Troubleshooting, Installation | Galil DMC-2X00 manual

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	Amplifier offset too	Adjust amplifier offset
no additional inputs.	large.
Same as above, but offset adjustment does not stop	Damaged amplifier.	Replace amplifier.
the motor.
Controller does not read changes in encoder position.	Wrong encoder	Check encoder wiring.
	connections.
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.

130 • Chapter 9 Troubleshooting

DMC-2X00

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Galil DMC-2X00 user manual Troubleshooting, Installation

Contents

By Galil Motion Control, Inc DMC-2x00 Using This Manual Contents Connecting Hardware Communication Iv Contents DMC-2X00 Application Programming Troubleshooting 130 Contents y Index 210 Overview Electrical Specifications SpecificationsMechanical Specifications DMC- 2000 Family Part Number Definition Equipment Maintenance Environmental SpecificationsStandard Servo Motor with +/- 10 Volt Command Signal Overview of Motor Types Amplifiers in Current Mode Stepper Motor with Step and Direction SignalsAmplifiers in Velocity Mode Overview of Amplifiers Microcomputer Section DMC-2x00 Functional ElementsMotor Interface Communication System Elements General I/OMotor Amplifier Driver Encoder Watch Dog Timer This page Left Blank Intentionally Getting Started Outline of the DMC-2000 Daughter Board DMC-2000 Daughter Board 3B Outline of the DMC-2200 Daughter Board DMC-2200 Daughter Board CABLE-USB-2M CABLE-USB-3M Elements You Need Recommended System Elements of DMC-2100/DMC-2200 Standard Servo Motor Operation Installing the DMC-2x00Determine Overall Motor Configuration Master Reset and Upgrade Jumpers Install Jumpers on the DMC-2x00Sinusoidal Commutation Stepper Motor Operation Configure DIP switches on the DMC-2000 Switch 10 USB Switch 4, 5 and 6 Main Serial Port Baud RateConfigure DIP switches on the DMC-2100 Configure DIP switches on the DMC-2200 Connect AC Power to the Controller Install the Communications Software Communicating through the Main Serial Communications Port Establish Communications with Galil Software Communicating through the Ethernet Communicating through the Universal Serial Bus USB Determine the Axes to be Used for Sinusoidal Commutation Sending Test Commands to the Terminal Make Connections to Amplifier and Encoder DMC-2X00 Connect Standard Servo Motors BGA CR Inverting the Loop Polarity ICM-2900 Connect Sinusoidal Commutation Motors Example Sinusoidal Commutation Configuration using a DMC Getting Started DMC-2X00 SHA Tune the Servo System Connect Step Motors System Set-up Design ExamplesInstructionInterpretation Instruction Interpretation Multiple Axes Profiled MoveIndependent Moves Position Interrogation Velocity Control Absolute Position Using the On-Board Editor Operation in the Buffer ModeOperation Under Torque Limit Interrogation Line # Instruction Interpretation Motion Programs with LoopsMotion Programs with Trippoints Linear Interpolation Control VariablesXQ #B AMA LM ABC Circular InterpolationBGS VM AB This page Left Blank Intentionally Overview Using Optoisolated InputsLimit Switch Input Abort Input Home Switch Input Reset Input Wiring the Opto-Isolated InputsUncommitted Digital Inputs Opto-Isolation Common Point Optoisolated Inputs Using an Isolated Power Supply Bypassing the Opto-Isolation Analog InputsAmplifier Interface Auxiliary Encoder Inputs TTL Inputs Output Compare TTL OutputsGeneral Use Outputs Interfacing to Grayhill or OPTO-22 G4PB24 Error OutputExtended I/O of the DMC-2x00 Controller RS232 Ports IntroductionRS232 Main Port P1 Dataterm RS232 Auxiliary Port P2 Dataset RS422 Main Port P1 RS-232 ConfigurationRS422 Auxiliary Port P2 Baud Rate Selection Address Daisy-Chaining DMC-2000 only Communication Protocols Ethernet Configuration DMC-2100/2200 onlyCommand Interpretation LED Addressing DMC-2X00 Communicating with Multiple Devices Multicasting Using Third Party Software Data Record Map Data Record DMC-2X00 BIT Header Information Byte 0, 1 of Header Bytes 2, 3 of Header Axis Switch Information 1 ByteGeneral Status Information 1 Byte Axis Status Information 2 Byte QZ Command Controller Response to Commands Galil Software Tools and Libraries Unsolicited Messages Generated by Controller Important All DMC-2x00 commands are sent in upper case Command Syntax Ascii BG Abcdefgh BG AbcdBG D BG S Header Format Command Syntax Binary Datafields Format Binary Command TableExample LE, VE Controller Response to Data Summary of Interrogation Commands Interrogation CommandsInterrogating Current Commanded Values Interrogating the Controller =TPA Command Summary This page Left Blank Intentionally Example Application Mode of Motion Commands VS,VA,VD Independent Axis PositioningGA, GD GP, GR Operand Summary Independent Axis Command Summary Independent Axis Multiple Move Sequence ExamplesAbsolute Position Movement 20000 Position Tracking15000 10000 5000 Time ms 100 Example Motion Command Description PT1 Motion Example Position vs. Time msec Motion Velocity vs.Time Motion Velocity cts/sec vs. Time msec with IT Motion Trip Points Independent Jogging Command Summary Position Tracking ModeCommand Summary Jogging Joystick Jogging Jog in X onlyAS a #JOY Specifying Linear Segments Linear Interpolation ModeSpecifying the Coordinate Plane Specifying Vector Speed for Each Segment Additional CommandsChanging Feed Rate #ALT Linear Interpolation Motion Command Summary Linear InterpolationOperand Summary Linear Interpolation LM CD Linear Move Position D Multiple Moves Vector Mode Linear and Circular Interpolation Motion Specifying Vector Segments Command Summary Coordinated Motion Sequence Compensating for Differences in Encoder ResolutionTrippoints Tangent Motion Operand Operand Summary Coordinated Motion SequenceTangent Axis BG ABC Coordinated MotionAM ABC SB0 Ramped Gearing Electronic Gearing Velocity cts/sec vs. Time msec Ramped Gearing Electronic Gearing Over a Specified Interval Command Summary Electronic GearingMO Z GA Z, Z Electronic Gearing Gantry ModeSimple Master/Slave GA,A Electronic Cam DMC-2X00 3000 2250 1500 2000 4000 6000 Master a Command Description Command Summary Electronic CAM Electronic CAM Operand Summary Electronic CAM Specifying Contour Segments Contour Mode DT0CD0 336 288 240 192 Time msCMA Command Description CM Abcdefgh Command Summary Contour ModeGeneral Velocity Profiles Generating an Array #POINTS Contour Mode Record and Playback Example Teach Record and Play-Back Sinusoidal Motion Example Virtual AxisEcam master example Stepper Motor Operation Monitoring Generated Pulses vs. Commanded PulsesSpecifying Stepper Motor Operation Stepper Motor Smoothing Motion Complete Trip point Using an Encoder with Stepper MotorsCommand Summary Stepper Motor Operation Operand Summary Stepper Motor Operation Stepper Position Maintenance Mode SPM Example SPM Mode Setup Error LimitCorrection SHX #MOTION Example Error Correction Example Friction Correction Dual Loop Auxiliary Encoder Backlash Compensation Additional Commands for the Auxiliary EncoderContinuous Dual Loop = Main Encoder Second Encoder Sampled Dual Loop Motion Smoothing#DUALOOP DE0 Using the IT and VT Commands Trapezoidal velocity and smooth velocity profiles Using the KS Command Step Motor Smoothing Homing Home Sensor Home Switch High Speed Position Capture The Latch Function Command Summary Homing OperationOperand Summary Homing Operation Input Function AL B #LATCH#WAIT JP #WAIT,ALB=1 Application Programming Using the DOS Editor to Enter Programs DMC-2000 only ED #BEGIN Edit Mode Commands Program Format Using Labels in ProgramsSpecial Labels #START Commenting Programs No Command REM Half Circle Motion VP 0,3000 REM TOP Line REM CommandExecuting Programs Multitasking Debugging Programs Trace Commands DMC-2100/2200 only RAM Memory Interrogation Commands Error Code CommandStop Code Command Event Triggers & Trippoints Program Flow Commands AS a B C D E F G H Command FunctionDMC-2x00 Event Triggers Example- Set Output after Distance Example- Multiple Move SequenceExample- Repetitive Position Trigger Example Start Motion on Input Example Change Speed along Vector Path Example Set Output when At Speed Conditional Jumps Example- Define Output Waveform Using ATExample Multiple Move with Wait Logical operators Command Format JP and JSConditional Statements Multiple Conditional Statements If, Else, and Endif ExamplesJP#A #BEGIN Using the Else Command Using the if and Endif CommandsCommand Format IF, Else and Endif Nesting if Conditional Statements Auto-Start Routine SubroutinesStack Manipulation Automatic Subroutines for Monitoring Conditions Example Limit Switch Example Input Interrupt Example Position ErrorExample Motion Complete Timeout Example Command Error PAA=0 Example Command Error w/MultitaskingExample Communication Interrupt Example Ethernet Communication Error Mathematical Operators Mathematical and Functional ExpressionsBit-Wise Operators Operator Function Response from command MG len6 S4 Functions Variables Assigning Variable Values to Controller Parameters Programmable VariablesAssigning Values to Variables Operands Example Using Variables for JoystickDisplaying the value of variables at the terminal Special Operands Keywords Defining Arrays ArraysAssignment of Array Entries Time Automatic Data Capture into Arrays Using a Variable to Address Array ElementsUploading and Downloading Arrays to On Board Memory Data Types for Recording Command Summary Automatic Data CaptureOperand Summary Automatic Data Capture Example Recording into an Array Deallocating Array Space Input of Data Numeric and StringInput of Data Example- Inputting Numeric Data Keyword Function Operator Data Entry Mode Using Communication Interrupt Inputting String Variables Output of Data Numeric and String Formatting Messages Sending MessagesSpecifying the Port for Messages Summary of Message Functions Using the MG Command to Configure TerminalsDisplaying Variables and Arrays Example Printing a Variable and an Array element LZ0 0000000009 Formatting Variables and Array Elements Local Formatting of Response of Interrogation CommandsLocal Formatting of Variables LZ1 Converting to User Units Hardware I/ODigital Outputs Alph Example- Output Bit Example- Set Bit and Clear BitExample- Output Port Example Turn on output after move Example Start Motion on Switch Example Using Inputs to control program flowInput Interrupt Function AI 1BGA Example Position Follower Point-to-Point Analog InputsTP AB ST AB Example Position Follower Continuous Move Configuring the I/O of the DMC-2x00PA VP #CONT Saving the State of the Outputs in Non-Volatile Memory Accessing Extended I/OBit I/O Block Binary Decimal Value for Representation Argument Blocks Bits Description Interfacing to Grayhill or OPTO-22 G4PB24 Wire CutterExample Applications JP #A Table Controller BGS AMS AMCBGC AMC Speed Control by Joystick Backlash Compensation by Sampled Dual-Loop Position Control by Joystick BGA JP #B This page Left Blank Intentionally Output Protection Lines Hardware Protection Input Protection Lines Software Protection Automatic Error Routine Off-On-ErrorProgrammable Position Limits #AJP #AEN Limit Switch Routine Installation Troubleshooting Operation CommunicationStability Theory of Operation Level Velocity and Position Profiles Operation of Closed-Loop Systems Functional Elements of a Motion Control System System Modeling Current Drive Motor-AmplifierVoltage Drive Elements of velocity loops Velocity Loop Voltage Source Digital Filter DAC ZOH System Analysis Magnitude 200 2000 Rad/s Analytical Method System Design and Compensation Theory of Operation DMC-2X00 Equivalent Filter Form Servo Control Electrical SpecificationsStepper Control Input / Output Power Performance SpecificationsMinimum Servo Loop Update Time Normal Fast Update Rate Mode DMC-2x00 Axes A-D High Density Connector Connectors for DMC-2x00 Main Board DMC-2x00 Axes E-H High Density Connector DMC-2x00 Extended I/O 80 Pin High Density Connector DMC-2x00 Auxiliary Encoder 36 Pin High Density Connector +5V RS-232-Main Port Pin SignalRS-232-Auxiliary Port USB USB Out Pin Serial Connector Male, D-type Standard RS-232 SpecificationsCable Connections for DMC-2x00 Ethernet Pin Male computer Pin female controller DMC-2x00 Serial Cable Specifications Pin Female terminal Pin Male Controller Pin Female Computer Pin Female ControllerPin Male terminal Pin male controller Inputs Pin-Out Description for DMC-2x00Outputs Appendices DMC-2X00 Function If jumpered Jumper Description for DMC-2x00Jumper Label Dimensions for DMC-2x00 DMCWIN16 DMCWIN32 SETUP16 SETUP32 KIT Accessories and Options Block 4 PIN Label Description ICM-2900 Interconnect ModuleDescription Pwmx ErrorMocmdy Signy IN8 ResetXlatch Ylatch MAZ +MAZ+MBZ MBZ ICM ICM-2900 Drawing ICM-2908 Interconnect Module ICM-2908 ICM-2908 Drawing PCB Layout of the ICM-2900 ISO OUT Power Error Reset CMP Mocmdw FeaturesICM-1900 Interconnect Module Terminal Label DMC-2X00 100 101 102 103 104 105 106 107 MBW +INW AMP-19x0 Mating Power AmplifiersICM-1900 Drawing Standard Opto-Isolation and High Current Opto-isolation SpecificationsOpto-Isolated Outputs for ICM-2900 / ICM-1900 / AMP Changing the Amplifier Enable Voltage Level Configuring the Amplifier Enable for ICM-2900 / ICMLaen Option DMC-2000 ICM-1900 / ICM-2900 Overview IOM-1964 Opto-Isolation Module for Extended I/O Figure A-7 Configuring Hardware Banks Input Circuit Figure A-10 High Power Digital Outputs Figure A-12 Standard Digital Outputs Figure A-14 Digital Inputs Relevant DMC Commands High Power Digital OutputsStandard Digital Outputs Screw Terminal Listing DMC-2X00 PWROUT31 PWROUT32PWROUT30 PWROUT29 CB-50-100 Adapter Board Connectors Appendices DMC-2X00 JC6 50 PIN IDC J9 100 PIN High Density Connector JC8 JC6 CB-50-100 Drawing Figure A-16 CB-50-80 Adapter Board JC8 JC6 CB-50-80 Outline CB-50-80 Drawing CB-50-80 Layout Figure A-19 TERM-1500 Operator Terminal Figure A-20 Specifications Hand-Held Keypad Maps Hand-Held Specifications Panel MountSingle Key Output Shift Key Output Keypad Map Panel Mount 6 columns x 5 rows Escape CommandsCursor Movement Commands Configuration Default Function Keys Default ConfigurationInput/Output of Data DMC-2x00 Commands Function Keys Ordering Information Pin Modular ConnectorPin D Adaptor Male For P2 Vs = Vx 2 + Vy Coordinated Motion Mathematical Analysis Lk = Xk 2 + Yk Velocity Example- Communicating with OPTO-22 SNAP-B3000 MODULE=2 #CFGDOUTCFGVALUE=$180 NUMOFIO=4 Appendices DMC-2X00 DMC-2x00 DMC-1500 DMC-2x00/DMC-1500 Comparison Training Seminars List of Other Publications Contacting Us Warranty Limswi Index PID Poserr