Galil DMC-2X00 Chapter 9 Troubleshooting

130 • Chapter 9 Troubleshooting DMC-2X00

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 CAUSE REMEDY

Motor runs away when connected to amplifier with

no additional inputs.

Amplifier offset too

large.

Adjust amplifier offset

Same as above, but offset adjustment does not stop

the motor.

Damaged amplifier. Replace amplifier.

Controller does not read changes in encoder position. Wrong encoder

connections.

Check encoder wiring.

Same as above Bad encoder Check the encoder signals.

Replace encoder if necessary.

Same as above Bad controller Connect the encoder to

different axis input. If it works,

controller failure. Repair or

replace.

Contents

Main USER MANUAL DMC-2x00 By Galil Motion Control, Inc. Using This Manual 2x80 Contents Page Page Page Page Page Page Page Chapter 1 Overview Specifications DMC- 2000 Family Part Number Definition Electrical Specifications Mechanical Specifications Environmental Specifications Overview of Motor Types Standard Servo Motor with +/- 10 Volt Command Signal Brushless Servo Motor with Sinusoidal Commutation Overview of Amplifiers DMC-2x00 Functional Elements Microcomputer Section Motor Interface Communication General I/O System Elements Motor Amplifier (Driver) Encoder Watch Dog Timer Page Chapter 2 Getting Started The DMC-2x00 Main Board 10 Chapter 2 Getting Started DMC-2X00 The DMC-2000 Daughter Board MC1488 MC1489 CMB-2001 USB Communications Status LED The DMC-2200 Daughter Board 9.5" CMB-21002 REV A GALIL MOTION CONTROL 3.94" Figure 2-3B - Outline of the DMC-2200 Daughter Board Elements You Need Figure 2-4 Recommended System Elements of DMC-2000 Page Installing the DMC-2x00 Step 1. Determine Overall Motor Configuration Standard Servo Motor Operation: Sinusoidal Commutation: Stepper Motor Operation Step 2. Install Jumpers on the DMC-2x00 Master Reset and Upgrade Jumpers Opto-Isolation Jumpers Page Page Switch 4,5 and 6 - Main Serial Port Baud Rate Switch 7-Option Switch 8-Ethernet Step 4. Install the Communications Software Using Windows 98SE, NT, ME, 2000 or XP: Using Galil Software for DOS (serial communication only) Using Galil Software for Windows Using Non-Galil Communication Software Communicating through the Universal Serial Bus (USB) Communicating through the Ethernet Using Galil Software for Windows Sending Test Commands to the Terminal: Step 7. Determine the Axes to be Used for Sinusoidal Commutation Notes on Configuring Sinusoidal Commutation: Example: Sinusoidal Commutation Configuration using a DMC-2x70 Step 8. Make Connections to Amplifier and Encoder. Page Step 9a. Connect Standard Servo Motors Inverting the Loop Polarity 26 Chapter 2 Getting Started DMC-2X00 DC Servo Motor Encoder - + ICM-2900 Power Gnd 4 Motor - 2 MSA 12-80 Step 9b. Connect Sinusoidal Commutation Motors Example: Sinusoidal Commutation Configuration using a DMC- 2x70 Page Page Step 10. Tune the Servo System Design Examples System Set-up Profiled Move Multiple Axes Independent Moves Position Interrogation Absolute Position Velocity Control Operation Under Torque Limit Interrogation Operation in the Buffer Mode Using the On-Board Editor Motion Programs with Loops Motion Programs with Trippoints Control Variables Linear Interpolation Circular Interpolation Page Chapter 3 Connecting Hardware Overview Using Optoisolated Inputs Limit Switch Input Home Switch Input Abort Input Reset Input Uncommitted Digital Inputs Wiring the Opto-Isolated Inputs The Opto-Isolation Common Point Using an Isolated Power Supply Bypassing the Opto-Isolation: Analog Inputs Amplifier Interface TTL Inputs The Auxiliary Encoder Inputs TTL Outputs General Use Outputs Output Compare Error Output Extended I/O of the DMC-2x00 Controller Interfacing to Grayhill or OPTO-22 G4PB24: Chapter 4 Communication Introduction RS232 Ports RS232 - Main Port {P1} DATATERM RS232 - Auxiliary Port {P2} DATASET *RS422 - Main Port {P1} *RS422 - Auxiliary Port {P2} RS-232 Configuration Baud Rate Selection Handshaking Modes Daisy-Chaining (DMC-2000 only) Example- Daisy Chain Synchronizing Sample Clocks in Daisy Chain Ethernet Configuration (DMC-2100/2200 only) Communication Protocols Addressing Page Communicating with Multiple Devices I/O Number = (HandleNum*1000) + ((Module-1)*4) + (BitNum-1) Multicasting Using Third Party Software Data Record Data Record Map DMC-2X00 Chapter 4 Communication y 11 12 Chapter 4 Communication DMC-2X00 NOTE: UB = Unsigned Byte, UW = Unsigned Word, SW = Signed Word, SL = Signed Long Word 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 T Block Present S Block Present Bytes 2, 3 of Header: Byte 2 is the low byte and byte 3 is the high byte General Status Information (1 Byte) Axis Switch Information (1 Byte) Axis Status Information (2 Byte) Controller Response to Commands Unsolicited Messages Generated by Controller Galil Software Tools and Libraries Chapter 5 Command Basics Introduction Command Syntax - ASCII Coordinated Motion with more than 1 axis Command Syntax - Binary Binary Command Format Header Format: Byte 1 Byte 2 Datafields Format Example Binary Command Table Controller Response to DATA Interrogating the Controller Interrogation Commands Summary of Interrogation Commands Interrogating Current Commanded Values. Operands Command Summary Page Chapter 6 Programming Motion DMC-2X00 Chapter 6 Programming Motion y 25 Independent Axis Positioning Command Summary - Independent Axis Operand Summary - Independent Axis DMC-2X00 Chapter 6 Programming Motion y 27 Examples Absolute Position Movement Instruction Interpretation Multiple Move Sequence Required Motion Profiles: Position Tracking Example Motion 1: Example Motion 2: Page Page Trip Points 34 Chapter 6 Programming Motion DMC-2X00 Command Summary Position Tracking Mode Independent Jogging Command Summary - Jogging Operand Summary - Independent Axis Examples Jog in X only Joystick Jogging Linear Interpolation Mode Specifying the Coordinate Plane Specifying Linear Segments Additional Commands Specifying Vector Speed for Each Segment Changing Feed Rate: Command Summary - Linear Interpolation Operand Summary - Linear Interpolation Example Linear Interpolation Motion Linear Move Page Multiple Moves Vector Mode: Linear and Circular Interpolation Motion Specifying the Coordinate Plane Specifying Vector Segments Additional commands Specifying Vector Speed for Each Segment: Changing Feed rate: Compensating for Differences in Encoder Resolution: Trippoints: Tangent Motion: Command Summary - Coordinated Motion Sequence Operand Summary - Coordinated Motion Sequence Example Tangent Axis Coordinated Motion C (-4000,3000) R = 1500 B (-4000,0) D (0,3000) A (0,0) Electronic Gearing Ramped Gearing Page Example Electronic Gearing Over a Specified Interval Command Summary - Electronic Gearing Example Simple Master/Slave Electronic Gearing Gantry Mode Synchronize two conveyor belts with trapezoidal velocity correction. Electronic Cam Page Page DMC-2X00 Chapter 6 Programming Motion y 53 Instruction Interpretation Command Summary - Electronic CAM Command Description Operand Summary - Electronic CAM Example Electronic CAM Contour Mode Specifying Contour Segments Additional Commands Command Summary - Contour Mode General Velocity Profiles 2= Example Generating an Array () )/2cos(1 = A B AT Contour Mode DMC-2X00 Chapter 6 Programming Motion y 59 Teach (Record and Play-Back) Record and Playback Example Instruction Interpretation Virtual Axis Ecam master example Sinusoidal Motion Example Stepper Motor Operation Specifying Stepper Motor Operation Stepper Motor Smoothing Monitoring Generated Pulses vs. Commanded Pulses Motion Complete Trip point Using an Encoder with Stepper Motors Command Summary - Stepper Motor Operation Operand Summary - Stepper Motor Operation Stepper Position Maintenance Mode (SPM) YC YBYATP TDQS = Error Limit Correction Example: SPM Mode Setup Example: Error Correction Example: Friction Correction Dual Loop (Auxiliary Encoder) Additional Commands for the Auxiliary Encoder Backlash Compensation Example Continuous Dual Loop Sampled Dual Loop Motion Smoothing Using the IT and VT Commands: Example Using the KS Command (Step Motor Smoothing): Homing Page Command Summary - Homing Operation Operand Summary - Homing Operation High Speed Position Capture (The Latch Function) Page Chapter 7 Application Programming Overview Using the DOS Editor to Enter Programs (DMC-2000 only) Edit Mode Commands Example Program Format Using Labels in Programs Example Special Labels Commenting Programs NO Command REM Command Executing Programs - Multitasking Debugging Programs Trace Commands ( DMC-2100/2200 only) Error Code Command Stop Code Command RAM Memory Interrogation Commands Operands Example Program Flow Commands Event Triggers & Trippoints 84 Chapter 7 Application Programming DMC-2X00 DMC-2x00 Event Triggers Command Function Example- Multiple Move Sequence Example- Set Output after Distance Example- Repetitive Position Trigger Example - Start Motion on Input Example - Set Output when At Speed Example - Change Speed along Vector Path Example - Multiple Move with Wait Example- Define Output Waveform Using AT Conditional Jumps Command Format - JP and JS Logical operators: Conditional Statements Multiple Conditional Statements Examples If, Else, and Endif Using the IF and ENDIF Commands Using the ELSE Command Nesting IF Conditional Statements Command Format - IF, ELSE and ENDIF Subroutines Stack Manipulation Auto-Start Routine Automatic Subroutines for Monitoring Conditions Example - Limit Switch: Example - Position Error Example - Input Interrupt Example - Motion Complete Timeout Example - Command Error DMC-2X00 Chapter 7 Application Programming y 95 Example - Command Error w/Multitasking Instruction Interpretation Example - Communication Interrupt Example Ethernet Communication Error Mathematical and Functional Expressions Mathematical Operators Bit-Wise Operators Page Functions Variables Programmable Variables Assigning Values to Variables Assigning Variable Values to Controller Parameters Displaying the value of variables at the terminal Example - Using Variables for Joystick Operands Special Operands (Keywords) Arrays Defining Arrays Assignment of Array Entries Using a Variable to Address Array Elements Uploading and Downloading Arrays to On Board Memory Automatic Data Capture into Arrays 104 Chapter 7 Application Programming DMC-2X00 Command Summary - Automatic Data Capture command description Data Types for Recording: data type description NOTE: A may be replaced by B,C,D,E,F,G, or H for capturing data on other axes. Input of Data (Numeric and String) Input of Data Example- Inputting Numeric Data Example- Cut-to-Length Operator Data Entry Mode Example Using Communication Interrupt Example Inputting String Variables Output of Data (Numeric and String) Sending Messages Specifying the Port for Messages: Formatting Messages Using the MG Command to Configure Terminals Summary of Message Functions Displaying Variables and Arrays Example - Printing a Variable and an Array element Interrogation Commands Using the PF Command to Format Response from Interrogation Commands Example Removing Leading Zeros from Response to Interrogation Commands Local Formatting of Response of Interrogation Commands Formatting Variables and Array Elements Local Formatting of Variables Converting to User Units Hardware I/O Digital Outputs Example- Set Bit and Clear Bit Example- Output Bit Example- Output Port Example - Turn on output after move Digital Inputs Example - Using Inputs to control program flow Example - Start Motion on Switch The Auxiliary Encoder Inputs Input Interrupt Function Example - Input Interrupt Analog Inputs Example - Position Follower (Point-to-Point) Example - Position Follower (Continuous Move) Extended I/O of the DMC-2x00 Controller Configuring the I/O of the DMC-2x00 Saving the State of the Outputs in Non-Volatile Memory Accessing Extended I/O Interfacing to Grayhill or OPTO-22 G4PB24 Example Applications Wire Cutter A-B Table Controller Page B A Speed Control by Joystick Position Control by Joystick Backlash Compensation by Sampled Dual-Loop Page Page Chapter 8 Hardware & Software Protection Introduction Hardware Protection Output Protection Lines Input Protection Lines Software Protection Programmable Position Limits Example Off-On-Error Example Automatic Error Routine Limit Switch Routine Example Chapter 9 Troubleshooting Overview Installation DMC-2X00 Chapter 9 Troubleshooting y 131 Communication SYMPTOM CAUSE REMEDY Stability SYMPTOM CAUSE REMEDY Operation Chapter 10 Theory of Operation COMPUTER CONTROLLER DRIVER LEVEL Operation of Closed-Loop Systems System Modeling CONTROLLER Motor-Amplifier [] R T ( Voltage Drive Velocity Loop VEWP VOLTAGE SOURCE VWP VIWP CURRENT SOURCE VELOCITY LOOP DAC Digital Filter ZOH System Analysis 1 50 200 2000 W (rad/s) 0.1 4 System Design and Compensation The Analytical Method Page Equivalent Filter Form Appendices Electrical Specifications Servo Control Stepper Control Input / Output Performance Specifications Minimum Servo Loop Update Time: Fast Update Rate Mode Connectors for DMC-2x00 Main Board DMC-2x00 Axes A-D High Density Connector DMC-2x00 Axes E-H High Density Connector DMC-2x00 Auxiliary Encoder 36 Pin High Density Connector DMC-2x00 Extended I/O 80 Pin High Density Connector Page RS-232-Main Port RS-232-Auxiliary Port USB - In USB - Out Ethernet Cable Connections for DMC-2x00 Standard RS-232 Specifications 25 pin Serial Connector (Male, D-type) DMC-2X00 Appendices y 155 9 Pin Serial Connector (Male, D-type) Standard serial port connections found on most computers. DMC-2x00 Serial Cable Specifications Cable to Connect Computer 25 pin to Main Serial Port 25 Pin (Male - computer) 9 Pin (female - controller) Cable to Connect Computer 9 pin to Main Serial Port Cable (9 pin) 9 Pin (FEMALE - Computer) 9 Pin (FEMALE - Controller) Cable to Connect Computer 25 pin to Auxiliary Serial Port Cable (9 pin) 25 Pin (Male - terminal) 9 Pin (male - controller) Cable to Connect Computer 9 pin to Auxiliary Serial Port Cable (9 pin) Pin-Out Description for DMC-2x00 Outputs Inputs Page DMC-2X00 Appendices y 159 Jumper Description for DMC-2x00 Jumper Label Function (If jumpered) NOTE: MB denotes motherboard. DB denotes daughter board. Page Accessories and Options ICM-2900 Interconnect Module Mechanical Specifications Environmental Specifications Equipment Maintenance Description DMC-2X00 Appendices y 163 164 Appendices DMC-2X00 DMC-2X00 Appendices y 165 ICM-2900 Drawing: Page 168 Appendices DMC-2X00 ICM-2908 Drawing: Figure A-2 Front Side Back ICM-2908 DMC-2X00 Appendices y 169 PCB Layout of the ICM-2900: ICM-2900 BOARD LAYOUT ICM-1900 Interconnect Module DMC-2X00 Appendices y 171 172 Appendices DMC-2X00 ICM-1900 Drawing: AMP-19x0 Mating Power Amplifiers Features Specifications Opto-Isolated Outputs for ICM-2900 / ICM-1900 / AMP- 19x0 Standard Opto-Isolation and High Current Opto-isolation: Configuring the Amplifier Enable for ICM-2900 / ICM- 1900 -LAEN Option: -Changing the Amplifier Enable Voltage Level: IOM-1964 Opto-Isolation Module for Extended I/O Description: 0 1 32 5 764 Overview Configuring Hardware Banks Page High Power Digital Outputs V Standard Digital Outputs Electrical Specifications Digital Inputs 182 Appendices DMC-2X00 High Power Digital Outputs Standard Digital Outputs Relevant DMC Commands Screw Terminal Listing Rev A+B boards (orange) and Rev C boards (black) have the pinouts listed below DMC-2X00 Appendices y 183 184 Appendices DMC-2X00 DMC-2X00 Appendices y 185 NOTE: The part number for the 100-pin connector is #2-178238-9 from AMP. CB-50-100 Adapter Board Connectors: JC8 50 PIN IDC J9 100 PIN HIGH DENSITY CONNECTOR 186 Appendices DMC-2X00 DMC-2X00 Appendices y 187 JC6 50 PIN IDC J9 100 PIN HIGH DENSITY CONNECTOR 188 Appendices DMC-2X00 CB-50-100 Drawing: CB-50-80 Adapter Board 190 Appendices DMC-2X00 Connectors: DMC-2X00 Appendices y 191 JC6 J9 ( Continued ) 192 Appendices DMC-2X00 CB-50-80 Drawing: Figure A-17 CB-50-80 Outline DMC-2X00 Appendices y 193 J9 JC6 CB-50-80 Layout TERM-1500 Operator Terminal Features Description Specifications - Hand-Held Page Keypad Map - Panel Mount 6 columns x 5 rows Single Key Output Shift Key Output CTRL Key Output Escape Commands Cursor Movement Commands Page Default Configuration: Function Keys Default Function Keys Input/Output of Data DMC-2x00 Commands Example: 6-Pin Modular Connector 9-Pin D Adaptor - Male (For P2) Ordering Information Coordinated Motion - Mathematical Analysis Y CD B A Velocity time (s) Example- Communicating with OPTO-22 SNAP-B3000- ENET DMC-2X00 Appendices y 205 Page DMC-2X00 Appendices y 207 DMC-2x00/DMC-1500 Comparison BENEFIT DMC-2x00 DMC-1500 List of Other Publications Training Seminars MOTION CONTROL MADE EASY ADVANCED MOTION CONTROL PRODUCT WORKSHOP Contacting Us WARRANTY COPYRIGHT (3-97) Index