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Galil DMC-3425 user manual User Manual, By Galil Motion Control, Inc, Manual Rev. 1.1b

Models: DMC-3425

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USER MANUAL

DMC-3425

Manual Rev. 1.1b

By Galil Motion Control, Inc.

Galil Motion Control, Inc. 3750 Atherton Road Rocklin, California 95765 Phone: (916) 626-0101 Fax: (916) 626-0102

Internet Address: support@galilmc.com URL: www.galilmc.com

Rev 6/06

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Galil DMC-3425 user manual User Manual, By Galil Motion Control, Inc, Manual Rev. 1.1b

Contents

By Galil Motion Control, Inc USER MANUALManual Rev. 1.1b DMC-3425Page Contents ContentsChapter 1 Overview Chapter 2 Getting StartedChapter 5 Command Basics Chapter 3 Connecting HardwareChapter 4 Communication Chapter 6 Programming Motion Chapter 7 Application Programming Chapter 8 Hardware & Software Protection Chapter 9 TroubleshootingChapter 10 Theory of Operation Index AppendicesIntroduction Chapter 1 OverviewOverview of Motor Types Stepper Motor with Step and Direction SignalsBrushless Servo Motor with Sinusoidal Commutation The DMC-3415can control BLMs equipped with Hall sensors as well as without Hall sensors. If hall sensors are available, once the controller has been setup, the controller will estimate the commutation phase upon reset. This allows the motor to function immediately upon power up. The Hall effect sensors also provide a method for setting the precise commutation phase. Chapter 2 describes the proper connection and procedure for using sinusoidal commutation of brushless motors Microcomputer Section DMC-3425Functional ElementsMotor Interface CommunicationSystem Elements General I/OMotor Amplifier DriverEncoder Watch Dog Timer6 • Chapter 1 Overview DMC-3425The DMC-3425Motion Controller Chapter 2 Getting StartedFigure 2.1 – Outline of the DMC-3425 DMC-3425Elements You Need Installing the DMC-3425ControllerStep 2. Configuring Jumpers on the DMC-3425 Step 1. Determine Overall Motor ConfigurationMaster Reset and Upgrade Jumper Standard Servo Motor OperationSelecting MO as default on the DMC-3425 Setting the Baud Rate on the DMC-3425Stepper Motor Jumpers SD MCA1 A2 A4 A8 Axis Configuration JumpersUsing Galil Software for DOS Step 4. Installing the Communications SoftwareUsing DOS Using Windows 3.x 16 bit versionsUsing Galil Software for Windows DMC-3425 14 • Chapter 2 Getting StartedSending Test Commands to the Terminal Using Non-GalilCommunication SoftwareCommunicating through the Ethernet Using Galil Software for Windows16 • Chapter 2 Getting Started ADDRESSDMC-3425 Sending Test Commands to the Terminal Step 7. Make connections to amplifier and encoderStep C. Connect the encoders Step 8a. Connect Standard Servo Motor Check the Polarity of the Feedback Loop Inverting the Loop Polarity Motor Power Supply22 • Chapter 2 Getting Started DMC-3425Step A. Disable the motor amplifier If Hall Sensors are Available If Hall Sensors are Not Available If Hall Sensors are Not AvailableIf Hall Sensors are Available Step 8c. Connect Step Motors Step 9. Tune the Servo System Configuring Operation for Distributed Control Step 10. Configure the Distributed Control SystemManual Slave IP configuration with HC command Manual Configuration of Distributed Control Automatic Configuration ExampleInstruction InterpretationManual Configuration Example Example 1 - System Set-up Design ExamplesExample 2 - Profiled Move Example 3 - Position InterrogationExample 6 - Operation Under Torque Limit Example 5 - Velocity Control JoggingExample 7 - Interrogation Example 8 - Operation in the Buffer ModeExample 10 - Motion Programs with Loops Example 9 - Motion ProgramsExample 11- Motion Programs with Trippoints Example 13 - Control Variables and Offset Example 12 - Control VariablesDMC-3425 36 • Chapter 2 Getting StartedUsing Inputs Chapter 3 Connecting HardwareLimit Switch Input OverviewAbort Input Home Switch Input38 • Chapter 3 Connecting Hardware DMC-3425Uncommitted Digital Inputs Amplifier InterfaceAnalog Inputs TTL InputsDMC-3425 AMPENTTL Outputs 42 • Chapter 3 Connecting Hardware THIS PAGE LEFT BLANK INTENTIONALLYDMC-3425 Chapter 4 Communication RS-232ConfigurationRS232 Port RS232 - Port 1 DATATERMCommunication Protocols Ethernet ConfigurationAddressing Handshaking ModesGlobal vs. Local Operation Ethernet HandlesGLOBAL OPERATION LOCAL OPERATION46 • Chapter 4 Communication DMC-3425Operation of Distributed Control Accessing the I/O of the SlavesMulticasting Handling Communication ErrorsDigital Outputs Digital InputsIOC-7007Support Unsolicited Message HandlingFunction Code Modbus SupportDefinition Handle Restore on Communication Failure Handle SwitchingOther Communication Options User Defined Ethernet VariablesData Record Map Data RecordWaiting on Handle Responses DMC-3425 general output bank 2 DB-14064Chapter 4 Communication• DMC-3425 54 Chapter 4 CommunicationHeader Information - Byte 0, 1 of Header Axis Switch Information 1 ByteBytes 2, 3 of Header General Status Information 1 ByteNotes Regarding Velocity and Torque Information QZ CommandAxis Status Information 2 Byte Using Third Party Software 58 • Chapter 4 Communication THIS PAGE LEFT BLANK INTENTIONALLYDMC-3425 Command Syntax - ASCII Chapter 5 Command BasicsIntroduction Coordinated Motion with more than 1 axis Command Syntax - BinaryByte Binary Command FormatHeader Format ByteDatafields Format Binary command tableExample Controller Response to DATA Summary of Interrogation Commands Interrogation CommandsInterrogating Current Commanded Values Interrogating the ControllerCommand Summary THIS PAGE LEFT BLANK INTENTIONALLY 66 • Chapter 5 Command BasicsDMC-3425 Overview Chapter 6 Programming MotionGlobal vs. Local Operation DMC-3425Mode of Motion CommandsBasic description GlobalIndependent Axis Positioning Operand Summary - Independent Axis Command Summary - Independent AxisExamples Absolute Position MovementCOUNTS/SEC VELOCITY20000 15000Independent Jogging Command Summary - JoggingJog in A and C axes Operand Summary - Independent AxisSpecifying Linear Segments Linear Interpolation Mode Local ModeJoystick Jogging Specifying Vector Speed for Each Segment Additional CommandsOperand Summary - Linear Interpolation Command Summary - Linear InterpolationChanging Feedrate Example - Linear Move ExampleLinear Interpolation Motion VS = VA 2 + VBFigure 6.2 - Linear Interpolation Example - Multiple MovesInstruction Interpretation78 • Chapter 6 Programming Motion Specifying Vector SegmentsDMC-3425 Specifying Vector Speed for Each Segment Additional commandsChanging Feedrate Operand Summary - Coordinated Motion Sequence Command Summary - Coordinated Motion SequenceTrippoints B -4000,0 C -4000,3000D 0,3000 R =A 0,0 ExampleElectronic Gearing Local Mode Command Summary - Electronic GearingExample - Electronic Gearing Example - Gantry ModeEAp where p = A,B p is the selected master axis Electronic Cam Local ModeEM a,b ET0=,0 ET1=,3000 ET2=,2250 ET3=,1500 2000 3000 2250 15004000 6000This is done with the program DMC-3425 88 • Chapter 6 Programming MotionSpecifying Contour Segments Contour Mode Local ModeDescription InstructionPOSITION COUNTSOperand Summary - Contour Mode Command Summary - Contour ModeGeneral Velocity Profiles Generating an Array - An ExampleContour Mode Example Record and Playback Example Teach Record and Play-BackDMC-3425 Chapter 6 Programming Motion•Commands Virtual Axis Local ModeMode of Motion Virtual Axis usageEcam Master Example Stepper Motor OperationSinusoidal Motion Example Specifying Stepper Motor OperationStepper Motor Smoothing Monitoring Generated Pulses vs. Commanded Pulses96 • Chapter 6 Programming Motion DMC-3425Command Summary - Stepper Motor Operation Using an Encoder with Stepper MotorsMotion Complete Trippoint Operand Summary - Stepper Motor OperationAdditional Commands for the Auxiliary Encoder Using the CE CommandDual Loop Auxiliary Encoder Backlash CompensationSampled Dual Loop Continuous Dual LoopExample Motion Smoothing Using the IT and VT CommandsExample ACCELERATION TIME VELOCITY TIME ACCELERATION WITH HomingSMOOTHING TIME VELOCITY WITH SMOOTHING TIME 102 Chapter 6 Programming Motion ExampleDMC-3425 DMC-3425 HOME SWITCHChapter 6 Programming Motion• High Speed Position Capture Latch Command Summary - Homing OperationOperand Summary - Homing Operation #Latch ExampleDMC-3425 Chapter 6 Programming Motion•106 • Chapter 6 Programming Motion THIS PAGE LEFT BLANK INTENTIONALLYDMC-3425 Global vs. Local Programming Chapter 7 Application ProgrammingOverview Entering Programs Edit Mode CommandsProgram Format Using Labels in ProgramsValid labels Invalid labelsSpecial Labels NO Command and the Apostrophe ‘Commenting Programs Executing Programs - Multitasking REM CommandDebugging Programs Error Code Command Trace CommandStop Code Command RAM Memory Interrogation CommandsEEPROM Memory Interrogation Operands Breakpoints and single steppingError Condition OperandsEvent Triggers & Trippoints Program Flow CommandsExample- Multiple Move Sequence DMC-3425Event Triggers116 • Chapter 7 Application Programming DMC-3425Example- Repetitive Position Trigger Example- Set Output after DistanceExample - Start Motion on Input Example - Change Speed along Vector Path Example - Set Output when At SpeedExample - Multiple Move with Wait 118 • Chapter 7 Application ProgrammingCommand Format - JP and JS Example- Define Output Waveform Using ATConditional Jumps Logical operators Example using variables named V1, V2, V3 andConditional Statements Multiple Conditional StatementsIf, Else, and Endif Using the IF and ENDIF CommandsExamples Command Format - IF, ELSE and ENDIF Using the ELSE CommandNesting IF Conditional Statements 122 • Chapter 7 Application ProgrammingSubroutines Auto-Startand Auto Error RoutineStack Manipulation Example - Position Error Example - Limit SwitchAutomatic Subroutines for Monitoring Conditions Example - Command Error Example - Motion Complete TimeoutExample - Input Interrupt OPERAND Example - Command Error w/MultitaskingFUNCTION InstructionMathematical and Functional Expressions Example – Ethernet Communication ErrorMathematical Operators 128 • Chapter 7 Application Programming Bit-WiseOperatorsDMC-3425 Functions VariablesAssigning Values to Variables Programmable VariablesDisplaying the value of variables at the terminal Operands Example - Using Variables for JoystickSpecial Operands Defining Arrays ArraysAssignment of Array Entries ExamplesAutomatic Data Capture into Arrays Using a Variable to Address Array ElementsData Types for Recording Command Summary - Automatic Data CaptureOperand Summary - Automatic Data Capture Example - Recording into An ArrayDeallocating Array Space Outputting Numbers and StringsSending Messages Specifying the Port for MessagesFormatting Messages Using the MG Command to Configure TerminalsExample Summary of Message Functions Displaying Variables and ArraysInterrogation Commands Example Local Formatting of Variables Formatting Variables and Array ElementsConverting to User Units Hardware I/ODigital Outputs Example- Set Bit and Clear BitExample - Start Motion on Switch Example - Using Inputs to control program flowDigital Inputs Example- Output PortAnalog Inputs Input Interrupt FunctionExample - Position Follower Point-to-Point Example - Input InterruptExtended I/O of the DMC-3425Controller Configuring the I/O of the DMC-3425Example - Position Follower Continuous Move 8-BitI/O Accessing Extended I/OBlock Binary RepresentationExample Applications Wire CutterInterfacing to Grayhill or OPTO-22G4PB24 146 Chapter 7 Application Programming A-B X-YTable ControllerDMC-3425 1 inch = 40,000 counts and the speeds of Speed Control by Joystick Position Control by Joystick 150 • Chapter 7 Application Programming THIS PAGE LEFT BLANK INTENTIONALLYDMC-3425 Hardware Protection Chapter 8 Hardware & Software ProtectionOutput Protection Lines IntroductionInput Protection Lines Software ProtectionProgrammable Position Limits ExampleAutomatic Error Routine Off-On-ErrorExample ExamplesLimit Switch Example Limit Switch RoutineInstallation Chapter 9 TroubleshootingOverview Stability CommunicationOperation 156 • Chapter 9 TroubleshootingOverview Chapter 10 Theory of OperationCOMPUTER CONTROLLERLEVEL Figure 10.3 - Velocity and Position Profiles Operation of Closed-LoopSystemsCONTROLLER System ModelingVoltage Drive Motor-AmplifierPV = KV Kt SSTm + 1STe + = RJVelocity Loop CURRENT SOURCE VOLTAGE SOURCEVELOCITY LOOP KZ − A Digital Filter1 − B Z − BSystem Analysis Page The Analytical Method System Design and CompensationMs = P/I = Kt/Js2 = 1000/s2 Amp However, since As = Ls Gs Equivalent Filter Form Performance Specifications Electrical SpecificationsPower Requirements AppendicesJ3 DMC-3425General I/O; 37- PIN D-type Connectors for DMC-3425J3 DMC-3425-StepperGeneral I/O; 37- PIN D-type J5 POWER; 6 PIN MOLEXJ1 RS232 Main port: DB-9Pin Male Pin-OutDescriptionFeatures ICM-1460Interconnect ModuleSpecifications DMC-3425 176 • AppendicesOpto-isolatedinputs Opto-IsolationOption for ICM-1460ICM-1460 Opto-isolatedoutputsTO CONTROLLER CONNECTIONS64 Extended I/O of the DMC-3425Controller Configuring the I/O of the DMC-3425with DB-14064Accessing extended I/O Signal Connector DescriptionJ6 50-PINIDC BlockBlock J8 50-PINIDCBit @INn Bit NoDescription 184 • Appendices OverviewDMC-3425 Digital Inputs Configuring Hardware BanksSinking Input CircuitSourcing SinkingFigure A-6 High Power Digital OutputsFigure A-7 Output Command Standard Digital OutputsResult High Power Digital Outputs Electrical SpecificationsStandard Digital Outputs Digital InputsScrew Terminal Listing Relevant DMC CommandsDMC-3425 I/O65Appendices• DMC-3425 192 • Appendices1000 Coordinated Motion - Mathematical Analysis2000 2000time s VelocityLk = Xk 2 + Yk Lk = Rk ΔΘk 2π= 0.05s 1000002000000 Ts = VSD − Ta = 10000035708 - 0.05 = 0.307sTraining Seminars List of Other PublicationsMOTION CONTROL MADE EASY ADVANCED MOTION CONTROLGalil Motion Control Contacting UsDMC-3425 AppendicesWARRANTY Index Differential Encoder, 19, 21, Jumper, SDK, 27,