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