By Galil Motion Control, Inc
USER MANUAL
Manual Rev. 1.1b
DMC-3425
Page
Contents
Contents
Chapter 1 Overview
Chapter 2 Getting Started
Chapter 4 Communication
Chapter 3 Connecting Hardware
Chapter 5 Command Basics
Chapter 6 Programming Motion
Chapter 7 Application Programming
Chapter 10 Theory of Operation
Chapter 9 Troubleshooting
Chapter 8 Hardware & Software Protection
Index
Appendices
Introduction
Chapter 1 Overview
Brushless Servo Motor with Sinusoidal Commutation
Stepper Motor with Step and Direction Signals
Overview of Motor Types
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 Elements
Motor Interface
Communication
System Elements
General I/O
Motor
Amplifier Driver
Encoder
Watch Dog Timer
6 • Chapter 1 Overview
DMC-3425
The DMC-3425Motion Controller
Chapter 2 Getting Started
Figure 2.1 – Outline of the DMC-3425
DMC-3425
Elements You Need
Installing the DMC-3425Controller
Step 2. Configuring Jumpers on the DMC-3425
Step 1. Determine Overall Motor Configuration
Master Reset and Upgrade Jumper
Standard Servo Motor Operation
Selecting MO as default on the DMC-3425
Setting the Baud Rate on the DMC-3425
Stepper Motor Jumpers
SD MC
A1 A2 A4 A8
Axis Configuration Jumpers
Using Galil Software for DOS
Step 4. Installing the Communications Software
Using DOS
Using Windows 3.x 16 bit versions
Using Galil Software for Windows
DMC-3425
14 • Chapter 2 Getting Started
Sending Test Commands to the Terminal
Using Non-GalilCommunication Software
Communicating through the Ethernet
Using Galil Software for Windows
DMC-3425
ADDRESS
16 • Chapter 2 Getting Started
Sending Test Commands to the Terminal
Step 7. Make connections to amplifier and encoder
Step C. Connect the encoders
Step 8a. Connect Standard Servo Motor
Check the Polarity of the Feedback Loop
Inverting the Loop Polarity
Motor
Power Supply
22 • Chapter 2 Getting Started
DMC-3425
Step A. Disable the motor amplifier
If Hall Sensors are Available
If Hall Sensors are Available
If Hall Sensors are Not Available
If Hall Sensors are Not Available
Step 8c. Connect Step Motors
Step 9. Tune the Servo System
Configuring Operation for Distributed Control
Step 10. Configure the Distributed Control System
Manual Slave IP configuration with HC command
Manual Configuration of Distributed Control
Automatic Configuration Example
Instruction
Interpretation
Manual Configuration Example
Example 1 - System Set-up
Design Examples
Example 2 - Profiled Move
Example 3 - Position Interrogation
Example 6 - Operation Under Torque Limit
Example 5 - Velocity Control Jogging
Example 7 - Interrogation
Example 8 - Operation in the Buffer Mode
Example 11- Motion Programs with Trippoints
Example 9 - Motion Programs
Example 10 - Motion Programs with Loops
Example 13 - Control Variables and Offset
Example 12 - Control Variables
DMC-3425
36 • Chapter 2 Getting Started
Using Inputs
Chapter 3 Connecting Hardware
Limit Switch Input
Overview
Abort Input
Home Switch Input
38 • Chapter 3 Connecting Hardware
DMC-3425
Uncommitted Digital Inputs
Amplifier Interface
Analog Inputs
TTL Inputs
DMC-3425
AMPEN
TTL Outputs
DMC-3425
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42 • Chapter 3 Connecting Hardware
Chapter 4 Communication
RS-232Configuration
RS232 Port
RS232 - Port 1 DATATERM
Communication Protocols
Ethernet Configuration
Addressing
Handshaking Modes
Global vs. Local Operation
Ethernet Handles
GLOBAL OPERATION
LOCAL OPERATION
46 • Chapter 4 Communication
DMC-3425
Operation of Distributed Control
Accessing the I/O of the Slaves
Multicasting
Handling Communication Errors
Digital Outputs
Digital Inputs
IOC-7007Support
Unsolicited Message Handling
Definition
Modbus Support
Function Code
Handle Restore on Communication Failure
Handle Switching
Other Communication Options
User Defined Ethernet Variables
Waiting on Handle Responses
Data Record
Data Record Map
Chapter 4 Communication•
general output bank 2 DB-14064
DMC-3425
DMC-3425
54 Chapter 4 Communication
Header Information - Byte 0, 1 of Header
Axis Switch Information 1 Byte
Bytes 2, 3 of Header
General Status Information 1 Byte
Axis Status Information 2 Byte
QZ Command
Notes Regarding Velocity and Torque Information
Using Third Party Software
DMC-3425
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58 • Chapter 4 Communication
Introduction
Chapter 5 Command Basics
Command Syntax - ASCII
Coordinated Motion with more than 1 axis
Command Syntax - Binary
Byte
Binary Command Format
Header Format
Byte
Example
Binary command table
Datafields Format
Controller Response to DATA
Summary of Interrogation Commands
Interrogation Commands
Interrogating Current Commanded Values
Interrogating the Controller
Command Summary
DMC-3425
66 • Chapter 5 Command Basics
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Overview
Chapter 6 Programming Motion
Global vs. Local Operation
DMC-3425
Mode of Motion
Commands
Basic description
Global
Independent Axis Positioning
Operand Summary - Independent Axis
Command Summary - Independent Axis
Examples
Absolute Position Movement
COUNTS/SEC
VELOCITY
20000
15000
Independent Jogging
Command Summary - Jogging
Jog in A and C axes
Operand Summary - Independent Axis
Joystick Jogging
Linear Interpolation Mode Local Mode
Specifying Linear Segments
Specifying Vector Speed for Each Segment
Additional Commands
Changing Feedrate
Command Summary - Linear Interpolation
Operand Summary - Linear Interpolation
Example - Linear Move
Example
Linear Interpolation Motion
VS = VA 2 + VB
Figure 6.2 - Linear Interpolation
Example - Multiple Moves
Instruction
Interpretation
DMC-3425
Specifying Vector Segments
78 • Chapter 6 Programming Motion
Changing Feedrate
Additional commands
Specifying Vector Speed for Each Segment
Trippoints
Command Summary - Coordinated Motion Sequence
Operand Summary - Coordinated Motion Sequence
B -4000,0
C -4000,3000D 0,3000 R =
A 0,0
Example
Electronic Gearing Local Mode
Command Summary - Electronic Gearing
Example - Electronic Gearing
Example - Gantry Mode
EAp where p = A,B p is the selected master axis
Electronic Cam Local Mode
EM a,b
ET0=,0 ET1=,3000 ET2=,2250 ET3=,1500
2000
3000 2250 1500
4000
6000
This is done with the program
DMC-3425
88 • Chapter 6 Programming Motion
Specifying Contour Segments
Contour Mode Local Mode
Description
Instruction
POSITION
COUNTS
Operand Summary - Contour Mode
Command Summary - Contour Mode
General Velocity Profiles
Generating an Array - An Example
Contour Mode Example
Record and Playback Example
Teach Record and Play-Back
DMC-3425
Chapter 6 Programming Motion•
Commands
Virtual Axis Local Mode
Mode of Motion
Virtual Axis usage
Ecam Master Example
Stepper Motor Operation
Sinusoidal Motion Example
Specifying Stepper Motor Operation
Stepper Motor Smoothing
Monitoring Generated Pulses vs. Commanded Pulses
96 • Chapter 6 Programming Motion
DMC-3425
Command Summary - Stepper Motor Operation
Using an Encoder with Stepper Motors
Motion Complete Trippoint
Operand Summary - Stepper Motor Operation
Additional Commands for the Auxiliary Encoder
Using the CE Command
Dual Loop Auxiliary Encoder
Backlash Compensation
Example
Continuous Dual Loop
Sampled Dual Loop
Example
Using the IT and VT Commands
Motion Smoothing
SMOOTHING TIME VELOCITY WITH SMOOTHING TIME
Homing
ACCELERATION TIME VELOCITY TIME ACCELERATION WITH
DMC-3425
Example
102 Chapter 6 Programming Motion
Chapter 6 Programming Motion•
HOME SWITCH
DMC-3425
Operand Summary - Homing Operation
Command Summary - Homing Operation
High Speed Position Capture Latch
#Latch
Example
DMC-3425
Chapter 6 Programming Motion•
DMC-3425
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106 • Chapter 6 Programming Motion
Overview
Chapter 7 Application Programming
Global vs. Local Programming
Entering Programs
Edit Mode Commands
Program Format
Using Labels in Programs
Valid labels
Invalid labels
Commenting Programs
NO Command and the Apostrophe ‘
Special Labels
Executing Programs - Multitasking
REM Command
Debugging Programs
Error Code Command
Trace Command
Stop Code Command
RAM Memory Interrogation Commands
EEPROM Memory Interrogation Operands
Breakpoints and single stepping
Error Condition
Operands
Event Triggers & Trippoints
Program Flow Commands
Example- Multiple Move Sequence
DMC-3425Event Triggers
116 • Chapter 7 Application Programming
DMC-3425
Example - Start Motion on Input
Example- Set Output after Distance
Example- Repetitive Position Trigger
Example - Change Speed along Vector Path
Example - Set Output when At Speed
Example - Multiple Move with Wait
118 • Chapter 7 Application Programming
Conditional Jumps
Example- Define Output Waveform Using AT
Command Format - JP and JS
Logical operators
Example using variables named V1, V2, V3 and
Conditional Statements
Multiple Conditional Statements
Examples
Using the IF and ENDIF Commands
If, Else, and Endif
Command Format - IF, ELSE and ENDIF
Using the ELSE Command
Nesting IF Conditional Statements
122 • Chapter 7 Application Programming
Stack Manipulation
Auto-Startand Auto Error Routine
Subroutines
Automatic Subroutines for Monitoring Conditions
Example - Limit Switch
Example - Position Error
Example - Input Interrupt
Example - Motion Complete Timeout
Example - Command Error
OPERAND
Example - Command Error w/Multitasking
FUNCTION
Instruction
Mathematical Operators
Example – Ethernet Communication Error
Mathematical and Functional Expressions
DMC-3425
Bit-WiseOperators
128 • Chapter 7 Application Programming
Functions
Variables
Displaying the value of variables at the terminal
Programmable Variables
Assigning Values to Variables
Special Operands
Example - Using Variables for Joystick
Operands
Defining Arrays
Arrays
Assignment of Array Entries
Examples
Automatic Data Capture into Arrays
Using a Variable to Address Array Elements
Data Types for Recording
Command Summary - Automatic Data Capture
Operand Summary - Automatic Data Capture
Example - Recording into An Array
Deallocating Array Space
Outputting Numbers and Strings
Sending Messages
Specifying the Port for Messages
Example
Using the MG Command to Configure Terminals
Formatting Messages
Interrogation Commands
Displaying Variables and Arrays
Summary of Message Functions
Example
Local Formatting of Variables
Formatting Variables and Array Elements
Converting to User Units
Hardware I/O
Digital Outputs
Example- Set Bit and Clear Bit
Example - Start Motion on Switch
Example - Using Inputs to control program flow
Digital Inputs
Example- Output Port
Analog Inputs
Input Interrupt Function
Example - Position Follower Point-to-Point
Example - Input Interrupt
Example - Position Follower Continuous Move
Configuring the I/O of the DMC-3425
Extended I/O of the DMC-3425Controller
8-BitI/O
Accessing Extended I/O
Block
Binary Representation
Interfacing to Grayhill or OPTO-22G4PB24
Wire Cutter
Example Applications
DMC-3425
A-B X-YTable Controller
146 Chapter 7 Application Programming
1 inch = 40,000 counts and the speeds of
Speed Control by Joystick
Position Control by Joystick
DMC-3425
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150 • Chapter 7 Application Programming
Hardware Protection
Chapter 8 Hardware & Software Protection
Output Protection Lines
Introduction
Input Protection Lines
Software Protection
Programmable Position Limits
Example
Automatic Error Routine
Off-On-Error
Example
Examples
Limit Switch Example
Limit Switch Routine
Overview
Chapter 9 Troubleshooting
Installation
Stability
Communication
Operation
156 • Chapter 9 Troubleshooting
Overview
Chapter 10 Theory of Operation
COMPUTER
CONTROLLER
LEVEL
Figure 10.3 - Velocity and Position Profiles
Operation of Closed-LoopSystems
CONTROLLER
System Modeling
Voltage Drive
Motor-Amplifier
PV = KV Kt SSTm + 1STe +
= RJ
Velocity Loop
VELOCITY LOOP
VOLTAGE SOURCE
CURRENT SOURCE
KZ − A
Digital Filter
1 − B
Z − B
System Analysis
Page
The Analytical Method
System Design and Compensation
Ms = P/I = Kt/Js2 = 1000/s2 Amp
However, since As = Ls Gs
Equivalent Filter Form
Performance Specifications
Electrical Specifications
Power Requirements
Appendices
J3 DMC-3425General I/O; 37- PIN D-type
Connectors for DMC-3425
J3 DMC-3425-StepperGeneral I/O; 37- PIN D-type
J5 POWER; 6 PIN MOLEX
J1 RS232 Main port: DB-9Pin Male
Pin-OutDescription
Specifications
ICM-1460Interconnect Module
Features
DMC-3425
176 • Appendices
Opto-isolatedinputs
Opto-IsolationOption for ICM-1460
ICM-1460
Opto-isolatedoutputs
TO CONTROLLER
CONNECTIONS
64 Extended I/O of the DMC-3425Controller
Configuring the I/O of the DMC-3425with DB-14064
Accessing extended I/O
Signal
Connector Description
J6 50-PINIDC
Block
Block
J8 50-PINIDC
Bit @INn
Bit No
Description
DMC-3425
Overview
184 • Appendices
Digital Inputs
Configuring Hardware Banks
Sinking
Input Circuit
Sourcing
Sinking
Figure A-7
High Power Digital Outputs
Figure A-6
Result
Standard Digital Outputs
Output Command
High Power Digital Outputs
Electrical Specifications
Standard Digital Outputs
Digital Inputs
Screw Terminal Listing
Relevant DMC Commands
Appendices•
I/O65
DMC-3425
DMC-3425
192 • Appendices
1000
Coordinated Motion - Mathematical Analysis
2000
2000
time s
Velocity
Lk = Xk 2 + Yk
Lk = Rk ΔΘk 2π
= 0.05s
100000
2000000
Ts = VSD − Ta = 10000035708 - 0.05 = 0.307s
Training Seminars
List of Other Publications
MOTION CONTROL MADE EASY
ADVANCED MOTION CONTROL
Galil Motion Control
Contacting Us
DMC-3425
Appendices
WARRANTY
Index
Differential Encoder, 19, 21,
Jumper,
SDK, 27,