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Galil DMC-2X00 - User Manual

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USER MANUAL
DMC-2x00
Manual Rev. 2.1
By Galil Motion Control, Inc.
Galil Motion Control, Inc.
270 Technology Way
Rocklin, California 95765
Phone: (916) 626-0101
Fax: (916) 626-0102
E-mail Address: support@galilmc.com
URL: www.galilmc.com
Rev 03/2011

Table of Contents

Questions and Answers

Summary

Using This Manual

Introduction

Provides an overview of the DMC-2x00 series controller, highlighting enhanced features and capabilities for motion control.

Specifications

Details electrical, mechanical, and environmental specifications for the DMC-2000 family.

Overview of Motor Types

Describes the types of motor control supported: servo motors, brushless motors, and stepper motors.

Overview of Amplifiers

Discusses amplifier types and configurations in current and velocity modes for motor control.

DMC-2 x00 Functional Elements

Details the main functional groups of the DMC-2x00 circuitry, including microcomputer, motor interface, and I/O.

Chapter 2 Getting Started

The DMC-2 x00 Main Board

Provides an outline and description of the main board components and connectors.

Elements You Need

Lists the recommended system elements required for setting up a DMC-2000 system.

Installing the DMC-2 x00

Guides users through the 9-step process of installing and configuring the DMC-2x00 motion controller.

Step 1. Determine Overall Motor Configuration

User must determine the desired motor configuration for the motion control system.

Step 2. Install Jumpers on the DMC-2 x00

Describes the installation of master reset, upgrade, opto-isolation, and stepper motor jumpers.

Step 6. Establish Communications with Galil Software

Steps to establish communication via serial or USB ports using Galil software.

Step 8. Make Connections to Amplifier and Encoder.

Details connecting motors to amplifiers and encoders, including amplifier enable signals.

Step 10. Tune the Servo System

Guidance on adjusting PID filter parameters (KP, KD, KI) for servo system tuning.

Chapter 3 Connecting Hardware

Overview

Describes opto-isolated digital inputs, TTL outputs, and analog inputs of the DMC-2x00.

Using Optoisolated Inputs

Details the functionality and connection of limit switch, home, and abort inputs.

Limit Switch Input

Explains how forward/reverse limit switches inhibit motion and trigger subroutines.

Home Switch Input

Describes homing routines (Find Edge, Find Index, Standard Homing) using the home switch input.

Analog Inputs

Covers the eight analog inputs and their resolution for sensors.

Amplifier Interface

Describes the +/-10V command signal for amplifiers and the amplifier enable signal (AMPEN).

TTL Outputs

Covers general use and dedicated TTL outputs.

Extended I;O of the DMC-2 x00 Controller

Details the 64 extended TTL I/O points configurable as inputs or outputs.

Chapter 4 Communication

Introduction

Overview of communication ports (RS232, USB, Ethernet) and capabilities.

RS232 Ports

Detailed pin-out descriptions for main and auxiliary RS-232 ports, including RS422 configuration.

RS-232 Configuration

PC configuration settings and front panel switch settings for RS-232 communication.

Ethernet Configuration (DMC-2100;2200 only)

Details Ethernet communication protocols and addressing setup.

Addressing

Explains Ethernet device addressing levels: hardware, IP, and UDP/TCP port.

Data Record

Describes the QR command for retrieving controller status and data record information.

Controller Response to Commands

Explains controller responses (colon for valid, question mark for invalid) and error codes.

Chapter 5 Command Basics

Introduction

Overview of the DMC-2x00's command set for motion control and parameter configuration.

Command Syntax - ASCII

Details the format, syntax, and rules for using ASCII commands.

Command Syntax - Binary

Explains the binary command format, including header structure and data fields.

Interrogating the Controller

Covers commands to directly interrogate controller status and parameters.

Interrogation Commands

Lists and describes commands used to retrieve controller information.

Operands

Describes operands used for interrogation and within expressions.

Command Summary

Refers to a comprehensive command summary in the Command Reference manual.

Chapter 6 Programming Motion

Overview

Introduces modes of motion: positioning, jogging, coordinated motion, electronic cam, and gearing.

Independent Axis Positioning

Explains motion where each axis operates independently, following its own profile.

Position Tracking

Describes a mode for changing absolute position targets on the fly during motion.

Linear Interpolation Mode

Explains coordinated motion along linear segments for 2+ axes.

Electronic Gearing

Allows electronic gearing of up to 8 axes to a master axis with specified gear ratios.

Electronic Cam

Enables periodic synchronization of axes using a table-based relationship.

Contour Mode

Allows arbitrary position curves for 1-8 axes, ideal for complex paths.

Stepper Motor Operation

Covers operation and commands specific to stepper motors.

Homing

Explains routines for moving the motor to a mechanical reference using Home or Find Edge inputs.

Virtual Axis

Introduces the virtual N axis for ECAM master and vector mode applications.

Chapter 7 Application Programming

Overview

Introduces the powerful programming language for customizing controller applications.

Using the DOS Editor to Enter Programs (DMC-2000 only)

Guides on using the controller's internal editor for program creation and editing.

Program Format

Defines the structure of DMC programs, including instructions and delimiters.

Executing Programs - Multitasking

Explains how to run up to 8 independent programs (threads) simultaneously.

Debugging Programs

Covers commands and operands for monitoring execution and diagnosing issues.

Program Flow Commands

Instructions that control program execution based on events or conditions.

Conditional Jumps

Details JP and JS instructions for branching based on specified conditions.

Subroutines

Explains creating and calling reusable blocks of instructions with labels.

Automatic Subroutines for Monitoring Conditions

Details using predefined labels for automatic execution based on specific conditions.

Mathematical and Functional Expressions

Covers mathematical operators, functions, and expressions for calculations.

Variables

Explains using programmable variables for dynamic parameter settings.

Arrays

Describes using arrays for storing and collecting numerical data.

Input of Data (Numeric and String)

Covers using the IN command to prompt for and input data.

Output of Data (Numeric and String)

Covers methods for outputting data using MG, interrogation commands, and variables.

Chapter 8 Hardware & Software Protection

Introduction

Overview of hardware and software features for error checking and motor inhibition.

Hardware Protection

Details input/output protection lines for errors and mechanical limits.

Output Protection Lines

Explains Amp Enable signal and Error Output signal behavior.

Input Protection Lines

Describes general abort, selective abort, forward, and reverse limit switches.

Software Protection

Covers programmable error limits and the Off-On-Error function.

Programmable Position Limits

Explains setting forward and reverse position limits using BL and FL commands.

Off-On-Error

Details the function to turn off motors under specific error conditions.

Automatic Error Routine

Explains the #POSERR subroutine for automatic execution on position error.

Limit Switch Routine

Describes the #LIMSWI subroutine for automatic execution upon limit switch activation.

Chapter 9 Troubleshooting

Overview

Discusses potential problems, causes, and remedies for system setup and operation.

Installation

Provides a table of common installation symptoms, causes, and remedies.

Communication

Lists common communication issues and their troubleshooting steps.

Stability

Addresses motor oscillation and runaway issues related to feedback polarity and gain.

Operation

Covers troubleshooting for command rejection, incomplete moves, and motor drift.

Chapter 10 Theory of Operation

Overview

Explains the fundamental levels of motion control systems: loop closing, motion profiling, and programming.

Operation of Closed-Loop Systems

Explains how servo systems maintain position through feedback and error correction.

System Modeling

Describes the functional elements of a servo system and their mathematical models.

Motor-Amplifier

Details the three modes of operation (Voltage Drive, Current Drive, Velocity Loop) and their transfer functions.

Digital Filter

Explains the PID, low-pass, and notch filter elements and their parameters.

System Analysis

Presents an example of analyzing a position control system using block diagrams.

System Design and Compensation

Discusses stabilizing closed-loop systems using digital filters and analytical design methods.

Appendices

Electrical Specifications

Provides electrical specifications for servo control, stepper control, I/O, and analog inputs.

Performance Specifications

Details servo loop update times and position accuracy.

Fast Update Rate Mode

Explains operating the controller with faster servo update rates using fast firmware.

Connectors for DMC-2 x00 Main Board

Pin-out descriptions for high-density connectors on the main board.

ICM-2900 Interconnect Module

Details mechanical, environmental, and description of the ICM-2900 module.

ICM-1900 Interconnect Module

Details the ICM-1900 for easy connections to amplifiers, encoders, and switches.

AMP-19 x0 Mating Power Amplifiers

Describes mating servo amplifiers for the DMC-2x00, rated for 7A continuous, 10A peak.

Opto-Isolated Outputs for ICM-2900; ICM-1900; AMP-19 x0

Explains opto-isolation options for outputs on ICM/AMP modules.

TERM-1500 Operator Terminal

Details the operator terminal (hand-held and panel mount) and its features.

Coordinated Motion - Mathematical Analysis

Explains the mathematical basis of coordinated motion, including vector velocity and path segments.

Summary

Using This Manual

Introduction

Provides an overview of the DMC-2x00 series controller, highlighting enhanced features and capabilities for motion control.

Specifications

Details electrical, mechanical, and environmental specifications for the DMC-2000 family.

Overview of Motor Types

Describes the types of motor control supported: servo motors, brushless motors, and stepper motors.

Overview of Amplifiers

Discusses amplifier types and configurations in current and velocity modes for motor control.

DMC-2 x00 Functional Elements

Details the main functional groups of the DMC-2x00 circuitry, including microcomputer, motor interface, and I/O.

Chapter 2 Getting Started

The DMC-2 x00 Main Board

Provides an outline and description of the main board components and connectors.

Elements You Need

Lists the recommended system elements required for setting up a DMC-2000 system.

Installing the DMC-2 x00

Guides users through the 9-step process of installing and configuring the DMC-2x00 motion controller.

Step 1. Determine Overall Motor Configuration

User must determine the desired motor configuration for the motion control system.

Step 2. Install Jumpers on the DMC-2 x00

Describes the installation of master reset, upgrade, opto-isolation, and stepper motor jumpers.

Step 6. Establish Communications with Galil Software

Steps to establish communication via serial or USB ports using Galil software.

Step 8. Make Connections to Amplifier and Encoder.

Details connecting motors to amplifiers and encoders, including amplifier enable signals.

Step 10. Tune the Servo System

Guidance on adjusting PID filter parameters (KP, KD, KI) for servo system tuning.

Chapter 3 Connecting Hardware

Overview

Describes opto-isolated digital inputs, TTL outputs, and analog inputs of the DMC-2x00.

Using Optoisolated Inputs

Details the functionality and connection of limit switch, home, and abort inputs.

Limit Switch Input

Explains how forward/reverse limit switches inhibit motion and trigger subroutines.

Home Switch Input

Describes homing routines (Find Edge, Find Index, Standard Homing) using the home switch input.

Analog Inputs

Covers the eight analog inputs and their resolution for sensors.

Amplifier Interface

Describes the +/-10V command signal for amplifiers and the amplifier enable signal (AMPEN).

TTL Outputs

Covers general use and dedicated TTL outputs.

Extended I;O of the DMC-2 x00 Controller

Details the 64 extended TTL I/O points configurable as inputs or outputs.

Chapter 4 Communication

Introduction

Overview of communication ports (RS232, USB, Ethernet) and capabilities.

RS232 Ports

Detailed pin-out descriptions for main and auxiliary RS-232 ports, including RS422 configuration.

RS-232 Configuration

PC configuration settings and front panel switch settings for RS-232 communication.

Ethernet Configuration (DMC-2100;2200 only)

Details Ethernet communication protocols and addressing setup.

Addressing

Explains Ethernet device addressing levels: hardware, IP, and UDP/TCP port.

Data Record

Describes the QR command for retrieving controller status and data record information.

Controller Response to Commands

Explains controller responses (colon for valid, question mark for invalid) and error codes.

Chapter 5 Command Basics

Introduction

Overview of the DMC-2x00's command set for motion control and parameter configuration.

Command Syntax - ASCII

Details the format, syntax, and rules for using ASCII commands.

Command Syntax - Binary

Explains the binary command format, including header structure and data fields.

Interrogating the Controller

Covers commands to directly interrogate controller status and parameters.

Interrogation Commands

Lists and describes commands used to retrieve controller information.

Operands

Describes operands used for interrogation and within expressions.

Command Summary

Refers to a comprehensive command summary in the Command Reference manual.

Chapter 6 Programming Motion

Overview

Introduces modes of motion: positioning, jogging, coordinated motion, electronic cam, and gearing.

Independent Axis Positioning

Explains motion where each axis operates independently, following its own profile.

Position Tracking

Describes a mode for changing absolute position targets on the fly during motion.

Linear Interpolation Mode

Explains coordinated motion along linear segments for 2+ axes.

Electronic Gearing

Allows electronic gearing of up to 8 axes to a master axis with specified gear ratios.

Electronic Cam

Enables periodic synchronization of axes using a table-based relationship.

Contour Mode

Allows arbitrary position curves for 1-8 axes, ideal for complex paths.

Stepper Motor Operation

Covers operation and commands specific to stepper motors.

Homing

Explains routines for moving the motor to a mechanical reference using Home or Find Edge inputs.

Virtual Axis

Introduces the virtual N axis for ECAM master and vector mode applications.

Chapter 7 Application Programming

Overview

Introduces the powerful programming language for customizing controller applications.

Using the DOS Editor to Enter Programs (DMC-2000 only)

Guides on using the controller's internal editor for program creation and editing.

Program Format

Defines the structure of DMC programs, including instructions and delimiters.

Executing Programs - Multitasking

Explains how to run up to 8 independent programs (threads) simultaneously.

Debugging Programs

Covers commands and operands for monitoring execution and diagnosing issues.

Program Flow Commands

Instructions that control program execution based on events or conditions.

Conditional Jumps

Details JP and JS instructions for branching based on specified conditions.

Subroutines

Explains creating and calling reusable blocks of instructions with labels.

Automatic Subroutines for Monitoring Conditions

Details using predefined labels for automatic execution based on specific conditions.

Mathematical and Functional Expressions

Covers mathematical operators, functions, and expressions for calculations.

Variables

Explains using programmable variables for dynamic parameter settings.

Arrays

Describes using arrays for storing and collecting numerical data.

Input of Data (Numeric and String)

Covers using the IN command to prompt for and input data.

Output of Data (Numeric and String)

Covers methods for outputting data using MG, interrogation commands, and variables.

Chapter 8 Hardware & Software Protection

Introduction

Overview of hardware and software features for error checking and motor inhibition.

Hardware Protection

Details input/output protection lines for errors and mechanical limits.

Output Protection Lines

Explains Amp Enable signal and Error Output signal behavior.

Input Protection Lines

Describes general abort, selective abort, forward, and reverse limit switches.

Software Protection

Covers programmable error limits and the Off-On-Error function.

Programmable Position Limits

Explains setting forward and reverse position limits using BL and FL commands.

Off-On-Error

Details the function to turn off motors under specific error conditions.

Automatic Error Routine

Explains the #POSERR subroutine for automatic execution on position error.

Limit Switch Routine

Describes the #LIMSWI subroutine for automatic execution upon limit switch activation.

Chapter 9 Troubleshooting

Overview

Discusses potential problems, causes, and remedies for system setup and operation.

Installation

Provides a table of common installation symptoms, causes, and remedies.

Communication

Lists common communication issues and their troubleshooting steps.

Stability

Addresses motor oscillation and runaway issues related to feedback polarity and gain.

Operation

Covers troubleshooting for command rejection, incomplete moves, and motor drift.

Chapter 10 Theory of Operation

Overview

Explains the fundamental levels of motion control systems: loop closing, motion profiling, and programming.

Operation of Closed-Loop Systems

Explains how servo systems maintain position through feedback and error correction.

System Modeling

Describes the functional elements of a servo system and their mathematical models.

Motor-Amplifier

Details the three modes of operation (Voltage Drive, Current Drive, Velocity Loop) and their transfer functions.

Digital Filter

Explains the PID, low-pass, and notch filter elements and their parameters.

System Analysis

Presents an example of analyzing a position control system using block diagrams.

System Design and Compensation

Discusses stabilizing closed-loop systems using digital filters and analytical design methods.

Appendices

Electrical Specifications

Provides electrical specifications for servo control, stepper control, I/O, and analog inputs.

Performance Specifications

Details servo loop update times and position accuracy.

Fast Update Rate Mode

Explains operating the controller with faster servo update rates using fast firmware.

Connectors for DMC-2 x00 Main Board

Pin-out descriptions for high-density connectors on the main board.

ICM-2900 Interconnect Module

Details mechanical, environmental, and description of the ICM-2900 module.

ICM-1900 Interconnect Module

Details the ICM-1900 for easy connections to amplifiers, encoders, and switches.

AMP-19 x0 Mating Power Amplifiers

Describes mating servo amplifiers for the DMC-2x00, rated for 7A continuous, 10A peak.

Opto-Isolated Outputs for ICM-2900; ICM-1900; AMP-19 x0

Explains opto-isolation options for outputs on ICM/AMP modules.

TERM-1500 Operator Terminal

Details the operator terminal (hand-held and panel mount) and its features.

Coordinated Motion - Mathematical Analysis

Explains the mathematical basis of coordinated motion, including vector velocity and path segments.

Galil DMC-2X00 Specifications

General IconGeneral
CategoryController
Communication InterfaceEthernet
Encoder Inputup to 12 MHz
Analog Input12-bit resolution
Operating Temperature0 to +50 °C
Storage Temperature-20°C to 70°C
Humidity5% to 95% non-condensing
Dimensions38mm

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