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Galil DMC-3425 user manual Troubleshooting, Installation, Overview

Models: DMC-3425

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Chapter 9 Troubleshooting

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

DMC-3425

Chapter 9 Troubleshooting• 155

Image 163

Galil DMC-3425 user manual Troubleshooting, Installation, Overview

Contents

DMC-3425 USER MANUALBy Galil Motion Control, Inc Manual Rev. 1.1bPage Chapter 2 Getting Started ContentsContents Chapter 1 OverviewChapter 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 Communication DMC-3425Functional ElementsMicrocomputer Section Motor InterfaceAmplifier Driver General I/OSystem Elements MotorDMC-3425 Watch Dog TimerEncoder 6 • Chapter 1 OverviewDMC-3425 Chapter 2 Getting StartedThe DMC-3425Motion Controller Figure 2.1 – Outline of the DMC-3425Elements You Need Installing the DMC-3425ControllerStandard Servo Motor Operation Step 1. Determine Overall Motor ConfigurationStep 2. Configuring Jumpers on the DMC-3425 Master Reset and Upgrade JumperSD MC Setting the Baud Rate on the DMC-3425Selecting MO as default on the DMC-3425 Stepper Motor JumpersA1 A2 A4 A8 Axis Configuration JumpersUsing Windows 3.x 16 bit versions Step 4. Installing the Communications SoftwareUsing Galil Software for DOS Using DOSUsing Galil Software for Windows DMC-3425 14 • Chapter 2 Getting StartedUsing Galil Software for Windows Using Non-GalilCommunication SoftwareSending Test Commands to the Terminal Communicating through the Ethernet16 • 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 DMC-3425 Power SupplyMotor 22 • Chapter 2 Getting StartedStep 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 Interpretation Automatic Configuration ExampleManual Configuration of Distributed Control InstructionManual Configuration Example Example 3 - Position Interrogation Design ExamplesExample 1 - System Set-up Example 2 - Profiled MoveExample 8 - Operation in the Buffer Mode Example 5 - Velocity Control JoggingExample 6 - Operation Under Torque Limit Example 7 - InterrogationExample 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 StartedOverview Chapter 3 Connecting HardwareUsing Inputs Limit Switch InputDMC-3425 Home Switch InputAbort Input 38 • Chapter 3 Connecting HardwareUncommitted Digital Inputs Amplifier InterfaceAMPEN TTL InputsAnalog Inputs DMC-3425TTL Outputs 42 • Chapter 3 Connecting Hardware THIS PAGE LEFT BLANK INTENTIONALLYDMC-3425 RS232 - Port 1 DATATERM RS-232ConfigurationChapter 4 Communication RS232 PortHandshaking Modes Ethernet ConfigurationCommunication Protocols AddressingGlobal vs. Local Operation Ethernet HandlesDMC-3425 LOCAL OPERATIONGLOBAL OPERATION 46 • Chapter 4 CommunicationOperation of Distributed Control Accessing the I/O of the SlavesDigital Inputs Handling Communication ErrorsMulticasting Digital OutputsIOC-7007Support Unsolicited Message HandlingFunction Code Modbus SupportDefinition User Defined Ethernet Variables Handle SwitchingHandle Restore on Communication Failure Other Communication OptionsData Record Map Data RecordWaiting on Handle Responses DMC-3425 general output bank 2 DB-14064Chapter 4 Communication• DMC-3425 54 Chapter 4 CommunicationGeneral Status Information 1 Byte Axis Switch Information 1 ByteHeader Information - Byte 0, 1 of Header Bytes 2, 3 of HeaderNotes 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 FormatByte Header FormatDatafields Format Binary command tableExample Controller Response to DATA Interrogating the Controller Interrogation CommandsSummary of Interrogation Commands Interrogating Current Commanded ValuesCommand Summary THIS PAGE LEFT BLANK INTENTIONALLY 66 • Chapter 5 Command BasicsDMC-3425 DMC-3425 Chapter 6 Programming MotionOverview Global vs. Local OperationGlobal CommandsMode of Motion Basic descriptionIndependent Axis Positioning Absolute Position Movement Command Summary - Independent AxisOperand Summary - Independent Axis Examples15000 VELOCITYCOUNTS/SEC 20000Operand Summary - Independent Axis Command Summary - JoggingIndependent Jogging Jog in A and C axesSpecifying Linear Segments Linear Interpolation Mode Local ModeJoystick Jogging Specifying Vector Speed for Each Segment Additional CommandsOperand Summary - Linear Interpolation Command Summary - Linear InterpolationChanging Feedrate VS = VA 2 + VB ExampleExample - Linear Move Linear Interpolation MotionInterpretation Example - Multiple MovesFigure 6.2 - Linear Interpolation Instruction78 • 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 Example C -4000,3000D 0,3000 R =B -4000,0 A 0,0Example - Gantry Mode Command Summary - Electronic GearingElectronic Gearing Local Mode Example - Electronic GearingEAp where p = A,B p is the selected master axis Electronic Cam Local ModeEM a,b ET0=,0 ET1=,3000 ET2=,2250 ET3=,1500 6000 3000 2250 15002000 4000This is done with the program DMC-3425 88 • Chapter 6 Programming MotionSpecifying Contour Segments Contour Mode Local ModeCOUNTS InstructionDescription POSITIONGenerating an Array - An Example Command Summary - Contour ModeOperand Summary - Contour Mode General Velocity ProfilesContour Mode Example Chapter 6 Programming Motion• Teach Record and Play-BackRecord and Playback Example DMC-3425Virtual Axis usage Virtual Axis Local ModeCommands Mode of MotionSpecifying Stepper Motor Operation Stepper Motor OperationEcam Master Example Sinusoidal Motion ExampleDMC-3425 Monitoring Generated Pulses vs. Commanded PulsesStepper Motor Smoothing 96 • Chapter 6 Programming MotionOperand Summary - Stepper Motor Operation Using an Encoder with Stepper MotorsCommand Summary - Stepper Motor Operation Motion Complete TrippointBacklash Compensation Using the CE CommandAdditional Commands for the Auxiliary Encoder Dual Loop Auxiliary EncoderSampled 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 Chapter 6 Programming Motion• Example#Latch DMC-3425106 • Chapter 6 Programming Motion THIS PAGE LEFT BLANK INTENTIONALLYDMC-3425 Global vs. Local Programming Chapter 7 Application ProgrammingOverview Entering Programs Edit Mode CommandsInvalid labels Using Labels in ProgramsProgram Format Valid labelsSpecial Labels NO Command and the Apostrophe ‘Commenting Programs Executing Programs - Multitasking REM CommandDebugging Programs RAM Memory Interrogation Commands Trace CommandError Code Command Stop Code CommandOperands Breakpoints and single steppingEEPROM Memory Interrogation Operands Error ConditionEvent Triggers & Trippoints Program Flow CommandsDMC-3425 DMC-3425Event TriggersExample- Multiple Move Sequence 116 • Chapter 7 Application ProgrammingExample- Repetitive Position Trigger Example- Set Output after DistanceExample - Start Motion on Input 118 • Chapter 7 Application Programming Example - Set Output when At SpeedExample - Change Speed along Vector Path Example - Multiple Move with WaitCommand Format - JP and JS Example- Define Output Waveform Using ATConditional Jumps Multiple Conditional Statements Example using variables named V1, V2, V3 andLogical operators Conditional StatementsIf, Else, and Endif Using the IF and ENDIF CommandsExamples 122 • Chapter 7 Application Programming Using the ELSE CommandCommand Format - IF, ELSE and ENDIF Nesting IF Conditional StatementsSubroutines 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 Instruction Example - Command Error w/MultitaskingOPERAND FUNCTIONMathematical 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 Examples ArraysDefining Arrays Assignment of Array EntriesAutomatic Data Capture into Arrays Using a Variable to Address Array ElementsExample - Recording into An Array Command Summary - Automatic Data CaptureData Types for Recording Operand Summary - Automatic Data CaptureSpecifying the Port for Messages Outputting Numbers and StringsDeallocating Array Space Sending 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 ElementsExample- Set Bit and Clear Bit Hardware I/OConverting to User Units Digital OutputsExample- Output Port Example - Using Inputs to control program flowExample - Start Motion on Switch Digital InputsExample - Input Interrupt Input Interrupt FunctionAnalog Inputs Example - Position Follower Point-to-PointExtended I/O of the DMC-3425Controller Configuring the I/O of the DMC-3425Example - Position Follower Continuous Move Binary Representation Accessing Extended I/O8-BitI/O BlockExample 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 Introduction Chapter 8 Hardware & Software ProtectionHardware Protection Output Protection LinesExample Software ProtectionInput Protection Lines Programmable Position LimitsExamples Off-On-ErrorAutomatic Error Routine ExampleLimit Switch Example Limit Switch RoutineInstallation Chapter 9 TroubleshootingOverview 156 • Chapter 9 Troubleshooting CommunicationStability OperationCONTROLLER Chapter 10 Theory of OperationOverview COMPUTERLEVEL Figure 10.3 - Velocity and Position Profiles Operation of Closed-LoopSystemsCONTROLLER System Modeling= RJ Motor-AmplifierVoltage Drive PV = KV Kt SSTm + 1STe +Velocity Loop CURRENT SOURCE VOLTAGE SOURCEVELOCITY LOOP Z − B Digital FilterKZ − A 1 − 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 Appendices Electrical SpecificationsPerformance Specifications Power RequirementsJ3 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-1460CONNECTIONS Opto-isolatedoutputsICM-1460 TO CONTROLLER64 Extended I/O of the DMC-3425Controller Configuring the I/O of the DMC-3425with DB-14064Accessing extended I/O Block Connector DescriptionSignal J6 50-PINIDCBit No J8 50-PINIDCBlock Bit @INnDescription 184 • Appendices OverviewDMC-3425 Digital Inputs Configuring Hardware BanksSinking Input CircuitSinking SourcingFigure A-6 High Power Digital OutputsFigure A-7 Output Command Standard Digital OutputsResult Digital Inputs Electrical SpecificationsHigh Power Digital Outputs Standard Digital OutputsScrew Terminal Listing Relevant DMC CommandsDMC-3425 I/O65Appendices• DMC-3425 192 • Appendices2000 Coordinated Motion - Mathematical Analysis1000 2000Lk = Rk ΔΘk 2π Velocitytime s Lk = Xk 2 + YkTs = VSD − Ta = 10000035708 - 0.05 = 0.307s 100000= 0.05s 2000000ADVANCED MOTION CONTROL List of Other PublicationsTraining Seminars MOTION CONTROL MADE EASYAppendices Contacting UsGalil Motion Control DMC-3425WARRANTY Index Differential Encoder, 19, 21, Jumper, SDK, 27,