors Command Summary - Stepper Motor OperationOperand Summary - Stepper Motor Operation Motion Complete TrippointStepper Position Maintenance Mode SPM Error LimitInternal Controller Commands user can query QS = TD − TP ⋅ YA ⋅ YB YCExample: SPM Mode Setup CorrectionFull-SteppingDrive, X axis Half-SteppingDrive, X axisExample Error Correction DMC-1700/1800Chapter 6 Programming Motion • Example: Friction Correction 124 • Chapter 6 Programming MotionUsing the CE Command CE Additional Commands for the Auxiliary EncoderDual Loop Auxiliary Encoder DE 0,500,-30,300Backlash Compensation Continuous Dual Loop - ExampleSampled Dual Loop - Example V1= _DEXUsing the IT and VT Commands Motion SmoothingExample - Smoothing Using the KS Command Step Motor Smoothing ACCELERATION VELOCITY ACCELERATION VELOCITYHoming StageStage StageExample: Homing InstructionInterpretation 130 • Chapter 6 Programming MotionSWITCH Command Summary - Homing Operation High Speed Position Capture The Latch FunctionOperand Summary - Homing Operation Example Find EdgeFast Update Rate Mode Pole PL Analog Feedback AF DMA channelDual 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 Edit Mode Commands Using Labels in ProgramsProgram Format Valid labelsUsing the command, NO or Apostrophe ‘ Special LabelsCommenting Programs Executing Programs - Multitasking XQ #A, nHX n Trace Commands Error Code CommandStop Code Command RAM Memory Interrogation CommandsProgram Flow Commands OperandsDebugging Example Event Triggers & Trippoints Command DMC-1700and DMC-1800Event TriggersFunction 142 • Chapter 7 Application ProgrammingEvent Trigger Examples Event Trigger - Multiple Move SequenceEvent Trigger - Set Output after Distance Event Trigger - Repetitive Position TriggerEvent Trigger - Set output when At speed Event Trigger - Start Motion on InputEvent Trigger - Change Speed along Vector Path 144 • Chapter 7 Application ProgrammingDefine Output Waveform Using AT Conditional JumpsEvent Trigger - Multiple Move with Wait Command Format - JP and JS Logical operatorsConditional Statements Multiple Conditional StatementsUsing If, Else, and Endif Commands Using the JP CommandExample Using JP command Using the IF and ENDIF CommandsUsing the ELSE Command Command Format - IF, ELSE and ENDIFExample using IF, ELSE and ENDIF Nesting IF Conditional StatementsSubroutines Stack ManipulationAuto-StartRoutine Automatic Subroutines for Monitoring ConditionsExample - Limit Switch Example - Position ErrorNotes regarding the #LIMSWI Routine Example - Motion Complete Timeout Example - Input InterruptDMC-1700/1800 Chapter 7 Application Programming •Example - Command Error Example - Command Error w/MultitaskingMathematical and Functional Expressions Mathematical OperatorsBit-WiseOperators Functions 154 • Chapter 7 Application ProgrammingVariables Programmable VariablesPOSX Assigning Values to VariablesExample - Using Variables for Joystick OperandsDisplaying the value of variables at the terminal Arrays Special Operands KeywordsDefining Arrays Examples of Internal VariablesUsing a Variable to Address Array Elements Assignment of Array EntriesCommand Summary - Automatic Data Capture Automatic Data Capture into ArraysData Types for Recording Deallocating Array Space Input of DataOperand Summary - Automatic Data Capture Example - Recording into An ArrayOutput of Data Numeric and String Sending MessagesCut-to-LengthExample Inputting String VariablesUsing the MG Command to Configure Terminals Formatting MessagesMG STR S3 The Final Value isInterrogation Commands Displaying Variables and ArraysSummary of Message Functions MG ^07 ^255Example - Using the LZ command PF m.nFormatting Variables and Array Elements Converting to User UnitsLocal Formatting of Variables VF m.nHardware I/O Digital OutputsExample - Start Motion on Switch Digital InputsInput Interrupt Function Example - Turn on output after moveAnalog Inputs Examples - Input InterruptExample - Position Follower Point-to-Point Wire Cutter Example - Position Follower Continuous Move4000/2π = 637 count/inch INSTRUCTIONX-YTable Controller 1 inch = 40,000 countsCR 80000,270,-360 Speed Control by Joystick Speed = 20000 x VIN DMC-1700/1800Chapter 7 Application Programming • Position Control by Joystick Backlash Compensation by Sampled Dual-LoopINSTRUCTION FUNCTIONExample motion program INSTRUCTIONFUNCTION THIS PAGE LEFT BLANK INTENTIONALLY 176 • Chapter 7 Application ProgrammingChapter 8 Hardware & Software Protection IntroductionHardware Protection Output Protection LinesSoftware Protection Programmable Position LimitsOff-On-Error Automatic Error RoutineLimit Switch Routine 180 • Chapter 8 Hardware & Software Protection Chapter 9 Troubleshooting InstallationOverview SYMPTOM SYMPTOM182 • Chapter 9 Troubleshooting DIAGNOSISSYMPTOM Chapter 9 Troubleshooting •DIAGNOSIS CAUSE184 • Chapter 9 Troubleshooting THIS PAGE LEFT BLANK INTENTIONALLYChapter 10 Theory of Operation COMPUTERCONTROLLER DRIVERLEVEL Operation of Closed-LoopSystems Figure 10.3 - Velocity and Position ProfilesSystem Modeling CONTROLLERMotor-Amplifier Voltage DrivePV = KV Kt SSTm + 1STe + = RJVelocity Loop T1 = J/Ka Kt KgVOLTAGE SOURCE CURRENT SOURCEVELOCITY LOOP Digital Filter KZ − A1 − B Z − BSystem Analysis Encoder Digital FilterDz = 1030 z-0.95/Z System Design and Compensation The Analytical Methodα= 76 - 180 - 6 = PM = 180 + α =Motor Kd = 10/32768 =Gs = P + sD G = 82.4 + 0.2744sP = 4 ∗ KP 4 ∗ KD = D/TEquivalent Filter Form DMC-1700/1800Appendices Electrical SpecificationsServo Control Stepper ControlPerformance Specifications PowerJ1 DMC-1740/1840 A-DAXES MAIN J5-DMC-1740/1840 A-DAXES100-PINHIGH DENSITY AUXILIARY ENCODERS; 26-PINIDCJ8 DMC-1780/1880 J6 DMC-1780/1880J7 DMC-1780/1880 E-HAXES MAINPin-OutDescription for DMC-1700/1800 OutputsPWM/STEP OUT Sign/Direction Error Inputs Setting Addresses for the DMC-1700 Standard AddressesAddress JPR A8JPR A7 JPR A6Address JPR A8JPR A7 JPR A6Plug and Play Addresses Communications JumpersAccessories and Options 210 • AppendicesPC/AT Interrupts and Their Vectors ICM-1900Interconnect ModuleThese occur on the first Features MOCMDX DMC-1700/1800Appendices • 214 • Appendices AMP-19X0Mating Power Amplifiers Figure A.1 – ICM-1900DimensionsFeatures SpecificationsICM-2900Interconnect Module Mounting: Keyholes --¼” ∅ Gain: 1 amp/VBlock 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 Connector Description OP 7,,,,7J6 50-PINIDC MG @IN17222 • Appendices Signal J8 50-PINIDCBlock Bit @INnDescription Overview Figure A.3 – IOM-1964LayoutConfiguring Hardware Banks Figure A.4 – CB-50-80and CB-50-100Bracket LayoutFigure A.5 – IOM-1964Chip Configuration Layout Digital InputsFigure A.7 – Input Sinking and Sourcing Diagram Figure A.8 – Output 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 Output Command Figure A.11 – Output Circuit DiagramStandard Digital Outputs ResultElectrical Specifications High Power Digital OutputsOutput Command Digital InputsRelevant DMC Commands Screw Terminal ListingREV A+B REV CI/O64 DMC-1700/1800Appendices • Coordinated Motion - Mathematical Analysis Vs = Vx 2 + Vy234 • Appendices Page Velocity time sLk = Xk 2 + Yk 100000DMC-1700/DMC-1000Comparison Vy = VsVx = timeList of Other Publications Training Seminars MOTION CONTROL MADE EASYADVANCED MOTION CONTROL PRODUCT WORKSHOPWARRANTY Contacting UsInternet address: support@galilmc.com COPYRIGHTIndex Compensation Gear Ratio 104–7 Gearing 85–86, 104–8 Quit Stop