USER MANUAL
DMC-2x00
Manual Rev. 2.0
By Galil Motion Control, Inc.
Galil Motion Control, Inc.
270 Technology Way
Rocklin, California 95765
Phone: (916) 626-0101
Fax: (916) 626-0102
URL: www.galilmc.com
Rev 02/08
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Contents
Using This Manual ....................................................................................................................ii
Contents
i
Chapter 1 Overview
1
Introduction ...............................................................................................................................1
Specifications.............................................................................................................................2
DMC- 2000 Family Part Number Definition...............................................................2
Electrical Specifications..............................................................................................2
Mechanical Specifications...........................................................................................2
Environmental Specifications......................................................................................3
Equipment Maintenance..............................................................................................3
Overview of Motor Types..........................................................................................................3
Standard Servo Motor with +/- 10 Volt Command Signal ..........................................3
Brushless Servo Motor with Sinusoidal Commutation................................................3
Stepper Motor with Step and Direction Signals ..........................................................4
Overview of Amplifiers.............................................................................................................4
Amplifiers in Current Mode ........................................................................................4
Amplifiers in Velocity Mode.......................................................................................4
Stepper Motor Amplifiers............................................................................................4
DMC-2x00 Functional Elements...............................................................................................5
Microcomputer Section ...............................................................................................5
Motor Interface............................................................................................................5
Communication ...........................................................................................................5
General I/O..................................................................................................................6
System Elements .........................................................................................................6
Motor...........................................................................................................................6
Amplifier (Driver) .......................................................................................................6
Encoder........................................................................................................................7
Watch Dog Timer........................................................................................................7
Chapter 2 Getting Started
9
The DMC-2x00 Main Board......................................................................................................9
The DMC-2000 Daughter Board .............................................................................................10
The DMC-2200 Daughter Board .............................................................................................11
Elements You Need.................................................................................................................12
Installing the DMC-2x00.........................................................................................................14
Step 1. Determine Overall Motor Configuration.......................................................14
Step 2. Install Jumpers on the DMC-2x00.................................................................15
Step 3a. Configure DIP switches on the DMC-2000.................................................16
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Step 3b. Configure DIP switches on the DMC-2100.................................................17
Step 3c. Configure DIP switches on the DMC-2200.................................................17
Step 4. Install the Communications Software............................................................18
Step 5. Connect AC Power to the Controller.............................................................18
Step 6. Establish Communications with Galil Software............................................19
Step 7. Determine the Axes to be Used for Sinusoidal Commutation.......................21
Step 8. Make Connections to Amplifier and Encoder. ..............................................22
Step 9a. Connect Standard Servo Motors..................................................................24
Step 9b. Connect Sinusoidal Commutation Motors...................................................27
Step 9c. Connect Step Motors ...................................................................................30
Step 10. Tune the Servo System................................................................................30
Design Examples .....................................................................................................................31
System Set-up............................................................................................................31
Profiled Move............................................................................................................32
Multiple Axes............................................................................................................32
Objective: Move the four axes independently...........................................................32
Independent Moves ...................................................................................................32
The motion parameters may be specified independently as illustrated below...........32
Position Interrogation................................................................................................32
The position error, which is the difference between the commanded position and the
actual position can be interrogated with the instruction TE. .....................................33
Absolute Position ......................................................................................................33
Velocity Control........................................................................................................33
Operation Under Torque Limit..................................................................................34
Interrogation..............................................................................................................34
Operation in the Buffer Mode ...................................................................................34
Using the On-Board Editor........................................................................................34
Motion Programs with Loops....................................................................................35
Motion Programs with Trippoints .............................................................................35
Control Variables ......................................................................................................36
Linear Interpolation...................................................................................................36
Circular Interpolation ................................................................................................37
Chapter 3 Connecting Hardware
39
Overview .................................................................................................................................39
Using Optoisolated Inputs .......................................................................................................39
Limit Switch Input.....................................................................................................39
Home Switch Input....................................................................................................40
Abort Input ................................................................................................................40
Reset Input.................................................................................................................41
Uncommitted Digital Inputs......................................................................................41
Wiring the Opto-Isolated Inputs ..............................................................................................41
The Opto-Isolation Common Point ...........................................................................41
Using an Isolated Power Supply................................................................................42
Bypassing the Opto-Isolation: ...................................................................................43
Analog Inputs ..........................................................................................................................43
Amplifier Interface ..................................................................................................................43
TTL Inputs...............................................................................................................................44
The Auxiliary Encoder Inputs ...................................................................................44
TTL Outputs ............................................................................................................................45
General Use Outputs..................................................................................................45
Output Compare ........................................................................................................45
Error Output ..............................................................................................................46
Extended I/O of the DMC-2x00 Controller.............................................................................46
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Chapter 4 Communication
2
Introduction ...............................................................................................................................2
RS232 Ports...............................................................................................................................2
RS232 - Main Port {P1} DATATERM.......................................................................2
RS232 - Auxiliary Port {P2} DATASET................................................................2
*RS422 - Main Port {P1}............................................................................................3
*RS422 - Auxiliary Port {P2}.....................................................................................3
RS-232 Configuration .................................................................................................3
Ethernet Configuration (DMC-2100/2200 only) .......................................................................5
Communication Protocols ...........................................................................................5
Addressing...................................................................................................................6
Communicating with Multiple Devices.......................................................................8
Multicasting.................................................................................................................9
Using Third Party Software.........................................................................................9
Data Record .............................................................................................................................10
Data Record Map.......................................................................................................10
Explanation of Status Information and Axis Switch Information..............................12
Notes Regarding Velocity and Torque Information ..................................................14
QZ Command............................................................................................................14
Controller Response to Commands .........................................................................................14
Unsolicited Messages Generated by Controller.......................................................................15
Galil Software Tools and Libraries..........................................................................................15
Chapter 5 Command Basics
16
Introduction .............................................................................................................................16
Command Syntax - ASCII.......................................................................................................16
Coordinated Motion with more than 1 axis...............................................................17
Command Syntax - Binary ......................................................................................................18
Binary Command Format..........................................................................................18
Binary Command Table ............................................................................................19
Controller Response to DATA ................................................................................................20
Interrogating the Controller .....................................................................................................21
Interrogation Commands...........................................................................................21
Summary of Interrogation Commands ......................................................................21
Interrogating Current Commanded Values................................................................21
Operands....................................................................................................................21
Command Summary..................................................................................................22
Chapter 6 Programming Motion
24
Overview .................................................................................................................................24
Independent Axis Positioning..................................................................................................25
Command Summary - Independent Axis ..................................................................26
Operand Summary - Independent Axis .....................................................................26
Examples ...................................................................................................................27
Position Tracking.....................................................................................................................28
Example.....................................................................................................................30
Example.....................................................................................................................31
Trip Points.................................................................................................................33
Command Summary – Position Tracking Mode .......................................................34
Independent Jogging................................................................................................................34
Command Summary - Jogging..................................................................................34
Operand Summary - Independent Axis .....................................................................34
Examples ...................................................................................................................35
Linear Interpolation Mode.......................................................................................................36
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Specifying the Coordinate Plane ...............................................................................36
Specifying Linear Segments......................................................................................36
Additional Commands...............................................................................................37
Command Summary - Linear Interpolation...............................................................38
Operand Summary - Linear Interpolation..................................................................38
Example.....................................................................................................................38
Vector Mode: Linear and Circular Interpolation Motion.........................................................41
Specifying the Coordinate Plane ...............................................................................41
Specifying Vector Segments .....................................................................................42
Additional commands................................................................................................42
Command Summary - Coordinated Motion Sequence..............................................43
Operand Summary - Coordinated Motion Sequence.................................................44
Example.....................................................................................................................44
Electronic Gearing...................................................................................................................46
Ramped Gearing......................................................................................................................46
Example.....................................................................................................................48
Command Summary - Electronic Gearing ................................................................48
Electronic Cam ........................................................................................................................50
Command Summary - Electronic CAM ....................................................................53
Operand Summary - Electronic CAM.......................................................................54
Example.....................................................................................................................54
Contour Mode..........................................................................................................................55
Specifying Contour Segments ...................................................................................55
Additional Commands...............................................................................................56
Command Summary - Contour Mode .......................................................................57
General Velocity Profiles ..........................................................................................57
Example.....................................................................................................................57
Virtual Axis .............................................................................................................................60
Ecam master example................................................................................................60
Sinusoidal Motion Example ......................................................................................60
Stepper Motor Operation .........................................................................................................61
Specifying Stepper Motor Operation.........................................................................61
Stepper Motor Smoothing .........................................................................................61
Monitoring Generated Pulses vs. Commanded Pulses ..............................................61
Motion Complete Trip point......................................................................................62
Using an Encoder with Stepper Motors.....................................................................62
Command Summary - Stepper Motor Operation.......................................................62
Operand Summary - Stepper Motor Operation..........................................................63
Stepper Position Maintenance Mode (SPM)............................................................................63
Error Limit.................................................................................................................64
Correction..................................................................................................................64
Dual Loop (Auxiliary Encoder)...............................................................................................67
Additional Commands for the Auxiliary Encoder.....................................................68
Backlash Compensation ............................................................................................68
Example.....................................................................................................................68
Motion Smoothing...................................................................................................................69
Using the IT and VT Commands:..............................................................................70
Example.....................................................................................................................70
Using the KS Command (Step Motor Smoothing):...................................................71
Homing....................................................................................................................................72
Example.....................................................................................................................72
Command Summary - Homing Operation.................................................................74
Operand Summary - Homing Operation....................................................................74
High Speed Position Capture (The Latch Function)................................................................74
Example.....................................................................................................................75
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Chapter 7 Application Programming
76
Overview .................................................................................................................................76
Using the DOS Editor to Enter Programs (DMC-2000 only)..................................................76
Edit Mode Commands...............................................................................................77
Example.....................................................................................................................77
Program Format.......................................................................................................................78
Using Labels in Programs .........................................................................................78
Special Labels............................................................................................................78
Commenting Programs..............................................................................................79
Executing Programs - Multitasking .........................................................................................80
Debugging Programs ...............................................................................................................81
Trace Commands ( DMC-2100/2200 only)...............................................................81
Error Code Command................................................................................................82
Stop Code Command.................................................................................................82
RAM Memory Interrogation Commands ..................................................................82
Operands....................................................................................................................82
Example.....................................................................................................................82
Program Flow Commands .......................................................................................................83
Event Triggers & Trippoints......................................................................................83
Conditional Jumps.....................................................................................................87
If, Else, and Endif......................................................................................................89
Subroutines................................................................................................................91
Stack Manipulation....................................................................................................91
Auto-Start Routine ....................................................................................................91
Automatic Subroutines for Monitoring Conditions...................................................92
Mathematical and Functional Expressions ..............................................................................97
Mathematical Operators ............................................................................................97
Bit-Wise Operators....................................................................................................97
Functions ...................................................................................................................99
Variables..................................................................................................................................99
Programmable Variables .........................................................................................100
Operands................................................................................................................................101
Special Operands (Keywords).................................................................................101
Arrays ....................................................................................................................................102
Defining Arrays.......................................................................................................102
Assignment of Array Entries...................................................................................102
Uploading and Downloading Arrays to On Board Memory....................................103
Automatic Data Capture into Arrays.......................................................................103
Deallocating Array Space........................................................................................105
Input of Data (Numeric and String).......................................................................................105
Input of Data............................................................................................................105
Operator Data Entry Mode ......................................................................................106
Using Communication Interrupt..............................................................................107
Output of Data (Numeric and String) ....................................................................................108
Sending Messages ...................................................................................................109
Displaying Variables and Arrays.............................................................................110
Interrogation Commands.........................................................................................110
Formatting Variables and Array Elements ..............................................................112
Converting to User Units.........................................................................................113
Hardware I/O .........................................................................................................................113
Digital Outputs ........................................................................................................113
Digital Inputs...........................................................................................................114
The Auxiliary Encoder Inputs .................................................................................115
Input Interrupt Function ..........................................................................................115
Analog Inputs ..........................................................................................................116
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Extended I/O of the DMC-2x00 Controller...........................................................................117
Configuring the I/O of the DMC-2x00....................................................................117
Saving the State of the Outputs in Non-Volatile Memory.......................................118
Accessing Extended I/O ..........................................................................................118
Interfacing to Grayhill or OPTO-22 G4PB24 .........................................................119
Example Applications............................................................................................................119
Wire Cutter..............................................................................................................119
A-B Table Controller...............................................................................................120
Speed Control by Joystick.......................................................................................122
Position Control by Joystick....................................................................................123
Backlash Compensation by Sampled Dual-Loop....................................................123
Chapter 8 Hardware & Software Protection
126
Introduction ...........................................................................................................................126
Hardware Protection ..............................................................................................................126
Output Protection Lines...........................................................................................126
Input Protection Lines .............................................................................................127
Software Protection ...............................................................................................................127
Programmable Position Limits................................................................................128
Off-On-Error ...........................................................................................................128
Automatic Error Routine.........................................................................................128
Limit Switch Routine ..............................................................................................129
Chapter 9 Troubleshooting
130
Overview ...............................................................................................................................130
Installation .............................................................................................................................130
Communication......................................................................................................................131
Stability..................................................................................................................................131
Operation ...............................................................................................................................131
Chapter 10 Theory of Operation
132
Overview ...............................................................................................................................132
Operation of Closed-Loop Systems.......................................................................................134
System Modeling...................................................................................................................135
Motor-Amplifier......................................................................................................136
Encoder....................................................................................................................138
DAC ........................................................................................................................139
Digital Filter ............................................................................................................139
ZOH.........................................................................................................................140
System Analysis.....................................................................................................................141
System Design and Compensation.........................................................................................143
The Analytical Method............................................................................................143
Appendices
146
Electrical Specifications ........................................................................................................146
Servo Control ..........................................................................................................146
Stepper Control........................................................................................................146
Input / Output ..........................................................................................................146
Power.......................................................................................................................147
Performance Specifications ...................................................................................................147
Minimum Servo Loop Update Time: ......................................................................147
Fast Update Rate Mode .........................................................................................................148
Connectors for DMC-2x00 Main Board................................................................................149
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DMC-2x00 Axes A-D High Density Connector......................................................149
DMC-2x00 Axes E-H High Density Connector......................................................150
DMC-2x00 Auxiliary Encoder 36 Pin High Density Connector.............................151
DMC-2x00 Extended I/O 80 Pin High Density Connector .....................................151
RS-232-Main Port ...................................................................................................153
RS-232-Auxiliary Port.............................................................................................153
USB - In
USB - Out.........................................................................................153
Ethernet ...................................................................................................................154
Cable Connections for DMC-2x00........................................................................................154
Standard RS-232 Specifications..............................................................................154
DMC-2x00 Serial Cable Specifications...................................................................155
Pin-Out Description for DMC-2x00......................................................................................157
Jumper Description for DMC-2x00.......................................................................................159
Dimensions for DMC-2x00 ...................................................................................................160
Accessories and Options........................................................................................................161
ICM-2900 Interconnect Module ............................................................................................162
Mechanical Specifications.......................................................................................162
Environmental Specifications..................................................................................162
Equipment Maintenance..........................................................................................162
Description ..............................................................................................................162
ICM-2900 Drawing:................................................................................................166
ICM-2908 Interconnect Module ............................................................................................167
ICM-2908 Drawing:................................................................................................168
PCB Layout of the ICM-2900:................................................................................169
ICM-1900 Interconnect Module ............................................................................................170
Features ...................................................................................................................170
ICM-1900 Drawing:................................................................................................173
AMP-19x0 Mating Power Amplifiers ...................................................................................173
Features ...................................................................................................................173
Specifications ..........................................................................................................174
Opto-Isolated Outputs for ICM-2900 / ICM-1900 / AMP-19x0............................................174
Standard Opto-Isolation and High Current Opto-isolation:.....................................174
Configuring the Amplifier Enable for ICM-2900 / ICM-1900..............................................175
-LAEN Option:........................................................................................................175
-Changing the Amplifier Enable Voltage Level:.....................................................175
IOM-1964 Opto-Isolation Module for Extended I/O.............................................................176
Description: .............................................................................................................176
Overview .................................................................................................................176
Configuring Hardware Banks..................................................................................177
Digital Inputs...........................................................................................................178
High Power Digital Outputs ....................................................................................179
Standard Digital Outputs.........................................................................................180
Electrical Specifications..........................................................................................181
Relevant DMC Commands......................................................................................182
Screw Terminal Listing...........................................................................................182
CB-50-100 Adapter Board.....................................................................................................185
Connectors:..............................................................................................................185
CB-50-100 Drawing:...............................................................................................188
CB-50-80 Adapter Board.......................................................................................................189
Connectors:..............................................................................................................190
CB-50-80 Drawing:.................................................................................................192
TERM-1500 Operator Terminal ............................................................................................194
Features ...................................................................................................................195
Description ..............................................................................................................195
Specifications - Hand-Held .....................................................................................195
Specifications - Panel Mount...................................................................................196
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Keypad Maps - Hand-Held......................................................................................196
Keypad Map - Panel Mount – 6 columns x 5 rows .................................................197
Configuration...........................................................................................................198
Function Keys..........................................................................................................199
Input/Output of Data – DMC-2x00 Commands ......................................................199
Ordering Information...............................................................................................200
Coordinated Motion - Mathematical Analysis.......................................................................201
Example- Communicating with OPTO-22 SNAP-B3000-ENET..........................................204
DMC-2x00/DMC-1500 Comparison.....................................................................................207
List of Other Publications......................................................................................................208
Training Seminars..................................................................................................................208
Contacting Us ........................................................................................................................209
WARRANTY ........................................................................................................................209
Index
210
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Chapter 1 Overview
Introduction
The DMC-2x00 Series are Galil’s highest performance stand-alone controller. The controller series
offers many enhanced features including high speed communications, non-volatile program memory,
faster encoder speeds, and improved cabling for EMI reduction.
Each DMC-2x00 provides two communication channels: high speed RS-232 (2 channels up to 115K
Baud) and Universal Serial Bus (12Mb/s) for the DMC-2000 or 10BaseT Ethernet for the DMC-2100
and 100BaseT Ethernet for the DMC-2200.
A 4Meg Flash EEPROM provides non-volatile memory for storing application programs, parameters,
arrays and firmware. New firmware revisions are easily upgraded in the field.
The DMC-2x00 is available with up to eight axes in a single stand alone unit. The DMC-2x10, 2x20,
2x30, 2x40 are one thru four axes controllers and the DMC-2x50, 2x60, 2x70, 2x80 are five thru eight
axes controllers.
Designed to solve complex motion problems, the DMC-2x00 can be used for applications involving
jogging, point-to-point positioning, vector positioning, electronic gearing, multiple move sequences,
and contouring. The controller eliminates jerk by programmable acceleration and deceleration with
profile smoothing. For smooth following of complex contours, the DMC-2x00 provides continuous
vector feed of an infinite number of linear and arc segments. The controller also features electronic
gearing with multiple master axes as well as gantry mode operation.
For synchronization with outside events, the DMC-2x00 provides uncommitted I/O, including 8 opto-
isolated digital inputs (16 inputs for DMC-2x50 thru DMC-2x80), 8 digital outputs (16 outputs for
DMC-2x50 thru DMC-2x80), and 8 analog inputs for interface to joysticks, sensors, and pressure
transducers. The DMC-2x00 also has an additional 64 I/O. Further I/O is available if the auxiliary
encoders are not being used (2 inputs / each axis). Dedicated optoisolated inputs are provided for
forward and reverse limits, abort, home, and definable input interrupts.
Commands can be sent in either Binary or ASCII. Additional software is available for automatic-
tuning, trajectory viewing on a PC screen, CAD translation, and program development using many
environments such as Visual Basic, C, C++ etc. Drivers for DOS, Linux, Windows 3.1, 95, 98, 2000,
ME and NT are available.
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Specifications
DMC- 2000 Family Part Number Definition
D M C - 2 0 0 0
| |
Communication Options ------| |
0: USB
|
|
|
2: Ethernet
Number of Axis ---------------|
1: One Axes
2: Two Axes
3: Three Axes
4: Four Axes
5: Five Axes
6: Six Axes
7: Seven Axes
8: Eight Axes
Electrical Specifications
Description
Unit
----
Specification
-------------
100-240
50-60
-----------
AC Input Line Voltage
AC Input Line Frequency
Power Dissipation
VAC
Hz
W
12
Mechanical Specifications
Description
-----------
Weight
Unit
----
lb
Specification
-------------
5.2
Length
in
12.25
Width
in
5.49
Height
in
2.37
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Environmental Specifications
Description
Unit
----
C
Specification
-------------
-25 to +70
0 to +70
-----------
Storage Temperature
Operating Temperature
Operating Altitude
C
feet
10,000
Equipment Maintenance
The DMC-2000 does not require maintenance.
Overview of Motor Types
The DMC-2x00 can provide the following types of motor control:
1. Standard servo motors with +/- 10 volt command signals
2. Brushless servo motors with sinusoidal commutation
3. Step motors with step and direction signals
4. Other actuators such as hydraulics - For more information, contact Galil.
The user can configure each axis for any combination of motor types, providing maximum flexibility.
Standard Servo Motor with +/- 10 Volt Command Signal
The DMC-2x00 achieves superior precision through use of a 16-Bit motor command output DAC and
a sophisticated PID filter that features velocity and acceleration feedforward, an extra pole filter and
integration limits.
The controller is configured by the factory for standard servo motor operation. In this configuration,
the controller provides an analog signal (+/- 10 volts) to connect to a servo amplifier. This connection
is described in Chapter 2.
Brushless Servo Motor with Sinusoidal Commutation
The DMC-2x00 can provide sinusoidal commutation for brushless motors (BLM). In this
configuration, the controller generates two sinusoidal signals for connection with amplifiers
specifically designed for this purpose.
Note: The task of generating sinusoidal commutation may be accomplished in the brushless motor
amplifier. If the amplifier generates the sinusoidal commutation signals, only a single command signal
is required and the controller should be configured for a standard servo motor (described above).
Sinusoidal commutation in the controller can be used with linear and rotary BLMs. However, the
motor velocity should be limited such that a magnetic cycle lasts at least 6 milliseconds with a standard
update rate of 1 millisecond. For faster motors, please contact the factory.
To simplify the wiring, the controller provides a one-time, automatic set-up procedure. When the
controller has been properly configured, the brushless motor parameters may be saved in non-volatile
memory.
The DMC-2x00 can control BLMs equipped with Hall sensors as well as without Hall sensors. If Hall
sensors are available, once the controller has been setup, the brushless motor parameters may be saved
in non-volatile memory. In this case, the controller will automatically estimate the commutation phase
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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.
Stepper Motor with Step and Direction Signals
The DMC-2x00 can control stepper motors. In this mode, the controller provides two signals to
connect to the stepper motor: Step and Direction. For stepper motor operation, the controller does not
require an encoder and operates the stepper motor in an open loop fashion. Chapter 2 describes the
proper connection and procedure for using stepper motors.
Overview of Amplifiers
The amplifiers should be suitable for the motor and may be linear or pulse-width-modulated. An
amplifier may have current feedback, voltage feedback or velocity feedback.
Amplifiers in Current Mode
Amplifiers in current mode should accept an analog command signal in the +/-10 volt range. The
amplifier gain should be set such that a +10V command will generate the maximum required current.
For example, if the motor peak current is 10A, the amplifier gain should be 1 A/V.
Amplifiers in Velocity Mode
For velocity mode amplifiers, a command signal of 10 volts should run the motor at the maximum
required speed. The velocity gain should be set such that an input signal of 10V runs the motor at the
maximum required speed.
Stepper Motor Amplifiers
For step motors, the amplifiers should accept step and direction signals.
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DMC-2x00 Functional Elements
The DMC-2x00 circuitry can be divided into the following functional groups as shown in Figure 1.1
and discussed below.
WATCHDOG TIMER
ISOLATED LIMITS AND
HOME INPUTS
MAIN ENCODERS
68331
MICROCOMPUTER
WITH
HIGH-SPEED
MOTOR/ENCODER
INTERFACE
FOR
USB/ETHERNET
AUXILIARY ENCODERS
+/- 10 VOLT OUTPUT FOR
SERVO MOTORS
4 Meg RAM
RS-232 /
RS-422
4 Meg FLASH EEPROM
A,B,C,D
PULSE/DIRECTION OUTPUT
FOR STEP MOTORS
HIGH SPEED ENCODER
COMPARE OUTPUT
64 Configurable I/O
I/O INTERFACE
8 UNCOMMITTED
ANALOG INPUTS
8 PROGRAMMABLE
OUTPUTS
8 PROGRAMMABLE,
OPTOISOLATED
INPUTS
HIGH-SPEED LATCH FOR EACH AXIS
Figure 1.1 - DMC-2x00 Functional Elements
Microcomputer Section
The main processing unit of the DMC-2x00 is a specialized 32-Bit Motorola 68331 Series
Microcomputer with 4 Meg RAM and 4 Meg Flash EEPROM. The RAM provides memory for
variables, array elements and application programs. The flash EEPROM provides non-volatile storage
of variables, programs, and arrays. It also contains the DMC-2x00 firmware.
Motor Interface
Galil’s GL-1800 custom, sub-micron gate array performs quadrature decoding of each encoder at up to
12 MHz. For standard servo operation, the controller generates a +/-10 volt analog signal (16 Bit
DAC). For sinusoidal commutation operation, the controller uses two DACs to generate two +/-10
volt analog signals. For stepper motor operation, the controller generates a step and direction signal.
Communication
The communication interface with the DMC-2x00 consists of high speed RS-232 and USB or high
speed RS-232 and Ethernet. The USB channel accepts based rates up to 12Mb/sec and the two RS-232
channels can generate up to 115K.
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General I/O
The DMC-2x00 provides interface circuitry for 8 bi-directional, optoisolated inputs, 8 TTL outputs and
8 analog inputs with 12-Bit ADC (16-Bit optional). The DMC-2x00 also has an additional 64 I/O and
unused auxiliary encoder inputs may also be used as additional inputs (2 inputs / each axis). The
general inputs can also be used as high speed latches for each axis. A high speed encoder compare
output is also provided.
The DMC-2x50 through DMC-2x80 controller provides an additional 8 optoisolated inputs and 8 TTL
outputs.
2x80
System Elements
As shown in Fig. 1.2, the DMC-2x00 is part of a motion control system which includes amplifiers,
motors and encoders. These elements are described below.
Power Supply
Amplifier (Driver)
Computer
DMC-2x00 Controller
Encoder
Motor
Figure 1.2 - Elements of Servo systems
Motor
A motor converts current into torque which produces motion. Each axis of motion requires a motor
sized properly to move the load at the required speed and acceleration. (Galil's "Motion Component
Selector" software can help you with motor sizing). Contact Galil at 800-377-6329 if you would like
this product.
The motor may be a step or servo motor and can be brush-type or brushless, rotary or linear. For step
motors, the controller can be configured to control full-step, half-step, or microstep drives. An encoder
is not required when step motors are used.
Amplifier (Driver)
For each axis, the power amplifier converts a +/-10 volt signal from the controller into current to drive
the motor. For stepper motors, the amplifier converts step and direction signals into current. The
amplifier should be sized properly to meet the power requirements of the motor. For brushless motors,
an amplifier that provides electronic commutation is required or the controller must be configured to
provide sinusoidal commutation. The amplifiers may be either pulse-width-modulated (PWM) or
linear. They may also be configured for operation with or without a tachometer. For current
amplifiers, the amplifier gain should be set such that a 10 volt command generates the maximum
required current. For example, if the motor peak current is 10A, the amplifier gain should be 1 A/V.
For velocity mode amplifiers, 10 volts should run the motor at the maximum speed.
6 •Chapter 1 Overview
DMC-2X00
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Encoder
An encoder translates motion into electrical pulses which are fed back into the controller. The DMC-
2x00 accepts feedback from either a rotary or linear encoder. Typical encoders provide two channels in
quadrature, known as CHA and CHB. This type of encoder is known as a quadrature encoder.
Quadrature encoders may be either single-ended (CHA and CHB) or differential (CHA,CHA- and
CHB,CHB-). The DMC-2x00 decodes either type into quadrature states or four times the number of
cycles. Encoders may also have a third channel (or index) for synchronization.
For stepper motors, the DMC-2x00 can also interface to encoders with pulse and direction signals.
There is no limit on encoder line density, however, the input frequency to the controller must not
exceed 3,000,000 full encoder cycles/second (12,000,000 quadrature counts/sec). For example, if the
encoder line density is 10000 cycles per inch, the maximum speed is 300 inches/second. If higher
encoder frequency is required, please consult the factory.
The standard voltage level is TTL (zero to five volts), however, voltage levels up to 12 volts are
acceptable. (If using differential signals, 12 volts can be input directly to the DMC-2x00. Single-
ended 12 volt signals require a bias voltage input to the complementary inputs).
The DMC-2x00 can accept analog feedback instead of an encoder for any axis.
To interface with other types of position sensors such as resolvers or absolute encoders, Galil can
customize the controller and command set. Please contact Galil and talk to one of our applications
engineers about your particular system requirements.
Watch Dog Timer
The DMC-2x00 provides an internal watch dog timer which checks for proper microprocessor
operation. The timer toggles the Amplifier Enable Output (AMPEN) which can be used to switch the
amplifiers off in the event of a serious DMC-2x00 failure. The AMPEN output is normally high.
During power-up and if the microprocessor ceases to function properly, the AMPEN output will go
low. The error light will also turn on at this stage. A reset is required to restore the DMC-2x00 to
normal operation. Consult the factory for a Return Materials Authorization (RMA) Number if your
DMC-2x00 is damaged.
DMC-2X00
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THIS PAGE LEFT BLANK INTENTIONALLY
8 •Chapter 1 Overview
DMC-2X00
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Chapter 2 Getting Started
The DMC-2x00 Main Board
AXES A-D
100 pin high density connector
AMP part # 2-178238-9
Error,
Power
LED's
AXES E-H
100 pin high density connector
AMP part # 2-178238-9
AUX Encoder inputs
36 pin high density connector
Reset
Switch
9.50 "
Stepper motor
configuration
header
Stepper Motor
configuration
header
J9
1
AXES E-H
J5 AUX ENCODERS
J1
AXES A-D (X-W)
SW1
Analog to Digital
Converter IC
7806 - 12 bit
7807 - 16 bit
SMA(X)
SMB(Y)
SMC(Z)
SMD(W)
SME
SMF
SMG
SMH
GL-1800
GL-1800
ADS7806
OPT1
OPT2
JP5
JP7
DMC-2000
REV A
GALIL MOTION CONTROL
SRAM
5.80"
Jumper to
connect
optoisolators to
onboard 5V
supply
SRAM
Motorola
68331
JP3
JP1
LSCOM
INCOM
MASTER RESET
UPGRADE
*
EEPROM
+5V+5V
+12V
-12V
GND
||| ||||| |||||
*AH-9999*
J2
MADE IN USA
Communications
Daughterboard
connector
Jumper Master
Reset to clear
EEPROM
Serial number label
Power connector
6 pin Molex
Microprocessor
Figure 2-1 - Outline of the main board of the DMC-2x00
DMC-2X00
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The DMC-2000 Daughter Board
MAIN Serial port
Configuration DIP
DB-9 Male
USB type A
connector (x2)
80 pin high
density connector
for extended I/O
USB type B
connector
Switches
AUX Serial port
DB-9 Female
7.85 "
AUX
J6
MAIN
J5
J3
EXTENDED I/O
8 S
J1
USB IN
J2 USB OUT
S
8
U2
U7
U6
U1
2.53"
U9
3.94"
CMB-2001 REV C
USB DAUGHTER CARD
GALIL MOTION CONTROL
RS-232 buffer
IC's
D1
1
J4
A1
B1
C1
USB Communications
Status LED
100 pin connector
(attaches to DMC-2000
Main board)
Figure 2-2 - Outline of the DMC-2000 Daughter Board
10 • Chapter 2 Getting Started
DMC-2X00
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The DMC-2200 Daughter Board
10 BASE-F
TRANSMITTER
100 BASE-T
80 PIN HIGH DENSITY
CONNECTOR FOR
EXTENDED I/O
MAIN SERIAL PORT
DB-9 MALE
AUX SERIAL PORT
DB-9 FEMALE
10 BASE-2
CONFIGURATION
DIP SWITCHES
COMMUNICATIONS
STATUS LED
10 BASE-F
RECEIVER
D1 D2
J2
JP4
JP5
U15
JP3
U16
U6
U4
CMB-21002 REV A
GALIL MOTION CONTROL
JP4
1
JP5
1
J8
A1
B1
C1
J7
100 PIN
CONNECTOR
(ATTACHES TO
DMC-2000 MAIN
BOARD)
9.5"
Figure 2-3B - Outline of the DMC-2200 Daughter Board
DMC-2X00
Chapter 2 Getting Started y 11
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Elements You Need
IOM-1964-80
Provides Opto-Isolation
and Interconnection for
Extended I/O
ICM-2900
Provides Connection to
Signals for Axes E-H
IOM-1964-80
Auxiliary Serial Port
Connection
(System Dependent
Cable)
ICM-2908
Provides Connection to All
Auxiliary Encoder Signals
0
1
2
3
4
6
7
5
ICM-2900
Connection to
Signals for Axes A-D
ICM-2900
ICM-2908
CABLE-80-1M (1Meter)
OR
ICM-2900
GALIL
Cable 9-PinD
Main Serial Port to
Computer
CABLE-80-4M (4Meter)
CABLE-100-1M
OR
CABLE-100-4M
CABLE-USB-2M
OR
CABLE-USB-3M
DMC-2000
CABLE-36-1M (1METER)
OR
Power Cable (Included
with the controller)
CABLE-36-4M (4METER)
Figure 2-4 Recommended System Elements of DMC-2000
12 • Chapter 2 Getting Started
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IOM-1964-80
Provides Opto-Isolation
and Interconnection for
Extended I/O
ICM-2900
Provides Connection to
Signals for Axes E-H
IOM-1964-80
100/10 BASE-T
Cable
ICM-2908
Provides Connection to All
Auxiliary Encoder Signals
0
1
2
3
4
6
7
5
Auxiliary Serial Port
Connection
(System Dependent
Cable)
ICM-2900
Connection to
Signals for Axes A-D
ICM-2900
ICM-2908
CABLE-80-1M (1Meter)
OR
ICM-2900
GALIL
CABLE-80-4M (4Meter)
Cable 9-PinD
Main Serial Port to
Computer
CABLE-100-1M
OR
CABLE-100-4M
DMC-2000
CABLE-36-1M (1METER)
OR
Power Cable (Included
with the controller)
CABLE-36-4M (4METER)
Figure 2-5 Recommended System Elements of DMC-2100/DMC-2200
For a complete system, Galil recommends the following elements:
1a. DMC-2x10, 2x20, 2x30, or DMC-2x40 Motion Controller
or
1b. DMC-2x50, 2x60, 2x70 or DMC-2x80
2a. (1) ICM-2900 and (1) CABLE-100 for controllers DMC-2x10 through DMC-2x40
or
2b. (2) ICM-2900's and (2) CABLE-100’s for controllers DMC-2x50 through DMC-2x80.
or
2c. An interconnect board provided by the user.
3. (1) IOM-1964 and (1) CABLE-80 for access to the extended I/O. Only required if extended
I/O will be used. The CABLE-80 can also be converted for use with OPTO-22 or Grayhill
I/O modules - consult Galil.
4. (1) ICM-2908 and (1) CABLE-36 for access to auxiliary encoders. Only required if auxiliary
encoders are needed.
DMC-2X00
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5. Motor Amplifiers.
6. Power Supply for Amplifiers.
7. Brush or Brushless Servo motors with Optical Encoders or stepper motors.
8. PC (Personal Computer - RS232 or USB for DMC-2000 or Ethernet for DMC-2100)
9a. WSDK-16 or WSDK-32 (recommend for first time users.)
or
9b. DMCWIN16, DMCWIN32 or DMCDOS communication software.
The WSDK software is highly recommended for first time users of the DMC-2x00. It provides step-
by-step instructions for system connection, tuning and analysis.
Installing the DMC-2x00
Installation of a complete, operational DMC-2x00 system consists of 9 steps.
Step 1. Determine overall motor configuration.
Step 2. Install Jumpers on the DMC-2x00.
Step 3a. Configure the DIP switches on the DMC-2000.
Step 3b. Configure the DIP switches on the DMC-2100.
Step 3c. Configure the DIP switches on the DMC-2200
Step 4. Install the communications software.
Step 5. Connect AC power to controller.
Step 6. Establish communications with the Galil Communication Software.
Step 7. Determine the Axes to be used for sinusoidal commutation.
Step 8. Make connections to amplifier and encoder.
Step 9a. Connect standard servo motors.
Step 9b. Connect sinusoidal commutation motors
Step 9c. Connect step motors.
Step 10. Tune the servo system
Step 1. Determine Overall Motor Configuration
Before setting up the motion control system, the user must determine the desired motor configuration.
The DMC-2x00 can control any combination of standard servo motors, sinusoidally commutated
brushless motors, and stepper motors. Other types of actuators, such as hydraulics can also be
controlled, please consult Galil.
The following configuration information is necessary to determine the proper motor configuration:
Standard Servo Motor Operation:
The DMC-2x00 has been setup by the factory for standard servo motor operation providing an analog
command signal of +/- 10V. No hardware or software configuration is required for standard servo
motor operation.
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Sinusoidal Commutation:
Sinusoidal commutation is configured through a single software command, BA. This configuration
causes the controller to reconfigure the number of available control axes.
Each sinusoidally commutated motor requires two DACs. In standard servo operation, the DMC-2x00
has one DAC per axis. In order to have the additional DAC for sinusoidal commutation, the controller
must be designated as having one additional axis for each sinusoidal commutation axis. For example,
to control two standard servo axes and one axis of sinusoidal commutation, the controller will require a
total of four DACs and the controller must be a DMC-2x40.
Sinusoidal commutation is configured with the command, BA. For example, BAA sets the A axis to
be sinusoidally commutated. The second DAC for the sinusoidal signal will be the highest available
DAC on the controller. For example: Using a DMC-2x40, the command BAA will configure the A
axis to be the main sinusoidal signal and the 'D' axis to be the second sinusoidal signal.
The BA command also reconfigures the controller to indicate that the controller has one less axis of
'standard' control for each axis of sinusoidal commutation. For example, if the command BAA is
given to a DMC-2x40 controller, the controller will be re-configured to a DMC-2x30 controller. By
definition, a DMC-2x30 controls 3 axes: A,B and C. The 'D' axis is no longer available since the
output DAC is being used for sinusoidal commutation.
Further instruction for sinusoidal commutation connections are discussed in Step 6.
Stepper Motor Operation
To configure the DMC-2x00 for stepper motor operation, the controller requires a jumper for each
stepper motor and the command, MT, must be given. The installation of the stepper motor jumper is
discussed in the following section entitled "Installing Jumpers on the DMC-2x00". Further instruction
for stepper motor connections are discussed in Step 9.
Step 2. Install Jumpers on the DMC-2x00
Master Reset and Upgrade Jumpers
JP1 on the main board contains two jumpers, MRST and UPGRD. The MRST jumper is the Master
Reset jumper. When MRST is connected, the controller will perform a master reset upon PC power up
or upon the reset input going low. The MRST can also be set with the DIP switches on the outside of
the controller. Whenever the controller has a master reset, all programs, arrays, variables, and motion
control parameters stored in EEPROM will be ERASED.
The UPGRD jumper enables the user to unconditionally update the controller’s firmware. This jumper
is not necessary for firmware updates when the controller is operating normally, but may be necessary
in cases of corrupted EEPROM. EEPROM corruption should never occur, however, it is possible if
there is a power fault during a firmware update. If EEPROM corruption occurs, your controller may
not operate properly. In this case, install the UPGRD Jumper and use the update firmware function on
the Galil Terminal to re-load the system firmware.
Opto-Isolation Jumpers
The inputs and limit switches are opto-isolated. If you are not using an isolated supply, the internal
+5V supply from the PC may be used to power the opto-isolators. This is done by installing jumpers
on JP3 on main board.
DMC-2X00
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Stepper Motor Jumpers
For each axis that will used for stepper motor operation, the corresponding stepper mode (SM) jumper
must be connected. The stepper mode jumpers, labeled JP5 and JP7 are located directly beside the
GL-1800 IC's on the main board (see the diagram of the DMC-2x00). The individual jumpers are
labeled SMA thru SMH and configure the controller for ‘Stepper Motors’ for the corresponding axes
A-H when installed. Note that the daughter board must be removed to access these jumpers. Contact
the Galil factory if stepper motor jumpers should be placed on your controller with each order for a
special part number.
(Optional) Motor Off Jumpers
The state of the motor upon power up may be selected with the placement of a hardware jumper on the
controller. With a jumper installed at the MO location, the controller will be powered up in the “motor
off” state. The SH command will need to be issued in order for the motor to be enabled. With no
jumper installed, the controller will immediately enable the motor upon power up. The MO command
will need to be issued to turn the motor off.
The MO jumper is always located on the same block of jumpers as the stepper motor jumpers (SM).
This feature is only available to newer revision controllers. Please consult Galil for adding this
functionality to older revision controllers.
Communications Jumpers for DMC-2000
The Main and Auxiliary Serial Communication Ports are normally connected for RS-232 connection.
The jumpers JP3 and JP4 on the DMC-2001 daughter-board allows the DMC-2000 to be configured
for RS-422. This can be specified as an option when the unit is purchased or the DMC-2000 may be
re-configured by the user, please consult Galil for instructions. Other serial communication protocols,
such as RS-485, can be implemented as a special - consult Galil.
Communications Jumpers for DMC-2100/DMC-2200
The main and Auxiliary Serial Commutations Ports are normally connected for RS-232 connection.
The jumpers JP4 and JP5 on the DMC-21001 daughter board allows the controller to be configured for
RS-422. This can be specified as an option when the unit is purchased or the controller may be re-
configured by the user, please consult Galil for instructions. Other serial communications protocols,
such as RS-485, can be implemented as a special - consult Galil.
Step 3a. Configure DIP switches on the DMC-2000
Located on the outside of the controller box is a set of 5 DIP switches. When the controller is powered
on or reset, the state of the dip switches are read.
Switch 1 - Master Reset
When this switch is on, the controller will perform a master reset upon PC power up. Whenever the
controller has a master reset, all programs and motion control parameters stored in EEPROM will be
ERASED. During normal operation, this switch should be off.
Switch 2 - XON / XOFF
When on, this switch will enable software handshaking (XON/XOFF) through the main serial port.
Switch 3 - Hardware Handshake Mode
When on, this switch will enable hardware handshaking through the main serial port.
16 • Chapter 2 Getting Started
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Switch 4, 5 and 6 - Main Serial Port Baud Rate
The following table describes the baud rate settings:
9600
ON
19.2
ON
3800
OFF
OFF
OFF
ON
BAUD RATE
1200
ON
OFF
ON
9600
OFF
OFF
OFF
19200
OFF
ON
38400
ON
115200
Switch 10 - USB
When on, the controller will use the USB port as a default port for messages. When off, the controller
will use the RS-232 port as default. When the firmware is updated, the controller will send the
response (a colon), to the default port setting. If this is not the same port that was used to download
the firmware, the Galil software will not return control to the user. In this case, the software will have
to be re-started.
Step 3b. Configure DIP switches on the DMC-2100
Switch 1 - Master Reset
When this switch is on, the controller will perform a master reset upon PC power up. Whenever the
controller has a master reset, all programs and motion control parameters stored in EEPROM will be
ERASED. During normal operation, this switch should be off.
Switch 2 - XON / XOFF
When on, this switch will enable software handshaking (XON/XOFF) through the main serial port.
Switch 3 - Hardware Handshake Mode
When on, this switch will enable hardware handshaking through the main serial port.
Step 3c. Configure DIP switches on the DMC-2200
Switch 1 - Master Reset
When this switch is on, the controller will perform a master reset upon PC power up. Whenever the
controller has a master reset, all programs and motion control parameters stored in EEPROM will be
ERASED. During normal operation, this switch should be off.
Switch 2 - XON / XOFF
When on, this switch will enable software handshaking (XON/XOFF) through the main serial port.
Switch 3 - Hardware Handshake Mode
When on, this switch will enable hardware handshaking through the main serial port.
DMC-2X00
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Switch 4,5 and 6 - Main Serial Port Baud Rate
The following table describes the baud rate settings:
9600
ON
19.2
ON
3800
OFF
OFF
OFF
ON
BAUD RATE
1200
ON
OFF
ON
9600
OFF
OFF
OFF
19200
OFF
ON
38400
ON
115200
Switch 7-Option
When OFF, the controller will use the auto-negotiate function to set the Ethernet connection speed.
When the DIP switch is ON, the controller defaults to 10BaseT.
Switch 8-Ethernet
When ON, the controller will use the Ethernet port as the default port for unsolicited messages. When
OFF, the controller will use the RS-232 port as the default. When the firmware is updated, the
controller will send the response (a colon) to the default port setting. If this is not the same port that
was used to download the firmware, the Galil software will not return control to the user. In this case,
the software will have to be re-started.
Step 4. Install the Communications Software
After applying power to the computer, you should install the Galil software that enables
communication between the controller and PC.
Using Windows 98SE, NT, ME, 2000 or XP:
The Galil Software CD-ROM will automatically begin the installation procedure when the CD-ROM is
installed. To install the basic communications software, run the Galil Software CD-ROM and choose
DMC Smart Term. This will install the Galil Smart Terminal, which can be used for communication.
Step 5. Connect AC Power to the Controller
Before applying power, connect the 100-pin cable between the DMC-2x00 and ICM-2900 interconnect
module. The DMC-2x00 requires a single AC supply voltage, single phase, 50 Hz or 60 Hz. from 90
volts to 260 volts.
WARNING: Dangerous voltages, current, temperatures and energy levels exist in this product and
the associated amplifiers and servo motor(s). Extreme caution should be exercised in the
application of this equipment. Only qualified individuals should attempt to install, set up and
operate this equipment. Never open the controller box when AC power is applied to it.
The green power light indicator should go on when power is applied.
18 • Chapter 2 Getting Started
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Step 6. Establish Communications with Galil Software
Communicating through the Main Serial Communications Port
Connect the DMC-2x00 MAIN serial port to your computer via the Galil CABLE-9PIN-D (RS-232
Cable).
Using Galil Software for DOS (serial communication only)
To communicate with the DMC-2000, type TALK2DMC at the prompt. Once you have established
communication, the terminal display should show a colon, :. If you do not receive a colon, press the
carriage return. If a colon prompt is not returned, there is most likely an incorrect setting of the serial
communications port. The user must ensure that the correct communication port and baud rate are
specified when attempting to communicate with the controller. Please note that the serial port on the
controller must be set for handshake mode for proper communication with Galil software. The user
must also insure that the proper serial cable is being used, see appendix for pin-out of serial cable.
Using Galil Software for Windows
In order for the windows software to communicate with a Galil controller, the controller must be
registered in the Windows Registry. To register a controller, you must specify the model of the
controller, the communication parameters, and other information. The registry is accessed through the
Galil software under the “File” menu in WSDK or under the “Tools” menu in the Galil Smart
Terminal.
The registry window is equipped with buttons to Add a New Controller, change the Properties of an
existing controller, Delete a controller, or Find an Ethernet Controller.
Use the “New Controller” button to add a new entry to the Registry. You will need to supply the
Galil Controller model (eg: DMC-2000). Pressing the down arrow to the right of this field will reveal
a menu of valid controller types. You then need to choose serial or Ethernet connection. Remember, a
DMC-2000 connected via USB is plug and play and should be automatically added to the registry
upon connection. The registry information will show a default Comm Port of 1 and a default Comm
Speed of 19200 appears. This information can be changed as necessary to reflect the computers
Comm Port and the baud rate set by the dip switches on the front of the controller (default is 19200
with HSHK on). The registry entry also displays timeout and delay information. These are advanced
parameters which should only be modified by advanced users (see software documentation for more
information).
Once you have set the appropriate Registry information for your controller, Select OK and close the
registry window. You will now be able to communicate with the controller.
If you are not properly communicating with the controller, the program will pause for 3-15 seconds
and an error message will be displayed. In this case, there is most likely an incorrect setting of the
serial communications port or the serial cable is not connected properly. The user must ensure that the
correct communication port and baud rate are specified when attempting to communicate with the
controller. Please note that the serial port on the controller must be set for handshake mode for proper
communication with Galil software. The user must also insure that a “straight-through” serial cable is
being used (NOT a Null Modem cable), see appendix for pin-out of serial cable.
Once you establish communications, open up the Terminal and hit the “Enter” key. You should
receive a colon prompt. Communicating with the controller is described in later sections.
DMC-2X00
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Using Non-Galil Communication Software
The DMC-2x00 main serial port is configured as DATASET. Your computer or terminal must be
configured as a DATATERM for full duplex, no parity, 8 data bits, one start bit and one stop bit.
Check to insure that the baud rate switches have been set to the desired baud rate as described above.
Your computer needs to be configured as a "dumb" terminal which sends ASCII characters as they are
typed to the DMC-2x00.
Communicating through the Universal Serial Bus (USB)
NOTE: Galil Software only supports the use of the USB port under Windows 98SE, ME, 2000 and
XP.
Connect the USB cable from the computer to the USB IN port on the controller. Since the controller
has been powered on in the previous step, the computer will recognize the first connection to a Galil
USB controller. The computer will identify the USB controller and add it to the Windows Registry as
a plug and play device.
Communicating through the Ethernet
Using Galil Software for Windows
The controller must be registered in the Windows registry for the host computer to communicate with
it. The registry may be accessed via Galil software, such as WSDK or SmartTERM.
From WSDK, the registry is accessed under the FILE menu. From Smart TERM it is accessed under
the TOOLS menu. Use the NEW CONTROLLER button to add a new entry in the registry. Choose
DMC-2100 or DMC-2200 as the controller type. Enter the IP address obtained from your system
administrator. Select the button corresponding to the UDP or TCP protocol in which you wish to
communicate with the controller. If the IP address has not been already assigned to the controller,
click on ASSIGN IP ADDRESS.
ASSIGN IP ADDRESS will check the controllers that are linked to the network to see which ones do
not have an IP address. The program will then ask you whether you would like to assign the IP
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address you entered to the controller with the specified serial number. Click on YES to assign it, NO
to move to next controller, or CANCEL to not save the changes. If there are no controllers on the
network that do not have an IP address assigned, the program will state this.
When done registering, click on OK. If you do not wish to save the changes, click on CANCEL.
Once the controller has been register, select the correct controller from the list and click on OK. If the
software successfully established communications with the controller, the registry entry will be
displayed at the top of the screen.
NOTE: The controller must be registered via an Ethernet connection.
Sending Test Commands to the Terminal:
After you connect your terminal, press <return> or the <enter> key on your keyboard. In response to
carriage return <return>, the controller responds with a colon, :
Now type
TPA <return>
This command directs the controller to return the current position of the A axis. The controller should
respond with a number such as
0000000
Step 7. Determine the Axes to be Used for Sinusoidal
Commutation
* This step is only required when the controller will be used to control a brushless motor(s) with
sinusoidal commutation.
The command, BA is used to select the axes of sinusoidal commutation. For example, BAAC sets A
and C as axes with sinusoidal commutation.
Notes on Configuring Sinusoidal Commutation:
The command, BA, reconfigures the controller such that it has one less axis of 'standard' control for
each axis of sinusoidal commutation. For example, if the command BAA is given to a DMC-2x40
controller, the controller will be re-configured to be a DMC-2x30 controller. In this case the highest
axis is no longer available except to be used for the 2nd phase of the sinusoidal commutation. Note that
the highest axis on a controller can never be configured for sinusoidal commutation.
The DAC associated with the selected axis represents the first phase. The second phase uses the
highest available DAC. When more than one axis is configured for sinusoidal commutation, the
controller will assign the second phases to the DACs which have been made available through the axes
reconfiguration. The highest sinusoidal commutation axis will be assigned to the highest available
DAC and the lowest sinusoidal commutation axis will be assigned to the lowest available DAC. Note
that the lowest axis is the A axis and the highest axis is the highest available axis for which the
controller has been configured.
Example: Sinusoidal Commutation Configuration using a DMC-2x70
BAAC
This command causes the controller to be reconfigured as a DMC-2x50 controller. The A and C axes
are configured for sinusoidal commutation. The first phase of the A axis will be the motor command
A signal. The second phase of the A axis will be F signal. The first phase of the C axis will be the
motor command C signal. The second phase of the C axis will be the motor command G signal.
DMC-2X00
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Step 8. Make Connections to Amplifier and Encoder.
Once you have established communications between the software and the DMC-2x00, you are ready to
connect the rest of the motion control system. The motion control system typically consists of an
ICM-2900 Interface Module, an amplifier for each axis of motion, and a motor to transform the current
from the amplifier into torque for motion.
If you are using an ICM-2900, connect it to the DMC-2x00 via the 100-pin high density cable. The
ICM-2900 provides screw terminals for access to the connections described in the following
discussion.
Motion Controllers with more than 4 axes require a second ICM-2900 and 100-pin cable.
2x80
System connection procedures will depend on system components and motor types. Any combination
of motor types can be used with the DMC-2x00. If sinusoidal commutation is to be used, special
attention must be paid to the reconfiguration of axes.
Here are the first steps for connecting a motion control system:
Step A. Connect the motor to the amplifier with no connection to the controller. Consult the
amplifier documentation for instructions regarding proper connections. Connect and turn-on
the amplifier power supply. If the amplifiers are operating properly, the motor should stand
still even when the amplifiers are powered up.
Step B. Connect the amplifier enable signal.
Before making any connections from the amplifier to the controller, you need to verify that
the ground level of the amplifier is either floating or at the same potential as earth.
WARNING: When the amplifier ground is not isolated from the power line or when it has a different
potential than that of the computer ground, serious damage may result to the computer controller
and amplifier.
If you are not sure about the potential of the ground levels, connect the two ground signals
(amplifier ground and earth) by a 10 kΩ resistor and measure the voltage across the resistor.
Only if the voltage is zero, connect the two ground signals directly.
The amplifier enable signal is used by the controller to disable the motor. This signal is
labeled AMPENA for the A axis on the ICM-2900 and should be connected to the enable
signal on the amplifier. Note that many amplifiers designate this signal as the INHIBIT
signal. Use the command, MO, to disable the motor amplifiers - check to insure that the
motor amplifiers have been disabled (often this is indicated by an LED on the amplifier).
This signal changes under the following conditions: the watchdog timer activates, the motor-
off command, MO, is given, or the OE1 command (Enable Off-On-Error) is given and the
position error exceeds the error limit. AMPEN can be used to disable the amplifier for these
conditions.
The standard configuration of the AMPEN signal is TTL active high. In other words, the
AMPEN signal will be high when the controller expects the amplifier to be enabled. The
polarity and the amplitude can be changed if you are using the ICM-2900 interface board. To
change the polarity from active high (5 volts = enable, zero volts = disable) to active low
(zero volts = enable, 5 volts = disable), replace the 7407 IC with a 7406. Note that many
amplifiers designate the enable input as ‘inhibit’.
To change the voltage level of the AMPEN signal, note the state of the resistor pack on the
ICM-2900. When Pin 1 is on the 5V mark, the output voltage is 0-5V. To change to 12 volts,
pull the resistor pack and rotate it so that Pin 1 is on the 12 volt side. If you remove the
resistor pack, the output signal is an open collector, allowing the user to connect an external
supply with voltages up to 24V.
Step C. Connect the encoders
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For stepper motor operation, an encoder is optional.
For servo motor operation, if you have a preferred definition of the forward and reverse
directions, make sure that the encoder wiring is consistent with that definition.
The DMC-2x00 accepts single-ended or differential encoder feedback with or without an
index pulse. If you are not using the ICM-2900 you will need to consult the appendix for the
encoder pinouts for connection to the motion controller. The ICM-2900 accepts encoder
feedback via individual signal leads. Simply match the leads from the encoder you are using
to the encoder feedback inputs on the interconnect board. The signal leads are labeled CHA
(channel A), CHB (channel B), and INDEX. For differential encoders, the complement
signals are labeled CHA-, CHB-, and INDEX-.
NOTE: When using pulse and direction encoders, the pulse signal is connected to CHA and the
direction signal is connected to CHB. The controller must be configured for pulse and direction
with the command CE. See the command summary for further information on the command CE.
Step D. Verify proper encoder operation.
Start with the A encoder first. Once it is connected, turn the motor shaft and interrogate the
position with the instruction TPA <return>. The controller response will vary as the motor is
turned.
At this point, if TPA does not vary with encoder rotation, there are three possibilities:
1. The encoder connections are incorrect - check the wiring as necessary.
2. The encoder has failed - using an oscilloscope, observe the encoder signals. Verify
that both channels A and B have a peak magnitude between 5 and 12 volts. Note
that if only one encoder channel fails, the position reporting varies by one count
only. If the encoder failed, replace the encoder. If you cannot observe the encoder
signals, try a different encoder.
3. There is a hardware failure in the controller - connect the same encoder to a different
axis. If the problem disappears, you probably have a hardware failure. Consult the
factory for help.
Step E. Connect Hall Sensors if available.
Hall sensors are only used with sinusoidal commutation and are not necessary for proper
operation. The use of Hall sensors allows the controller to automatically estimate the
commutation phase upon reset and also provides the controller the ability to set a more precise
commutation phase. Without Hall sensors, the commutation phase must be determined
manually.
The Hall effect sensors are connected to the digital inputs of the controller. These inputs can
be used with the general use inputs (bits 1-8), the auxiliary encoder inputs (bits 81-96), or the
extended I/O inputs of the DMC-2x00 controller (bits 17-80).
NOTE: The general use inputs are optoisolated and require a voltage connection at the INCOM
point - for more information regarding the digital inputs, see Chapter 3, Connecting Hardware.
Each set of sensors must use inputs that are in consecutive order. The input lines are specified
with the command, BI. For example, if the Hall sensors of the C axis are connected to inputs
6, 7 and 8, use the instruction:
BI ,, 6 or
BIC = 6
DMC-2X00
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Step 9a. Connect Standard Servo Motors
The following discussion applies to connecting the DMC-2x00 controller to standard servo motor
amplifiers:
The motor and the amplifier may be configured in the torque or the velocity mode. In the torque
mode, the amplifier gain should be such that a 10 volt signal generates the maximum required current.
In the velocity mode, a command signal of 10 volts should run the motor at the maximum required
speed.
Step by step directions on servo system setup are also included on the WSDK (Windows Servo Design
Kit) software offered by Galil. See section on WSDK for more details.
Step A. Check the Polarity of the Feedback Loop
It is assumed that the motor and amplifier are connected together and that the encoder is
operating correctly (Step B). Before connecting the motor amplifiers to the controller, read
the following discussion on setting Error Limits and Torque Limits. Note that this discussion
only uses the A axis as an examples.
Step B. Set the Error Limit as a Safety Precaution
Usually, there is uncertainty about the correct polarity of the feedback. The wrong polarity
causes the motor to run away from the starting position. Using a terminal program, such as
DMCTERM, the following parameters can be given to avoid system damage:
Input the commands:
ER 2000 <CR> Sets error limit on the A axis to be 2000 encoder counts
OE 1 <CR>
Disables A axis amplifier when excess position error exists
If the motor runs away and creates a position error of 2000 counts, the motor amplifier will be
disabled.
NOTE: This function requires the AMPEN signal to be connected from the controller to the
amplifier.
Step C. Set Torque Limit as a Safety Precaution
To limit the maximum voltage signal to your amplifier, the DMC-2x00 controller has a torque
limit command, TL. This command sets the maximum voltage output of the controller and
can be used to avoid excessive torque or speed when initially setting up a servo system.
When operating an amplifier in torque mode, the voltage output of the controller will be
directly related to the torque output of the motor. The user is responsible for determining this
relationship using the documentation of the motor and amplifier. The torque limit can be set
to a value that will limit the motors output torque.
When operating an amplifier in velocity or voltage mode, the voltage output of the controller
will be directly related to the velocity of the motor. The user is responsible for determining
this relationship using the documentation of the motor and amplifier. The torque limit can be
set to a value that will limit the speed of the motor.
For example, the following command will limit the output of the controller to 1 volt on the X
axis:
TL 1 <CR>
NOTE: Once the correct polarity of the feedback loop has been determined, the torque limit
should, in general, be increased to the default value of 9.99. The servo will not operate properly if
the torque limit is below the normal operating range. See description of TL in the command
reference.
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Step D. Connect the Motor
Once the parameters have been set, connect the analog motor command signal (ACMD) to the
amplifier input.
To test the polarity of the feedback, command a move with the instruction:
PR 1000 <CR> Position relative 1000 counts
BGA <CR>
Begin motion on A axis
When the polarity of the feedback is wrong, the motor will attempt to run away. The
controller should disable the motor when the position error exceeds 2000 counts. If the motor
runs away, the polarity of the loop must be inverted.
Inverting the Loop Polarity
When the polarity of the feedback is incorrect, the user must invert the loop polarity and this may be
accomplished by several methods. If you are driving a brush-type DC motor, the simplest way is to
invert the two motor wires (typically red and black). For example, switch the M1 and M2 connections
going from your amplifier to the motor. When driving a brushless motor, the polarity reversal may be
done with the encoder. If you are using a single-ended encoder, interchange the signal CHA and CHB.
If, on the other hand, you are using a differential encoder, interchange only CHA+ and CHA-. The
loop polarity and encoder polarity can also be affected through software with the MT, and CE
commands. For more details on the MT command or the CE command, see the Command Reference
section.
Sometimes the feedback polarity is correct (the motor does not attempt to run away) but the direction
of motion is reversed with respect to the commanded motion. If this is the case, reverse the motor
leads AND the encoder signals.
If the motor moves in the required direction but stops short of the target, it is most likely due to
insufficient torque output from the motor command signal ACMD. This can be alleviated by reducing
system friction on the motors. The instruction:
TTA <return> Tell torque on A
reports the level of the output signal. It will show a non-zero value that is below the friction level.
Once you have established that you have closed the loop with the correct polarity, you can move on to
the compensation phase (servo system tuning) to adjust the PID filter parameters, KP, KD and KI. It is
necessary to accurately tune your servo system to ensure fidelity of position and minimize motion
oscillation as described in the next section.
DMC-2X00
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ICM-2900
MOCMDZ
SIGNZ
PWMZ
GND
MOCMDW
SIGNW
PWMW
GND
Signal Gnd
+Ref In
2
4
MOCMDX
SIGNX
MOCMDY
SIGNY
PWMY
GND
Inhibit* 11
PWMX
GND
Motor + 1
Motor - 2
OUT PWR
ERROR
CMP
AMPENW
AMPENZ
Power Gnd 4
High Volt
AMPENY
AMPENX
5
OUT GND
OUT5
OUT6
OUT7
OUT8
OUT1
OUT2
OUT3
OUT4
+5V
HOMEZ
RLSZ
LSCOM
HOMEW
RLSW
FLSZ
FLSW
HOMEX
RLSX
FLSX
HOMEY
RLSY
FLSY
GND
GND
IN5
IN6
IN7
IN8
XLATCH
YLATCH
ZLATCH
WLATCH
+5V
+12V
INCOM
ABORT
RESET
GND
-12V
ANA GND
ANALOG5
ANALOG6
ANALOG7
ANALOG8
ANALOG1
ANALOG2
ANALOG3
ANALOG4
Encoder
+5V
+INX
-INX
+MAX
-MAX
+MBX
-MBX
GND
+5V
+INY
-INY
+MAY
-MAY
+MBY
-MBY
GND
+5V
+INZ
-INZ
+MAZ
-MAZ
+MBZ
-MBZ
GND
+5V
+INW
-INW
GND
+MAW
-MAW
+MBW
-MBW
Figure 2-6 System Connections with a separate amplifier (MSA 12-80). This diagram shows the connections for a
standard DC Servo Motor and encoder
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Step 9b. Connect Sinusoidal Commutation Motors
When using sinusoidal commutation, the parameters for the commutation must be determined and
saved in the controller’s non-volatile memory. The setup for sinusoidal commutation is
different when using Hall Sensors. Each step which is affected by Hall Sensor Operation is
divided into two parts, part 1 and part 2. After connecting sinusoidal commutation motors,
the servos must be tuned as described in Step 10.
Step A. Disable the motor amplifier
Use the command, MO, to disable the motor amplifiers. For example, MOA will turn the A
axis motor off.
Step B. Connect the motor amplifier to the controller.
The sinusoidal commutation amplifier requires 2 signals, usually denoted as Phase A & Phase
B. These inputs should be connected to the two sinusoidal signals generated by the controller.
The first signal is the axis specified with the command, BA (Step 6). The second signal is
associated with the highest analog command signal available on the controller - note that this
axis was made unavailable for standard servo operation by the command BA.
When more than one axis is configured for sinusoidal commutation, the controller will assign
the second phase to the command output which has been made available through the axes
reconfiguration. The 2nd phase of the highest sinusoidal commutation axis will be the highest
command output and the 2nd phase of the lowest sinusoidal commutation axis will be the
lowest command output.
It is not necessary to be concerned with cross-wiring the 1st and 2nd signals. If this wiring is
incorrect, the setup procedure will alert the user (Step D).
Example: Sinusoidal Commutation Configuration using a DMC-
2x70
BAAC
This command causes the controller to be reconfigured as a DMC-2x50 controller. The A and
C axes are configured for sinusoidal commutation. The first phase of the A axis will be the
motor command A signal. The second phase of the A axis will be the motor command F
signal. The first phase of the C axis will be the motor command C signal. The second phase
of the C axis will be the motor command G signal.
Step C. Specify the Size of the Magnetic Cycle.
Use the command, BM, to specify the size of the brushless motors magnetic cycle in encoder
counts. For example, if the X axis is a linear motor where the magnetic cycle length is 62
mm, and the encoder resolution is 1 micron, the cycle equals 62,000 counts. This can be
commanded with the command:
BM 62000
On the other hand, if the C axis is a rotary motor with 4000 counts per revolution and 3
magnetic cycles per revolution (three pole pairs) the command is:
BM,, 1333.333
Step D - part 1 (Systems with or without Hall Sensors). Test the Polarity of the DACs
Use the brushless motor setup command, BS, to test the polarity of the output DACs. This
command applies a certain voltage, V, to each phase for some time T, and checks to see if the
motion is in the correct direction.
DMC-2X00
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The user must specify the value for V and T. For example, the command:
BSA = 2,700
will test the A axis with a voltage of 2 volts, applying it for 700 millisecond for each phase.
In response, this test indicates whether the DAC wiring is correct and will indicate an
approximate value of BM. If the wiring is correct, the approximate value for BM will agree
with the value used in the previous step.
NOTE: In order to properly conduct the brushless setup, the motor must be allowed to move a
minimum of one magnetic cycle in both directions.
NOTE: When using Galil Windows software, the timeout must be set to a minimum of 10
seconds (time-out = 10000) when executing the BS command. This allows the software to
retrieve all messages returned from the controller.
Step D - part 2 (Systems with Hall Sensors Only). Test the Hall Sensor Configuration.
Since the Hall sensors are connected randomly, it is very likely that they are wired in the
incorrect order. The brushless setup command indicates the correct wiring of the Hall
sensors. The Hall sensor wires should be re-configured to reflect the results of this test.
The setup command also reports the position offset of the Hall transition point and the zero
phase of the motor commutation. The zero transition of the Hall sensors typically occur at
0°, 30° or 90° of the phase commutation. It is necessary to inform the controller about the
offset of the Hall sensor and this is done with the instruction, BB.
Step E. Save Brushless Motor Configuration
It is very important to save the brushless motor configuration in non-volatile memory. After
the motor wiring and setup parameters have been properly configured, the burn command,
BN, should be given.
NOTE: Without Hall sensors, the controller will not be able to estimate the commutation phase
of the brushless motor. In this case, the controller could become unstable until the commutation
phase has been set using the BZ command (see next step). It is highly recommended that the
motor off command be given before executing the BN command. In this case, the motor will be
disabled upon power up or reset and the commutation phase can be set before enabling the motor.
Step F - part 1 (Systems with or without Hall Sensors). Set Zero Commutation Phase
When an axis has been defined as sinusoidally commutated, the controller must have an
estimate for commutation phase. When Hall sensors are used, the controller automatically
estimates this value upon reset of the controller. If no Hall sensors are used, the controller
will not be able to make this estimate and the commutation phase must be set before enabling
the motor.
To initialize the commutation without Hall effect sensor use the command, BZ. This function
drives the motor to a position where the commutation phase is zero, and sets the phase to zero.
The BZ command is followed by real numbers in the fields corresponding to the driven axes.
The number represents the voltage to be applied to the amplifier during the initialization.
When the voltage is specified by a positive number, the initialization process ends up in the
motor off (MO) state. A negative number causes the process to end in the Servo Here (SH)
state.
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WARNING: This command must move the motor to find the zero commutation phase. This
movement is instantaneous and will cause the system to jerk. Larger applied voltages will cause
more severe motor jerk. The applied voltage will typically be sufficient for proper operation of the
BZ command. For systems with significant friction, this voltage may need to be increased and for
systems with very small motors, this value should be decreased. For example:
BZ –2, 0,1
will drive both A and C axes to zero, will apply 2V and 1V respectively to A and C and will end up
with A in SH and C in MO.
Step F - part 2 (Systems with Hall Sensors Only). Set Zero Commutation Phase
With Hall sensors, the estimated value of the commutation phase is good to within 30°. This
estimate can be used to drive the motor but a more accurate estimate is needed for efficient
motor operation. There are 3 possible methods for commutation phase initialization:
Method 1. Use the BZ command as described above.
Method 2. Drive the motor close to commutation phase of zero and then use BZ command.
This method decreases the amount of system jerk by moving the motor close to zero
commutation phase before executing the BZ command. The controller makes an estimate for
the number of encoder counts between the current position and the position of zero
commutation phase. This value is stored in the operand _BZn. Using this operand the
controller can be commanded to move the motor. The BZ command is then issued as
described above. For example, to initialize the A axis motor upon power or reset, the
following commands may be given:
SHA
;Enable A axis motor
PRA=-1*(_BZA)
BGA
;Move A motor close to zero commutation phase
;Begin motion on A axis
AMA
;Wait for motion to complete on A axis
;Drive motor to commutation phase zero and leave
;motor on
BZA=-1
Method 3. Use the command, BC. This command uses the Hall transitions to determine the
commutation phase. Ideally, the Hall sensor transitions will be separated by exactly 60° and
any deviation from 60° will affect the accuracy of this method. If the Hall sensors are
accurate, this method is recommended. The BC command monitors the Hall sensors during a
move and monitors the Hall sensors for a transition point. When that occurs, the controller
computes the commutation phase and sets it. For example, to initialize the A axis motor upon
power or reset, the following commands may be given:
SHA
;Enable A axis motor
BCA
;Enable the brushless calibration command
;Command a relative position movement on A axis
;Begin motion on A axis. When the Hall sensors
PRA=50000
BGA
; detect a phase transition, the commutation phase is
;re-set.
DMC-2X00
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Step 9c. Connect Step Motors
In Stepper Motor operation, the pulse output signal has a 50% duty cycle. Step motors operate open
loop and do not require encoder feedback. When a stepper is used, the auxiliary encoder for the
corresponding axis is unavailable for an external connection. If an encoder is used for position
feedback, connect the encoder to the main encoder input corresponding to that axis. The commanded
position of the stepper can be interrogated with RP or TD. The encoder position can be interrogated
with TP.
The frequency of the step motor pulses can be smoothed with the filter parameter, KS. The KS
parameter has a range between 0.5 and 8, where 8 implies the largest amount of smoothing. See
Command Reference regarding KS.
The DMC-2x00 profiler commands the step motor amplifier. All DMC-2x00 motion commands apply
such as PR, PA, VP, CR and JG. The acceleration, deceleration, slew speed and smoothing are also
used. Since step motors run open-loop, the PID filter does not function and the position error is not
generated.
To connect step motors with the DMC-2x00 you must follow this procedure:
Step A. Install SM jumpers
Each axis of the DMC-2x00 that will operate a stepper motor must have the corresponding
stepper motor jumper installed. For a discussion of SM jumpers, see section Step 2. Install
Jumpers on the DMC-2x00.
Step B. Connect step and direction signals from controller to motor amplifier
From the controller to respective signals on your step motor amplifier. (These signals are
labeled PULSX and DIRX for the A-axis on the ICM-2900). Consult the documentation for
your step motor amplifier.
Step C. Configure DMC-2x00 for motor type using MT command. You can configure the DMC-
2x00 for active high or active low pulses. Use the command MT 2 for active low step motor
pulses and MT -2 for active high step motor pulses. See description of the MT command in
the Command Reference.
Step 10. Tune the Servo System
Adjusting the tuning parameters is required when using servo motors (standard or sinusoidal
commutation). The system compensation provides fast and accurate response and the following
presentation suggests a simple and easy way for compensation. More advanced design methods are
available with software design tools from Galil, such as the Servo Design Kit (SDK software)
The filter has three parameters: the damping, KD; the proportional gain, KP; and the integrator, KI.
The parameters should be selected in this order.
To start, set the integrator to zero with the instruction
KI 0 <return> Integrator gain
and set the proportional gain to a low value, such as
KP 1 <return> Proportional gain
KD 100 <return> Derivative gain
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For more damping, you can increase KD (maximum is 4095). Increase gradually and stop after the
motor vibrates. A vibration is noticed by audible sound or by interrogation. If you send the command
TE A <return> Tell error
a few times, and get varying responses, especially with reversing polarity, it indicates system vibration.
When this happens, simply reduce KD.
Next you need to increase the value of KP gradually (maximum allowed is 1023). You can monitor the
improvement in the response with the Tell Error instruction
KP 10 <return> Proportion gain
TE A <return> Tell error
As the proportional gain is increased, the error decreases.
Again, the system may vibrate if the gain is too high. In this case, reduce KP. Typically, KP should
not be greater than KD/4 (only when the amplifier is configured in the current mode).
Finally, to select KI, start with zero value and increase it gradually. The integrator eliminates the
position error, resulting in improved accuracy. Therefore, the response to the instruction
TE A <return>
becomes zero. As KI is increased, its effect is amplified and it may lead to vibrations. If this occurs,
simply reduce KI. Repeat tuning for the B, C and D axes.
For a more detailed description of the operation of the PID filter and/or servo system theory, see
Chapter 10 - Theory of Operation.
Design Examples
Here are a few examples for tuning and using your controller. These examples have remarks next to
each command - these remarks must not be included in the actual program.
System Set-up
This example assigns the system filter parameters, error limits and enables the automatic error shut-off.
Instruction
KP10,10,10,10
KP*=10
Interpretation
Set gains for a,b,c,d (or A,B,C,D axes)
Alternate method for setting gain on all axes
Method for setting only A axis gain
Set B axis gain only
KPA=10
KP, 20
Instruction
OE 1,1,1,1,1,1,1,1
ER*=1000
Interpretation
Enable automatic Off on Error function for all axes
Set error limit for all axes to 1000 counts
Set gains for a,b,c,d,e,f,g,and h axes
Alternate method for setting gain on all axes
Alternate method for setting A axis gain
Set C axis gain only
KP10,10,10,10,10,10,10,10
KP*=10
KPA=10
KP,,10
KPD=10
Alternate method for setting D axis gain
Alternate method for setting H axis gain
KPH=10
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Profiled Move
Rotate the A axis a distance of 10,000 counts at a slew speed of 20,000 counts/sec and an acceleration
and deceleration rates of 100,000 counts/s2. In this example, the motor turns and stops:
Instruction
PR1000
Interpretation
Distance
SP20000
Speed
DC 100000
AC 100000
BG A
Deceleration
Acceleration
Start Motion
Multiple Axes
Objective: Move the four axes independently.
Instruction
Interpretation
PR 500,1000,600,-400
SP 10000,12000,20000,10000
AC 10000,10000,10000,10000
DC 80000,40000,30000,50000
BG AC
Distances of A,B,C,D
Slew speeds of A,B,C,D
Accelerations of A,B,C,D
Decelerations of A,B,C,D
Start A and C motion
Start B and D motion
BG BD
Independent Moves
The motion parameters may be specified independently as illustrated below.
Instruction
PR ,300,-600
SP ,2000
DC ,80000
AC ,100000
AC ,,100000
DC,,150000
BG C
Interpretation
Distances of B and C
Slew speed of B
Deceleration of B
Acceleration of B
Acceleration of C
Deceleration of C
Start C motion
BG B
Start B motion
Position Interrogation
The position of the four axes may be interrogated with the instruction, TP.
Instruction
TP
TP A
Interpretation
Tell position all four axes
Tell position – A axis only
Tell position – B axis only
Tell position – C axis only
Tell position – D axis only
TP B
TP C
TP D
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The position error, which is the difference between the commanded position and the actual position
can be interrogated with the instruction TE.
Instruction
TE
Interpretation
Tell error – all axes
TE A
Tell error – A axis only
Tell error – B axis only
Tell error – C axis only
Tell error – D axis only
TE B
TE C
TE D
Absolute Position
Objective: Command motion by specifying the absolute position.
Instruction
DP 0,2000
PA 7000,4000
BG A
Interpretation
Define the current positions of A,B as 0 and 2000
Sets the desired absolute positions
Start A motion
BG B
Start B motion
After both motions are complete, the A and B axes can be command back to zero:
PA 0,0
Move to 0,0
BG AB
Start both motions
Velocity Control
Objective: Drive the A and B motors at specified speeds.
Instruction
JG 10000,-20000
AC 100000, 40000
DC 50000,50000
BG AB
Interpretation
Set Jog Speeds and Directions
Set accelerations
Set decelerations
Start motion
after a few seconds, command:
JG -40000
New A speed and Direction
Returns A speed
TV A
and then
JG ,20000
New B speed
TV B
Returns B speed
These cause velocity changes including direction reversal. The motion can be stopped with the
instruction
ST
Stop
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Operation Under Torque Limit
The magnitude of the motor command may be limited independently by the instruction TL.
Instruction
TL 0.2
Interpretation
Set output limit of A axis to 0.2 volts
Set A speed
JG 10000
BG A
Start A motion
In this example, the A motor will probably not move since the output signal will not be sufficient to
overcome the friction. If the motion starts, it can be stopped easily by a touch of a finger.
Increase the torque level gradually by instructions such as
Instruction
TL 1.0
Interpretation
Increase torque limit to 1 volt.
Increase torque limit to maximum, 9.998 volts.
TL 9.998
The maximum level of 9.998 volts provides the full output torque.
Interrogation
The values of the parameters may be interrogated. Some examples …
Instruction
KP?
Interpretation
Return gain of A axis
Return gain of C axis.
Return gains of all axes.
KP ,,?
KP ?,?,?,?
Many other parameters such as KI, KD, FA, can also be interrogated. The command reference denotes
all commands which can be interrogated.
Operation in the Buffer Mode
The instructions may be buffered before execution as shown below.
Instruction
PR 600000
SP 10000
WT 10000
BG A
Interpretation
Distance
Speed
Wait 10000 milliseconds before reading the next instruction
Start the motion
Using the On-Board Editor
Motion programs may be edited and stored in the controller’s on-board memory. When the command,
ED is given from the Galil DOS terminal (such as DMCTERM), the controllers editor will be started.
The instruction
ED
Edit mode
moves the operation to the editor mode where the program may be written and edited. The editor
provides the line number. For example, in response to the first ED command, the first line is zero.
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Line # Instruction
Interpretation
Define label
Distance
000
001
002
003
004
#A
PR 700
SP 2000
BGA
EN
Speed
Start A motion
End program
To exit the editor mode, input <cntrl>Q. The program may be executed with the command.
XQ #A
Start the program running
If the ED command is issued from the Galil Windows terminal software (such as SmartTERM), the
software will open a Windows based editor. From this editor a program can be entered, edited,
downloaded and uploaded to the controller.
Motion Programs with Loops
Motion programs may include conditional jumps as shown below.
Instruction
#A
Interpretation
Label
DP 0
Define current position as zero
Set initial value of V1
Label for loop
V1=1000
#LOOP
PA V1
Move A motor V1 counts
Start A motion
BG A
AM A
After A motion is complete
Wait 500 ms
WT 500
TP A
Tell position A
V1=V1+1000
JP #LOOP,V1<10001
EN
Increase the value of V1
Repeat if V1<10001
End
After the above program is entered, quit the Editor Mode, <cntrl>Q. To start the motion, command:
XQ #A
Execute Program #A
Motion Programs with Trippoints
The motion programs may include trippoints as shown below.
Instruction
#B
Interpretation
Label
DP 0,0
Define initial positions
Set targets
PR 30000,60000
SP 5000,5000
BGA
Set speeds
Start A motion
AD 4000
BGB
Wait until A moved 4000
Start B motion
AP 6000
Wait until position A=6000
Change speeds
SP 2000,50000
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AP ,50000
SP ,10000
EN
Wait until position B=50000
Change speed of B
End program
To start the program, command:
XQ #B
Execute Program #B
Control Variables
Objective: To show how control variables may be utilized.
Instruction
#A;DP0
PR 4000
SP 2000
BGA
Interpretation
Label; Define current position as zero
Initial position
Set speed
Move A
AMA
Wait until move is complete
Wait 500 ms
WT 500
#B
V1 = _TPA
PR -V1/2
BGA
Determine distance to zero
Command A move 1/2 the distance
Start A motion
AMA
After A moved
WT 500
V1=
Wait 500 ms
Report the value of V1
Exit if position=0
Repeat otherwise
Label #C
JP #C, V1=0
JP #B
#C
EN
End of Program
To start the program, command
XQ #A
Execute Program #A
This program moves A to an initial position of 1000 and returns it to zero on increments of half the
distance. Note, _TPA is an internal variable which returns the value of the A position. Internal
variables may be created by preceding a DMC-2x00 instruction with an underscore, _.
Linear Interpolation
Objective: Move A,B,C motors distance of 7000,3000,6000, respectively, along linear trajectory.
Namely, motors start and stop together.
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Instruction
LM ABC
LI 7000,3000,6000
LE
Interpretation
Specify linear interpolation axes
Relative distances for linear interpolation
Linear End
VS 6000
Vector speed
VA 20000
VD 20000
BGS
Vector acceleration
Vector deceleration
Start motion
Circular Interpolation
Objective: Move the AB axes in circular mode to form the path shown on Fig. 2-7. Note that the
vector motion starts at a local position (0,0) which is defined at the beginning of any vector motion
sequence. See application programming for further information.
Instruction
VM AB
Interpretation
Select AB axes for circular interpolation
Linear segment
VP -4000,0
CR 2000,270,-180
VP 0,4000
CR 2000,90,-180
VS 1000
Circular segment
Linear segment
Circular segment
Vector speed
VA 50000
VD 50000
VE
Vector acceleration
Vector deceleration
End vector sequence
Start motion
BGS
B
(-4000,4000)
R=2000
(0,4000)
(-4000,0)
(0,0) local zero
A
Figure 2-7 Motion Path for Circular Interpolation Example
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Chapter 3 Connecting Hardware
Overview
The DMC-2x00 provides opto-isolated digital inputs for forward limit, reverse limit, home, and
abort signals. The controller also has 8 opto-isolated, uncommitted inputs (for general use) as well
as 8 TTL outputs and 8 analog inputs configured for voltages between +/- 10 volts.
Controllers with 5 or more axes have an additional 8 opto-isolated inputs and an additional 8 TTL
outputs.
2x80
This chapter describes the inputs and outputs and their proper connection.
If you plan to use the auxiliary encoder feature of the DMC-2x00, you will require a separate encoder
cable and breakout - contact Galil Motion control
Using Optoisolated Inputs
Limit Switch Input
The forward limit switch (FLSx) inhibits motion in the forward direction immediately upon activation
of the switch. The reverse limit switch (RLSx) inhibits motion in the reverse direction immediately
upon activation of the switch. If a limit switch is activated during motion, the controller will make a
decelerated stop using the deceleration rate previously set with the DC command. The motor will
remain “ON” (in a servo state) after the limit switch has been activated and will hold motor position.
When a forward or reverse limit switch is activated, the current application program that is running
will be interrupted and the controller will automatically jump to the #LIMSWI subroutine if one exists.
This is a subroutine which the user can include in any motion control program and is useful for
executing specific instructions upon activation of a limit switch. Automatic Subroutines are discussed
in Chapter 6.
After a limit switch has been activated, further motion in the direction of the limit switch will not be
possible until the logic state of the switch returns back to an inactive state. This usually involves
physically opening the tripped switch. Any attempt at further motion before the logic state has been
reset will result in the following error: “022 - Begin not possible due to limit switch” error.
The operands, _LFx and _LRx, contain the state of the forward and reverse limit switches, respectively
(x represents the axis, A,B,C,D etc.). The value of the operand is either a ‘0’ or ‘1’ corresponding to
the logic state of the limit switch. Using a terminal program, the state of a limit switch can be printed
to the screen with the command, MG _LFx or MG _LFx. This prints the value of the limit switch
operands for the 'x' axis. The logic state of the limit switches can also be interrogated with the TS
command. For more details on TS see the Command Reference.
DMC-2X00
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Home Switch Input
Homing inputs are designed to provide mechanical reference points for a motion control application.
A transition in the state of a Home input alerts the controller that a particular reference point has been
reached by a moving part in the motion control system. A reference point can be a point in space or an
encoder index pulse.
The Home input detects any transition in the state of the switch and toggles between logic states 0 and
1 at every transition. A transition in the logic state of the Home input will cause the controller to
execute a homing routine specified by the user.
There are three homing routines supported by the DMC-2x00: Find Edge (FE), Find Index (FI), and
Standard Home (HM).
The Find Edge routine is initiated by the command sequence: FEA <return>, BGA <return>. The Find
Edge routine will cause the motor to accelerate, then slew at constant speed until a transition is
detected in the logic state of the Home input. The direction of the FE motion is dependent on the state
of the home switch. The motor will then decelerate to a stop. The acceleration rate, deceleration rate
and slew speed are specified by the user, prior to the movement, using the commands AC, DC, and SP.
It is recommended that a high deceleration value be used so the motor will decelerate rapidly after
sensing the Home switch.
The Find Index routine is initiated by the command sequence: FIA <return>, BGA <return>. Find
Index will cause the motor to accelerate to the user-defined slew speed at a rate specified by the user
with the AC command and slew until the controller senses a change in the index pulse signal from low
to high. The slew speed and direction in which the motor will move is designated by the JG command.
The motor then decelerates to a stop at the rate previously specified by the user with the DC command.
Although Find Index is an option for homing, it is not dependent upon a transition in the logic state of
the Home input, but instead is dependent upon a transition in the level of the index pulse signal.
The Standard Homing routine is initiated by the sequence of commands HMA <return>, BGA
<return>. Standard Homing is a combination of Find Edge and Find Index homing. Initiating the
standard homing routine will cause the motor to slew until a transition is detected in the logic state of
the Home input. The motor will accelerate at the rate specified by the command, AC, up to the slew
speed. After detecting the transition in the logic state on the Home Input, the motor will decelerate to
a stop at the rate specified by the command, DC. After the motor has decelerated to a stop, it switches
direction and approaches the transition point at the speed of 256 counts/sec. When the logic state
changes again, the motor moves forward (in the direction of increasing encoder count) at the same
speed, until the controller senses the index pulse. After detection, it decelerates to a stop and defines
this position as 0. The logic state of the Home input can be interrogated with the command MG
_HMA. This command returns a 0 or 1 if the logic state is low or high, respectively. The state of the
Home input can also be interrogated indirectly with the TS command.
For examples and further information about Homing, see command HM, FI, FE of the Command
Reference and the section entitled ‘Homing’ in the Programming Motion Section of this manual.
Abort Input
The function of the Abort input is to immediately stop the controller upon transition of the logic state.
NOTE: The response of the abort input is significantly different from the response of an activated
limit switch. When the abort input is activated, the controller stops generating motion commands
immediately, whereas the limit switch response causes the controller to make a decelerated stop.
NOTE: The effect of an Abort input is dependent on the state of the Off-On-Error function for each
axis. If the Off-On-Error function is enabled for any given axis, the motor for that axis will be turned
off when the abort signal is generated. This could cause the motor to ‘coast’ to a stop since it is no
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longer under servo control. If the Off-On-Error function is disabled, the motor will decelerate to a stop
as fast as mechanically possible and the motor will remain in a servo state.
All motion programs that are currently running are terminated when a transition in the Abort input is
detected. For information on setting the Off-On-Error function, see the Command Reference, OE.
Reset Input
When this input is pulled low (to 0 volts), the controller will reset. This is equivalent to pushing the
reset button on the front of the DMC-2x00.
Uncommitted Digital Inputs
The DMC-2x00 has 8 opto-isolated inputs. These inputs can be read individually using the function @
IN[x] where x specifies the input number (1 thru 8). These inputs are uncommitted and can allow the
user to create conditional statements related to events external to the controller. For example, the user
may wish to have the x-axis motor move 1000 counts in the positive direction when the logic state of
IN1goes high.
Controllers with more than 4 axes have 16 optoisolated inputs which are denoted as Inputs 1 thru 16.
2x80
Wiring the Opto-Isolated Inputs
The Opto-isolation inputs have a bi-directional capability. To activate an input, at least 1mA of current
must flow from the input common through the input (see figure 3.1). This can be accomplished by 2
methods:
Method 1: Connect a positive voltage in the range of +5V to +24V (with respect to the input) at the
input common point. Each input is connected to ground to activate the input.
Method 2: Connect ground to the input common point. Each input is activated by connecting a
positive voltage between +5V and +24 volts.
The Opto-Isolation Common Point
The opto-isolated inputs are configured into 2 groups. The general inputs, IN[1]-IN[8], and the
ABORT input are in one group. The signal, INCOM, is a common connection for all inputs in this
group. The limit switches and home switches are in the second group. The signal, LSCOM, is a
common connection for all inputs in this group. Figure 3.1 illustrates the internal circuitry.
Group (Controllers with 1- 4
Axes)
Group (Controllers with 5 - 9
Axes)
Common
Signal
IN[1]-IN[8], ABORT
IN[1]-IN[16], ABORT
INCOM
LSCOM
FLA,RLA,HOMEA
FLB,RLB,HOMEB
FLC,RLC,HOMEC
FLD,RLD,HOMED
FLA,RLA,HOMEA,FLB,RLB,HOMEB
FLC,RLC,HOMEC,FLD,RLD,HOMED
FLE,RLE,HOMEE,FLF,RLF,HOMEF
FLG,RLG,HOMEG,FLH,RLH,HOMEH
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LSCOM
Additional Limit
Switches(Dependent on
Number of Axes)
FLSA
RLSA HOMEA FLSB
RLSB
HOMEB
INCO
M
ABOR
IN1
IN2
IN3
IN4
IN5
IN6
IN7
IN8
T
(ALATCH) (BLATCH) (CLATCH) (DLATCH)
Figure 3-1. The Optoisolated Inputs.
NOTE: Controllers with 5 or more axes have IN[9] through IN[16] also connected to INCOM.
Using an Isolated Power Supply
To take full advantage of opto-isolation, an isolated power supply should be connected to the input
common. When using an isolated power supply, do not connect the ground of the isolated power to the
ground of the controller. A power supply in the voltage range between 5 to 24 volts may be applied
directly (see Figure 3-2). For voltages greater than 24 volts, a resistor, R, is needed in series with the
input such that
1 mA < V supply/(R + 2.2KΩ) < 11 mA
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External Resistor Needed for
Voltages > +24V
External Resistor Needed for
Voltages > +24V
LSCOM
LSCOM
2.2K
2.2K
FLSA
FLSA
Configuration to source current at
LSCOM terminal and sink
switch
Configuration to sink current at
LSCOM terminal and source
switch
Figure 3-2. Connecting a single Limit or Home Switch to an Isolated Supply. This diagram only shows the
connection for the forward limit switch of the X axis.
NOTE: As stated in Chapter 2, the wiring is simplified when using a Galil Interconnect module, such
as the ICM-1900 or ICM-2900. These boards accept the cables of the DMC-2x00 and provide
terminals for easy access (Refer to figure 2-2).
Bypassing the Opto-Isolation:
If no isolation is needed, the internal 5 volt supply may be used to power the switches. This can be
done by connecting a jumper between the pins LSCOM or INCOM and 5V, labeled JP3 on the main
board. The Galil interconnect modules provide jumpers and the DMC-2x00 also provides a jumper for
making this connection.
Analog Inputs
The DMC-2x00 has eight analog inputs configured for the range between -10V and 10V. The inputs
are decoded by a 12-bit A/D decoder giving a voltage resolution of approximately .005V. A 16-bit
ADC is available as an option. The impedance of these inputs is 10 KΩ. The analog inputs are
specified as AN[x] where x is a number 1 thru 8.
Amplifier Interface
The DMC-2x00 command voltage ranges between +/-10V. This signal, along with GND, provides the
input to the motor amplifiers. The amplifiers must be sized to drive the motors and load. For best
performance, the amplifiers should be configured for a torque (current) mode of operation with no
additional compensation. The gain should be set such that a 10 volt input results in the maximum
required current.
The DMC-2x00 also provides an amplifier enable signal, AMPEN. This signal changes under the
following conditions: the motor-off command, MO, is given, the watchdog timer activates, or the OE1
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command (Enable Off-On-Error) is given and the position error exceeds the error limit. As shown in
Figure 3-4, AMPEN can be used to disable the amplifier for these conditions.
The standard configuration of the AMPEN signal is TTL active high. In other words, the AMPEN
signal will be high when the controller expects the amplifier to be enabled. The polarity and the
amplitude can be changed if you are using the ICM-2900 interface board. To change the polarity from
active high (5 volts= enable, zero volts = disable) to active low (zero volts = enable, 5 volts= disable),
replace the 7407 IC with a 7406. Note that many amplifiers designate the enable input as ‘inhibit’.
To change the voltage level of the AMPEN signal, note the state of the resistor pack on the ICM-2900.
When Pin 1 is on the 5V mark, the output voltage is 0-5V. To change to 12 volts, pull the resistor pack
and rotate it so that Pin 1 is on the 12 volt side. If you remove the resistor pack, the output signal is an
open collector, allowing the user to connect an external supply with voltages up to 24V.
DMC-2x00
ICM-2900
Connection to +5V or +12V made resistor
pack RP1. Removing the resistor allows
the user to connect their own resistor the
desired voltage level (Up to 24V) by
removing ICM-2900 cover
+12V
+5V
SERVO MOTOR
AMPLIFIER
AMPENX
GND
100-PIN
HIGH
DENSITY
CABLE
MOCMDX
7407 Open Collector Buffer.
The Enable can be inverted
by using a 7406. Accessed
by removing ICM-2900
cover.
Analog Switch
Figure 3-3 Connecting AMPEN to the motor amplifier
TTL Inputs
The Auxiliary Encoder Inputs
The auxiliary encoder inputs can be used for general use. For each axis, the controller has one
auxiliary encoder and each auxiliary encoder consists of two inputs, channel A and channel B. The
auxiliary encoder inputs are mapped to the inputs 81-96.
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Each input from the auxiliary encoder is a differential line receiver and can accept voltage levels
between +/- 12 volts. The inputs have been configured to accept TTL level signals. To connect TTL
signals, simply connect the signal to the + input and leave the - input disconnected. For other signal
levels, the - input should be connected to a voltage that is ½ of the full voltage range (for example,
connect the - input to 6 volts if the signal is a 0 - 12 volt logic).
Example:
A DMC-2x10 has one auxiliary encoder. This encoder has two inputs (channel A and channel B).
Channel A input is mapped to input 81 and Channel B input is mapped to input 82. To use this input
for 2 TTL signals, the first signal will be connected to AA+ and the second to AB+. AA- and AB-
will be left unconnected. To access this input, use the function @IN[81] and @IN[82].
NOTE: The auxiliary encoder inputs are not available for any axis that is configured for
stepper motor.
TTL Outputs
The DMC-2x00 provides dedicated and general use outputs.
General Use Outputs
The DMC-2x00 provides eight general use outputs, an output compare and an error signal output. The
general use outputs are TTL and are accessible through the ICM-2900 as OUT1 thru OUT8. These
outputs can be turned On and Off with the commands, SB (Set Bit), CB (Clear Bit), OB (Output Bit),
and OP (Output Port). For more information about these commands, see the Command Summary.
The value of the outputs can be checked with the operand _OP and the function @OUT[] (see Chapter
7, Mathematical Functions and Expressions).
Controllers with 5 or more axes have an additional eight general use TTL outputs.
2x80
NOTE: The ICM-2900 has an option to provide opto-isolation on the outputs. In this case, the user
provides an isolated power supply (+5volts to +24volts and ground). For more information, consult
Galil.
Output Compare
The output compare signal is TTL and is available on the ICM-2900 as CMP. Output compare is
controlled by the position of any of the main encoders on the controller. The output can be
programmed to produce an active low pulse (1usec) based on an incremental encoder value or to
activate once when an axis position has been passed. For further information, see the command OC in
the Command Reference.
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Error Output
The controller provides a TTL signal, ERROR, to indicate a controller error condition. When an error
condition occurs, the ERROR signal will go low and the controller LED will go on. An error occurs
because of one of the following conditions:
1. At least one axis has a position error greater than the error limit. The error limit is set by
using the command ER.
2. The reset line on the controller is held low or is being affected by noise.
3. There is a failure on the controller and the processor is resetting itself.
4. There is a failure with the output IC which drives the error signal.
Extended I/O of the DMC-2x00 Controller
The DMC-2x00 controller offers 64 extended TTL I/O points which can be configured as inputs or
outputs in 8 bit increments. Configuration is accomplished with command CO - see Chapter 7. The
I/O points are accessed through the 80 pin high density connector labeled EXTENDED I/O.
Interfacing to Grayhill or OPTO-22 G4PB24:
The DMC-2x00 controller uses one 80 Pin high density connector to access the extended I/O. This
connector is accessed via the Galil CABLE-80. The Galil CABLE-80 can be converted to (2) 50 pin
ribbon cables which are compatible with I/O mounting racks such as Grayhill 70GRCM32-HL and
OPTO-22 G4PB24. To convert the 80 pin cable, use the CB-50-80 adapter from Galil. The 50 pin
ribbon cables which connect to the CB-50-80 connect directly into the I/O mounting racks. The CB-
50-80 adapter board is described in the appendix.
When using the OPTO-22 G4PB24 I/O mounting rack, the user will only have access to 48 of the 64
I/O points available on the controller. Block 5 and Block 9 must be configured as inputs and will be
grounded by the I/O rack.
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Chapter 4 Communication
Introduction
The DMC-2x00 has two RS232 ports, and either one USB input port and 2 USB output ports, or
Ethernet ports. The main RS-232 port is the data set and can be configured through the switches on the
front panel. The auxiliary RS-232 port is the data term and can be configured with the software
command CC. The auxiliary RS-232 port can be configured either for daisy chain operation (DMC-
2000 only) or as a general port. This configuration can be saved using the Burn (BN) instruction. The
RS232 ports also have a clock synchronizing line that allows synchronization of motion on more than
one controller.
RS232 Ports
The RS232 pin-out description for the main and auxiliary port is given below. Note that the auxiliary
port is essentially the same as the main port except inputs and outputs are reversed. The DMC-2x00
may also be configured by the factory for RS422. These pin-outs are also listed below.
NOTE: If you are connecting the RS232 auxiliary port to a terminal or any device which is a
DATASET, it is necessary to use a connector adapter, which changes a dataset to a dataterm. This
cable is also known as a 'null' modem cable.
RS232 - Main Port {P1} DATATERM
1 CTS – output
6 CTS - output
2 Transmit Data - output
3 Receive Data - input
4 RTS – input
7 RTS - input
8 CTS - output
9 No connect (Can connect to +5V or sample clock)
5 Ground
RS232 - Auxiliary Port {P2}DATASET
1 CTS – input
6 CTS - input
2 Transmit Data - input
3 Receive Data - output
4 RTS – output
7 RTS - output
8 CTS - input
9 5V (Can be connected to sample clock with jumpers)
5 Ground
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*RS422 - Main Port {P1}
1 CTS - output
6 CTS+ output
7 Transmit+ output
8 Receive+ input
9 RTS+ input
2 Transmit Data - output
3 Receive Data - input
4 RTS - input
5 Ground
*RS422 - Auxiliary Port {P2}
1 CTS - input
6 CTS+ input
2 Receive Data - input
3 Transmit Data - output
4 RTS - output
7 Receive+ input
8 Transmit+ output
9 RTS+ output
5 Ground
*Default configuration is RS232. RS422 configuration available from factory.
RS-232 Configuration
Configure your PC for 8-bit data, one start-bit, one stop-bit, full duplex and no parity. The baud rate
for the RS232 communication can be selected by setting the proper switch configuration on the front
panel according to the table below.
Baud Rate Selection
SWITCH SETTINGS
9600
ON
19.2
ON
3800
OFF
OFF
OFF
ON
BAUD RATE
1200
ON
OFF
ON
9600
OFF
OFF
OFF
19200
OFF
ON
38400
ON
115200
Handshaking Modes
The RS232 main port can be configured for hardware and software handshaking. For Hardware
Handshaking, set the HSHK switch to ON. In this mode, the RTS and CTS lines are used. The CTS
line will go high whenever the DMC-2x00 is not ready to receive additional characters. The RTS line
will inhibit the DMC-2x00 from sending additional characters. Note, the RTS line goes high for
inhibit. The handshake should be turned on to ensure proper communication especially at higher baud
rates.
Software handshaking can be enabled by setting the XON switch to ON. In this mode, the controller
will generate / accept XON and XOFF characters to control the flow of characters to / from the
terminal. The controller uses the hex value $13 for the XOFF character and the hex value $11 for the
XON character.
The auxiliary port of the DMC-2x00 can be configured either as a general port or for the daisy-chain
(DMC-2000 only). When configured as a general port, the port can be commanded to send ASCII
messages to another DMC-2x00 controller or to a display terminal or panel.
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(Configure Communication) at port 2. The command is in the format of:
CC m,n,r,p
where m sets the baud rate, n sets for either handshake or non-handshake mode, r sets for general port
or the auxiliary port, and p turns echo on or off.
m - Baud Rate - 300,1200,4800,9600,19200,38400
n - Handshake - 0=No; 1=Yes
r - Mode - 0=General Port; 1=Daisy-chain
p - Echo - 0=Off; 1=On; Valid only if r=0
Note, for the handshake of the auxiliary port, the roles for the RTS and CTS lines are reversed.
Example:
CC 1200,0,0,1
Configure auxiliary communication port for 1200 baud, no handshake, general
port mode and echo turned on.
Daisy-Chaining (DMC-2000 only)
Up to eight DMC-2000 controllers may be connected in a daisy-chain allowing for multiple controllers
to be commanded from a single serial port. One DMC-2000 is connected to the host terminal via the
RS232 at port 1 or the main port. Port 2 or the auxiliary port of that DMC-2000 is then brought into
port 1 of the next DMC-2000, and so on. The address of each DMC-2000 is configured by setting the
three address dipswitches (A0, A1, A2) located on the front of the controller.
When connecting multiple controllers in a daisy-chain, the cable between controllers should be female
on both ends with all wires connected straight through.
ADR1 represents the 20 bit, ADR2 represents 21 bit, and ADR4 represents 22 bit of the address. The
eight possible addresses, 0 through 7, are set as follows:
A2
OFF
OFF
OFF
OFF
ON
A1
OFF
OFF
ON
A0
OFF
ON
ADDRESS
0
1
2
3
4
5
6
7
OFF
ON
ON
OFF
OFF
ON
OFF
ON
ON
ON
OFF
ON
ON
ON
To communicate with any one of the DMC-2000 units, give the command “%A”, where A is the
address of the board. All instructions following this command will be sent only to the board with that
address. Only when a new %A command is given will the instruction be sent to another board. The
only exception is "!" command. To talk to all the DMC-2000 boards in the daisy-chain at one time,
insert the character "!" before the software command. All boards receive the command, but only
address 0 will echo.
NOTE: The CC command must be specified to configure the port P2 of each unit.
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Example- Daisy Chain
Objective: Control a 7-axis motion system using two controllers, a DMC-2040 4 axis controller and a
DMC-2030 3 axis controller. Address 0 is the DMC-2040 and address 1 is the DMC-2030.
Desired motion profile:
Address 0 (DMC-2040)
A Axis is 500 counts
B Axis is 1000 counts
C Axis is 2000 counts
D Axis is 1500 counts
Address 1 (DMC-2030)
A Axis is 700 counts
B Axis is 1500 counts
C Axis is 2500 counts
Command
Interpretation
%0
Talk only to controller 0 (DMC-2040)
Specify A,B,C,D distances
PR 500,1000,2000,1500
%1
Talk only to controller board 1 (DMC-2030)
Specify A,B,C distances
PR 700,1500,2500
!BG
Begin motion on both controllers
Synchronizing Sample Clocks in Daisy Chain
It is possible to synchronize the sample clocks of all DMC-2000's in the daisy-chain. The first
controller (connected to the computer) should have a jumper placed on the jumper JP3 to connect the
pins labeled S and 8. Note that this connection requires a jumper to be placed sideways. The
subsequent controllers should have jumpers placed on the jumper JP3, JP4 to connect the pins labeled
S and 8 on both jumpers. Note that these connections require the jumpers to be placed sideways.
Ethernet Configuration (DMC-2100/2200 only)
Communication Protocols
The Ethernet is a local area network through which information is transferred in units known as
packets. Communication protocols are necessary to dictate how these packets are sent and received.
The DMC-2100 supports two industry standard protocols, TCP/IP and UDP/IP. The controller will
automatically respond in the format in which it is contacted.
TCP/IP is a "connection" protocol. The master must be connected to the slave in order to begin
communicating. Each packet sent is acknowledged when received. If no acknowledgement is
received, the information is assumed lost and is resent.
Unlike TCP/IP, UDP/IP does not require a "connection". This protocol is similar to communicating
via RS232. If information is lost, the controller does not return a colon or question mark. Because the
protocol does not provide for lost information, the sender must re-send the packet.
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Although UDP/IP is more efficient and simple, Galil recommends using the TCP/IP protocol. TCP/IP
insures that if a packet is lost or destroyed while in transit, it will be resent.
Ethernet communication transfers information in ‘packets’. The packets must be limited to 470 data
bytes or less. Larger packets could cause the controller to lose communication.
NOTE: In order not to lose information in transit, Galil recommends that the user wait for an
acknowledgement of receipt of a packet before sending the next packet.
There are four LEDs provided for the status of Ethernet connection. The representation of LED status
is given below.
LED Status
F
Uses Fiber Link
C
Uses Full Duplex – will blink when a collision Uses Full Duplex – will blink when a collision occurs with half
duplex
L
Ethernet link established – will blink for any activity
Uses 100Base T speed Ethernet
100
Addressing
There are three levels of addresses that define Ethernet devices. The first is the Ethernet or hardware
address. This is a unique and permanent 6 byte number. No other device will have the same Ethernet
address. The DMC-2100/2200 Ethernet address is set by the factory and the last two bytes of the
address are the serial number of the controller.
The second level of addressing is the IP address. This is a 32-bit (or 4 byte) number. The IP address is
constrained by each local network and must be assigned locally. Assigning an IP address to the
controller can be done in a number of ways.
The first method is to use the BOOT-P utility via the Ethernet connection (the DMC-2100/2200 must
be connected to network and powered). For a brief explanation of BOOT-P, see the section: Third
Party Software. Either a BOOT-P server on the internal network or the Galil terminal software may be
used. To use the Galil BOOT-P utility, select the registry in the terminal emulator. Select the DMC-
2100/2200 and then the Ethernet Parameters tab. Enter the IP address at the prompt and select either
TCP/IP or UDP/IP as the protocol. When done, click on the ASSIGN IP ADDRESS. The Galil
Terminal Software will respond with a list of all controllers on the network that do not currently have
IP addresses. The user selects the controller and the software will assign the controller the specified IP
address. Then enter the terminal and type in BN to save the IP address to the controller's non-volatile
memory.
CAUTION: Be sure that there is only one BOOT-P server running. If your network has DHCP or
BOOT-P running, it may automatically assign an IP address to the controller upon linking it to the
network. In order to ensure that the IP address is correct, please contact your system administrator
before connecting the controller to the Ethernet network.
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The second method for setting an IP address is to send the IA command through the DMC-2100/2200
main RS-232 port. The IP address you want to assign may be entered as a 4 byte number delimited by
commas (industry standard uses periods) or a signed 32 bit number (Ex. IA 124,51,29,31 or IA
2083724575). Type in BN to save the IP address to the controller's non-volatile memory.
NOTE: Galil strongly recommends that the IP address selected is not one that can be accessed across
the Gateway. The Gateway is an application that controls communication between an internal network
and the outside world.
The third level of Ethernet addressing is the UDP or TCP port number. The Galil controller does not
require a specific port number. The port number is established by the client or master each time it
connects to the controller.
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Communicating with Multiple Devices
The DMC-2100/2200 is capable of supporting multiple masters and slaves. The masters may be
multiple PC's that send commands to the controller. The slaves are typically peripheral I/O devices
that receive commands from the controller.
NOTE: The term "Master" is equivalent to the internet "client". The term "Slave" is equivalent to the
internet "server".
An Ethernet handle is a communication resource within a device. The DMC-2100/2200 can have a
maximum of 6 Ethernet handles open at any time. When using TCP/IP, each master or slave uses an
individual Ethernet handle. In UDP/IP, one handle may be used for all the masters, but each slave uses
one. (Pings and ARPs do not occupy handles.) If all 6 handles are in use and a 7th master tries to
connect, it will be sent a "reset packet" that generates the appropriate error in its windows application.
NOTE: There are a number of ways to reset the controller. Hardware reset (push reset button or
power down controller) and software resets (through Ethernet or RS232 by entering RS). The only
reset that will not cause the controller to disconnect is a software reset via the Ethernet.
When the Galil controller acts as the master, the IH command is used to assign handles and connect to
its slaves. The IP address may be entered as a 4 byte number separated with commas (industry
standard uses periods) or as a signed 32 bit number. A port number may also be specified, but if it is
not, it will default to 1000. The protocol (TCP/IP or UDP/IP) to use must also be designated at this
time. Otherwise, the controller will not connect to the slave. (Ex. IHB=151,25,255,9<179>2 This
will open handle #2 and connect to the IP address 151.25.255.9, port 179, using TCP/IP)
An additional protocol layer is available for speaking to I/O devices. Modbus is an RS-485 protocol
that packages information in binary packets that are sent as part of a TCP/IP packet. In this protocol,
each slave has a 1 byte slave address. The DMC-2100/2200 can use a specific slave address or default
to the handle number. The port number for Modbus is 502.
The Modbus protocol has a set of commands called function codes. The DMC-2100/2200 supports the
10 major function codes:
Function Code
Definition
01
02
03
04
05
06
07
15
16
17
Read Coil Status (Read Bits)
Read Input Status (Read Bits)
Read Holding Registers (Read Words)
Read Input Registers (Read Words)
Force Single Coil (Write One Bit)
Preset Single Register (Write One Word)
Read Exception Status (Read Error Code)
Force Multiple Coils (Write Multiple Bits)
Preset Multiple Registers (Write Words)
Report Slave ID
The DMC-2100/2200 provides three levels of Modbus communication. The first level allows the user
to create a raw packet and receive raw data. It uses the MBh command with a function code of –1.
The format of the command is
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MBh = -1,len,array[]
where len is the number of bytes
array[] is the array with the data
The second level incorporates the Modbus structure. This is necessary for sending configuration and
special commands to an I/O device. The formats vary depending on the function code that is called.
For more information refer to the Command Reference.
The third level of Modbus communication uses standard Galil commands. Once the slave has been
configured, the commands that may be used are @IN[], @AN[], SB, CB, OB, and AO. For example,
AO 2020,8.2 would tell I/O number 2020 to output 8.2 volts.
If a specific slave address is not necessary, the I/O number to be used can be calculated with the
following:
I/O Number = (HandleNum*1000) + ((Module-1)*4) + (BitNum-1)
Where HandleNum is the handle number from 1 (A) to 6 (F). Module is the position of the module in
the rack from 1 to 16. BitNum is the I/O point in the module from 1 to 4.
If an explicit slave address is to be used, the equation becomes:
I/O Number = (SlaveAddress*10000) + (HandleNum*1000) +((Module-1)*4) + (Bitnum-1)
To view an example procedure for communicating with an OPTO-22 rack, refer to the appendix.
Which devices receive what information from the controller depends on a number of things. If a
device queries the controller, it will receive the response unless it explicitly tells the controller to send
it to another device. If the command that generates a response is part of a downloaded program, the
response will route to whichever port is specified as the default (unless explicitly told to go to another
port) with the ENET switch ("ON" designates Ethernet in which case it goes to the last handle to
communicate with the controller, "OFF" designates main RS232). To designate a specific destination
for the information, add {Eh} to the end of the command. (Ex. MG{EC}"Hello" will send the
message "Hello" to handle #3. TP,,?{EF} will send the z axis position to handle #6.)
Multicasting
A multicast may only be used in UDP/IP and is similar to a broadcast (where everyone on the network
gets the information) but specific to a group. In other words, all devices within a specified group will
receive the information that is sent in a multicast. There can be many multicast groups on a network
and are differentiated by their multicast IP address. To communicate with all the devices in a specific
multicast group, the information can be sent to the multicast IP address rather than to each individual
device IP address. All Galil controllers belong to a default multicast address of 239.255.19.56. The
controller's multicast IP address can be changed by using the IA> u command.
Using Third Party Software
Galil supports ARP, BOOT-P, and Ping which are utilities for establishing Ethernet connections. ARP
is an application that determines the Ethernet (hardware) address of a device at a specific IP address.
BOOT-P is an application that determines which devices on the network do not have an IP address and
assigns the IP address you have chosen to it. Ping is used to check the communication between the
device at a specific IP address and the host computer.
The DMC-2100 can communicate with a host computer through any application that can send TCP/IP
or UDP/IP packets. A good example of this is Telnet, a utility that comes with most Windows
systems.
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Data Record
The DMC-2x00 can provide a block of status information with the use of a single command, QR. This
command, along with the QZ command can be very useful for accessing complete controller status.
The QR command will return 4 bytes of header information and specific blocks of information as
specified by the command arguments:
QR ABCDEFGHST
Each argument corresponds to a block of information according to the Data Record Map below. If no
argument is given, the entire data record map will be returned. Note that the data record size will
depend on the number of axes.
Data Record Map
DATA TYPE
ITEM
1st byte of header
2nd byte of header
3rd byte of header
4rth byte of header
BLOCK
Header
Header
Header
Header
I block
I block
I block
I block
I block
I block
I block
I block
I block
I block
I block
I block
I block
I block
I block
I block
I block
I block
I block
I block
I block
I block
I block
S block
S block
S block
T block
T block
UB
UB
UB
UB
UW
UB
sample number
general input 0
UB
general input 1
UB
general input 2
UB
general input 3
UB
general input 4
UB
general input 5
UB
general input 6
UB
general input 7
UB
general input 8
UB
general input 9
UB
general output 0
UB
general output 1
UB
general output 2
UB
general output 3
UB
general output 4
UB
general output 5
UB
general output 6
UB
general output 7
UB
general output 8
UB
general output 9
UB
error code
UB
general status
UW
UW
SL
segment count of coordinated move for S plane
coordinated move status for S plane
distance traveled in coordinated move for S plane
segment count of coordinated move for T plane
coordinated move status for T plane
UW
UW
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SL
distance traveled in coordinated move for T plane
a axis status
T block
A block
A block
A block
A block
A block
A block
A block
A block
A block
A block
B block
B block
B block
B block
B block
B block
B block
B block
B block
B block
C block
C block
C block
C block
C block
C block
C block
C block
C block
C block
D block
D block
D block
D block
D block
D block
D block
D block
D block
D block
E block
E block
E block
E block
UW
UB
UB
SL
a axis switches
a axis stop code
a axis reference position
a axis motor position
a axis position error
a axis auxiliary position
a axis velocity
SL
SL
SL
SL
SW
SW
UW
UB
UB
SL
a axis torque
a axis analog
b axis status
b axis switches
b axis stop code
b axis reference position
b axis motor position
b axis position error
b axis auxiliary position
b axis velocity
SL
SL
SL
SL
SW
SW
UW
UB
UB
SL
b axis torque
b axis analog
c axis status
c axis switches
c axis stop code
c axis reference position
c axis motor position
c axis position error
c axis auxiliary position
c axis velocity
SL
SL
SL
SL
SW
SW
UW
UB
UB
SL
c axis torque
c axis analog
d axis status
d axis switches
d axis stop code
d axis reference position
d axis motor position
d axis position error
d axis auxiliary position
d axis velocity
SL
SL
SL
SL
SW
SW
UW
UB
UB
SL
d axis torque
d axis analog
e axis status
e axis switches
e axis stop code
e axis reference position
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SL
e axis motor position
e axis position error
e axis auxiliary position
e axis velocity
E block
E block
E block
E block
E block
E block
F block
F block
F block
F block
F block
F block
F block
F block
F block
F block
G block
G block
G block
G block
G block
G block
G block
G block
G block
G block
H block
H block
H block
H block
H block
H block
H block
H block
H block
H block
SL
SL
SL
SW
SW
UW
UB
UB
SL
e axis torque
e axis analog
f axis status
f axis switches
f axis stop code
f axis reference position
f axis motor position
f axis position error
f axis auxiliary position
f axis velocity
SL
SL
SL
SL
SW
SW
UW
UB
UB
SL
f axis torque
f axis analog
g axis status
g axis switches
g axis stop code
g axis reference position
g axis motor position
g axis position error
g axis auxiliary position
g axis velocity
SL
SL
SL
SL
SW
SW
UW
UB
UB
SL
g axis torque
g axis analog
h axis status
h axis switches
h axis stop code
h axis reference position
h axis motor position
h axis position error
h axis auxiliary position
h axis velocity
SL
SL
SL
SL
SW
SW
h axis torque
h axis analog
NOTE: UB = Unsigned Byte, UW = Unsigned Word, SW = Signed Word, SL = Signed Long Word
Explanation of Status Information and Axis Switch
Information
Header Information - Byte 0, 1 of Header:
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
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in Data
Record
in Data
Record
in Data
Record
BIT 7
BIT 6
BIT 5
BIT 4
BIT 3
BIT 2
BIT 1
BIT 0
H Block
Present
in Data
Record
G Block
Present
in Data
Record
F Block
Present
in Data
Record
E Block
Present
in Data
Record
D Block
Present
in Data
Record
C Block
Present
in Data
Record
B Block
Present
in Data
Record
A Block
Present
in Data
Record
Bytes 2, 3 of Header:
Bytes 2 and 3 make a word which represents the Number of bytes in the data record, including the
header.
Byte 2 is the low byte and byte 3 is the high byte
NOTE: The header information of the data records is formatted in little endian.
General Status Information (1 Byte)
BIT 7
BIT
6
BIT
5
BIT
4
BIT
3
BIT 2
BIT 1
BIT 0
Program N/A
Running
N/A
N/A
N/A
Waiting for
input from IN
command
Trace On Echo On
Axis Switch Information (1 Byte)
BIT 7
BIT 6
BIT 5
BIT 4
N/A
BIT 3
BIT 2
BIT 1
BIT 0
Latch
Occurred Latch
Input
State of
N/A
State of
Forward
Limit
State of
Reverse
Limit
State of
Home
Input
SM
Jumper
Installed
Axis Status Information (2 Byte)
BIT 15
BIT 14
BIT 13
BIT 12
BIT 11
BIT 10
BIT 9
BIT 8
2nd Phase
of HM
complete
or FI
command Motion
issued
Move in
Progress Motion
Mode of Mode of (FE)
Home
(HM) in
Progress complete
1st Phase
of HM
Mode of
Motion
Motion
Find
Edge in
Progress
PA or
PR
PA only
Coord.
BIT 7
BIT 6
BIT 5
BIT 4
BIT 3
BIT 2
BIT 1
BIT 0
Motion is
stopping
due to ST
or Limit
Motion is
making
final
Negative Mode of Motion
Latch is
armed
Off-On-
Error
armed
Motor
Off
Direction Motion
is
Move
slewing
Contour
decel.
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Switch
Coordinated Motion Status Information for S or T plane (2 Byte)
BIT 15
BIT
14
BIT 13
BIT 12
BIT 11
BIT
10
BIT 9
BIT 8
Move in
Progress
N/A
N/A
N/A
N/A
N/A
N/A
N/A
BIT 7
BIT 6
BIT 5
BIT 4
BIT 3
BIT 2
BIT 1
BIT 0
N/A
N/A
Motion is Motion is
slewing
Motion is N/A
stopping due making
N/A
N/A
to ST or
Limit
final
decel.
Switch
Notes Regarding Velocity and Torque Information
The velocity information that is returned in the data record is 64 times larger than the value returned
when using the command TV (Tell Velocity). See command reference for more information about
TV.
The Torque information is represented as a number in the range of +/-32767. Maximum negative
torque is -32767. Maximum positive torque is 32767. Zero torque is 0.
QZ Command
The QZ command can be very useful when using the QR command, since it provides information
about the controller and the data record. The QZ command returns the following 4 bytes of
information.
BYTE # INFORMATION
0
Number of axes present
1
2
3
number of bytes in general block of data record
number of bytes in coordinate plane block of data record
Number of Bytes in each axis block of data record
Controller Response to Commands
Most DMC-2x00 instructions are represented by two characters followed by the appropriate
parameters. Each instruction must be terminated by a carriage return or semicolon.
Instructions are sent in ASCII, and the DMC-2x00 decodes each ASCII character (one byte) one at a
time. It takes approximately 0.5 msec for the controller to decode each command. However, the PC
can send data to the controller at a much faster rate because of the FIFO buffer.
After the instruction is decoded, the DMC-2x00 returns a response to the port from which the
command was generated. If the instruction was valid, the controller returns a colon (:) or a question
mark (?) if the instruction was not valid. For example, the controller will respond to commands which
are sent via the USB port back through the USB port, to commands which are sent via the main RS-
232 port back through the RS-232 port, and to commands which are sent via the Ethernet port back
through the Ethernet port.
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For instructions that return data, such as Tell Position (TP), the DMC-2x00 will return the data
followed by a carriage return, line feed and : .
It is good practice to check for : after each command is sent to prevent errors. An echo function is
provided to enable associating the DMC-2x00 response with the data sent. The echo is enabled by
sending the command EO 1 to the controller.
Unsolicited Messages Generated by Controller
When the controller is executing a program, it may generate responses which will be sent via the USB
port (DMC-2000), main RS-232 port, or Ethernet ports (DMC-2100/2200). This response could be
generated as a result of messages using the MG or IN command OR as a result of a command error.
These responses are known as unsolicited messages since they are not generated as the direct response
to a command.
Messages can be directed to a specific port using the specific Port arguments - see MG and IN
commands described in the Command Reference. If the port is not explicitly given, unsolicited
messages will be sent to the default port. The default port is determined by the state of the
USB/Ethernet dip switch when the system is reset.
The controller has a special command, CW, which can affect the format of unsolicited messages. This
command is used by Galil Software to differentiate response from the command line and unsolicited
messages. The command, CW1 causes the controller to set the high bit of ASCII characters to 1 of all
unsolicited characters. This may cause characters to appear garbled to some terminals. This function
can be disabled by issuing the command, CW2. For more information, see the CW command in the
Command Reference.
When handshaking is used (hardware and/or software handshaking) characters which are generated by
the controller are placed in a FIFO buffer before they are sent out of the controller. This size of the
USB buffer is 64 bytes and the size of the RS-232 buffer is 128 bytes. When this buffer becomes full,
the controller must either stop executing commands or ignore additional characters generated for
output. The command CW,1 causes the controller to ignore all output from the controller while the
FIFO is full. The command, CW ,0 causes the controller to stop executing new commands until more
room is made available in the FIFO. This command can be very useful when hardware handshaking is
being used and the communication line between controller and terminal will be disconnected. In this
case, characters will continue to build up in the controller until the FIFO is full. For more information,
see the CW command in the Command Reference.
Galil Software Tools and Libraries
API (Application Programming Interface) software is available from Galil. The API software is
written in C and is included in the Galil CD-ROM. They can be used for development under
Windows environments. With the API's, the user can incorporate already existing library functions
directly into a C program.
Galil has also developed a Visual Basic Toolkit. This provides 32-bit OCXs for handling all of the
DMC-2x00 communications including support of interrupts. These objects install directly into Visual
Basic and are part of the run-time environment.
Galil also has an Active-X Tool Kit to allow developers to rapidly develop their own user applications.
For more information, contact Galil.
DMC-2X00
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Chapter 5 Command Basics
Introduction
The DMC-2x00 provides over 100 commands for specifying motion and machine parameters.
Commands are included to initiate action, interrogate status and configure the digital filter. These
commands can be sent in ASCII or binary.
In ASCII, the DMC-2x00 instruction set is BASIC-like and easy to use. Instructions consist of two
uppercase letters that correspond phonetically with the appropriate function. For example, the
instruction BG begins motion, and ST stops the motion. In binary, commands are represented by a
binary code ranging from 80 to FF.
ASCII commands can be sent "live" over the bus for immediate execution by the DMC-2x00, or an
entire group of commands can be downloaded into the DMC-2x00 memory for execution at a later
time. Combining commands into groups for later execution is referred to as Applications
Programming and is discussed in the following chapter. Binary commands cannot be used in
Applications programming.
This section describes the DMC-2x00 instruction set and syntax. A summary of commands as well as
a complete listing of all DMC-2x00 instructions is included in the Command Reference chapter.
Command Syntax - ASCII
DMC-2x00 instructions are represented by two ASCII upper case characters followed by applicable
arguments. A space may be inserted between the instruction and arguments. A semicolon or <return>
is used to terminate the instruction for processing by the DMC-2x00 command interpreter.
NOTE: If you are using a Galil terminal program, commands will not be processed until an <return>
command is given. This allows the user to separate many commands on a single line and not begin
execution until the user gives the <return> command.
IMPORTANT: All DMC-2x00 commands are sent in upper case.
For example, the command
PR 4000 <return>
Position relative
PR is the two character instruction for position relative. 4000 is the argument which represents the
required position value in counts. The <return> terminates the instruction. The space between PR and
4000 is optional.
For specifying data for the A,B,C and D axes, commas are used to separate the axes. If no data is
specified for an axis, a comma is still needed as shown in the examples below. If no data is specified
for an axis, the previous value is maintained.
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To view the current values for each command, type the command followed by a ? for each axis
requested.
PR 1000
Specify A only as 1000
Specify B only as 2000
Specify C only as 3000
Specify D only as 4000
Specify A,B,C and D
Specify B and D only
Request A,B,C,D values
Request B value only
PR ,2000
PR ,,3000
PR ,,,4000
PR 2000, 4000,6000, 8000
PR ,8000,,9000
PR ?,?,?,?
PR ,?
The DMC-2x00 provides an alternative method for specifying data. Here data is specified individually
using a single axis specifier such as A, B, C or D. An equals sign is used to assign data to that axis.
For example:
PRA=1000
Specify a position relative movement for the A axis of 1000
ACB=200000
Specify acceleration for the B axis as 200000
Instead of data, some commands request action to occur on an axis or group of axes. For example, ST
AB stops motion on both the A and B axes. Commas are not required in this case since the particular
axis is specified by the appropriate letter A, B, C or D. If no parameters follow the instruction, action
will take place on all axes. Here are some examples of syntax for requesting action:
BG A
Begin A only
BG B
Begin B only
BG ABCD
BG BD
BG
Begin all axes
Begin B and D only
Begin all axes
For controllers with 5 or more axes, the axes are referred to as A,B,C,D,E,F,G,H.
2x80
BG ABCDEFGH
BG D
Begin all axes
Begin D only
Coordinated Motion with more than 1 axis
When requesting action for coordinated motion, the letter S and T are used to specify coordinated
motion planes. For example:
BG S
Begin coordinated sequence, S
BG TW
Begin coordinated sequence, T, and D axis
DMC-2X00
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Command Syntax - Binary
Some commands have an equivalent binary value. Binary communication mode can be executed much
faster than ASCII commands. Binary format can only be used when commands are sent from the PC
and cannot be embedded in an application program.
Binary Command Format
All binary commands have a 4 byte header and is followed by data fields. The 4 bytes are specified in
hexadecimal format.
Header Format:
Byte 1
Specifies the command number between 80 to FF. The complete binary command number table is
listed below.
Byte 2
Specifies the # of bytes in each field as 0,1,2,4 or 6 as follows:
00
01
02
04
06
No datafields (i.e. SH or BG)
One byte per field
One word (2 bytes per field)
One long word (4 bytes) per field
Galil real format (4 bytes integer and 2 bytes fraction)
Byte 3
Specifies whether the command applies to a coordinated move as follows:
00
01
No coordinated motion movement
Coordinated motion movement
For example, the command STS designates motion to stop on a vector motion. The third byte for the
equivalent binary command would be 01.
Byte 4
Specifies the axis # or data field as follows
Bit 7 = H axis or 8th data field
Bit 6 = G axis or 7th data field
Bit 5 = F axis or 6th data field
Bit 4 = E axis or 5th data field
Bit 3 = D axis or 4th data field
Bit 2 = C axis or 3rd data field
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Bit 1 = B axis or 2nd data field
Bit 0 = A axis or 1st data field
Datafields Format
Datafields must be consistent with the format byte and the axes byte. For example, the command PR
1000,, -500 would be
A7 02 00 05 03 E8 FE 0C
where A7 is the command number for PR
02 specifies 2 bytes for each data field
00 S is not active for PR
05 specifies bit 0 is active for A axis and bit 2 is active for C axis (20 + 22=5)
03 E8 represents 1000
FE OE represents -500
Example
The command ST ABCS would be
A1 00 01 07
where A1 is the command number for ST
00 specifies 0 data fields
01 specifies stop the coordinated axes S
07 specifies stop X (bit 0), Y (bit 1) and Z (bit 2) 20+21+23 =7
Binary Command Table
COMMAND
NO.
80
81
82
83
84
85
86
87
88
89
8a
8b
8c
8d
8e
8f
COMMAND
reserved
reserved
reserved
reserved
reserved
LM
NO.
ab
ac
COMMAND
reserved
reserved
RP
No.
d6
d7
d8
d9
da
db
dc
dd
de
df
reserved
KP
KI
ad
ae
KD
DV
AF
KF
PL
TP
af
TE
b0
b1
b2
a3
b4
b5
b6
b7
b8
b9
ba
TD
LI
TV
VP
RL
ER
IL
CR
TT
TN
TS
TL
LE, VE
VT
TI
e0
e1
e2
e3
e4
e5
MT
CE
OE
FL
SC
VA
reserved
reserved
reserved
TM
VD
VS
BL
VR
DMC-2X00
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AC
90
91
92
93
94
95
96
97
98
99
9a
9b
9c
9d
9e
9f
reserved
reserved
CM
CD
bb
bc
bd
be
bf
CN
e6
e7
e8
e9
ea
eb
ec
ed
ee
ef
f0
f1
f2
f3
f4
f5
f6
f7
f8
f9
fa
fb
fc
fd
fe
ff
DC
LZ
SP
OP
IT
OB
FA
DT
SB
FV
ET
c0
c1
c2
c3
c4
c5
c6
c7
c8
c9
ca
cb
cc
cd
ce
cf
CB
GR
EM
II
DP
EP
EI
DE
EG
AL
OF
EB
reserved
reserved
reserved
reserved
reserved
reserved
reserved
reserved
reserved
reserved
reserved
reserved
reserved
reserved
reserved
reserved
reserved
GM
reserved
reserved
reserved
reserved
reserved
BG
EQ
EC
reserved
AM
MC
TW
MF
a0
a1
a2
a3
a4
a5
a6
a7
a8
a9
aa
ST
MR
AD
AB
HM
FE
AP
AR
FI
AS
d0
d1
d2
d3
d4
d5
PA
AI
PR
AT
JG
WT
WC
reserved
MO
SH
Controller Response to DATA
The DMC-2x00 returns a : for valid commands and a ? for invalid commands.
For example, if the command BG is sent in lower case, the DMC-2x00 will return a ?.
:bg <return>
?
invalid command, lower case
DMC-2x00 returns a ?
When the controller receives an invalid command the user can request the error code. The error code
will specify the reason for the invalid command response. To request the error code type the command
TC1. For example:
?TC1 <return>
1 Unrecognized
Tell Code command
Returned response
There are many reasons for receiving an invalid command response. The most common reasons are:
unrecognized command (such as typographical entry or lower case), command given at improper time
(such as during motion), or a command out of range (such as exceeding maximum speed). A complete
listing of all codes is listed in the TC command in the Command Reference section.
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Interrogating the Controller
Interrogation Commands
The DMC-2x00 has a set of commands that directly interrogate the controller. When the command is
entered, the requested data is returned in decimal format on the next line followed by a carriage return
and line feed. The format of the returned data can be changed using the Position Format (PF), Variable
Format (VF) and Leading Zeros (LZ) command. See Chapter 7 and the Command Reference.
Summary of Interrogation Commands
RP
Report Command Position
RL
Report Latch
∧R ∧V
SC
TB
TC
TD
TE
TI
Firmware Revision Information
Stop Code
Tell Status
Tell Error Code
Tell Dual Encoder
Tell Error
Tell Input
TP
Tell Position
Trace
TR
TS
Tell Switches
Tell Torque
TT
TV
Tell Velocity
For example, the following example illustrates how to display the current position of the X axis:
TP A <return>
Tell position A
0000000000
Controllers Response
Tell position A and B
Controllers Response
TP AB <return>
0000000000,0000000000
Interrogating Current Commanded Values.
Most commands can be interrogated by using a question mark (?) as the axis specifier. Type the
command followed by a ? for each axis requested.
PR ?,?,?,?
PR ,?
Request A,B,C,D values
Request B value only
The controller can also be interrogated with operands.
Operands
Most DMC-2x00 commands have corresponding operands that can be used for interrogation.
Operands must be used inside of valid DMC expressions. For example, to display the value of an
operand, the user could use the command:
MG ‘operand’ where ‘operand’ is a valid DMC operand
DMC-2X00
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All of the command operands begin with the underscore character (_). For example, the value of the
current position on the A axis can be assigned to the variable ‘V’ with the command:
V=_TPA
The Command Reference denotes all commands which have an equivalent operand as "Used as an
Operand". Also, see description of operands in Chapter 7.
Command Summary
For a complete command summary, see Command Reference manual.
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DMC-2X00
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Chapter 6 Programming Motion
Overview
The DMC-2x00 provides several modes of motion, including independent positioning and jogging,
coordinated motion, electronic cam motion, and electronic gearing. Each one of these modes is
discussed in the following sections.
The DMC-2x10 is a single axis controller and uses A-axis motion only. Likewise, the DMC-2x20 uses
A and B, the DMC-2x30 uses A,B and C, and the DMC-2x40 uses A,B,C and D. The DMC-2x50 uses
A,B,C,D, and E. The DMC-2x60 uses A,B,C,D,E, and F. The DMC-2x70 uses A,B,C,D,E,F and G.
The DMC-2x80 uses the axes A,B,C,D,E,F,G, and H.
The example applications described below will help guide you to the appropriate mode of motion.
Example Application
Mode of Motion
Commands
Absolute or relative positioning where each axis is Independent Axis Positioning
PA,PR
independent and follows prescribed velocity
profile.
SP,AC,DC
Velocity control where no final endpoint is
prescribed. Motion stops on Stop command.
Independent Jogging
JG
AC,DC
ST
Absolute positioning mode where absolute position Position Tracking
targets may be sent to the controller while the axis
is in motion.
PA, PT
SP
AC, DC
Motion Path described as incremental position
points versus time.
Contour Mode
CM
CD
DT
WC
2,3 or 4 axis coordinated motion where path is
described by linear segments.
Linear Interpolation
LM
LI,LE
VS,VR
VA,VD
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2-D motion path consisting of arc segments and
linear segments, such as engraving or quilting.
Coordinated Motion
VM
VP
CR
VS,VR
VA,VD
VE
Third axis must remain tangent to 2-D motion path, Coordinated motion with tangent
VM
such as knife cutting.
axis specified
VP
CR
VS,VA,VD
TN
VE
Electronic gearing where slave axes are scaled to
master axis which can move in both directions.
Electronic Gearing
Electronic Gearing
GA, GD
_GP, GR
GM (if gantry)
Master/slave where slave axes must follow a
master such as conveyer speed.
GA, GD
_GP, GR
Moving along arbitrary profiles or mathematically Contour Mode
prescribed profiles such as sine or cosine
trajectories.
CM
CD
DT
WC
Teaching or Record and Play Back
Contour Mode with Automatic
Array Capture
CM
CD
DT
WC
RA
RD
RC
Backlash Correction
Dual Loop
DV
Following a trajectory based on a master encoder
position
Electronic Cam
EA
EM
EP
ET
EB
EG
EQ
Smooth motion while operating in independent axis Independent Motion Smoothing
positioning
IT
Smooth motion while operating in vector or linear
interpolation positioning
Vector Smoothing
Stepper Motor Smoothing
Gantry Mode
VT
KS
Smooth motion while operating with stepper
motors
Gantry - two axes are coupled by gantry
GR
GM
Independent Axis Positioning
In this mode, motion between the specified axes is independent, and each axis follows its own profile.
The user specifies the desired absolute position (PA) or relative position (PR), slew speed (SP),
DMC-2X00
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acceleration ramp (AC), and deceleration ramp (DC), for each axis. On begin (BG), the DMC-2x00
profiler generates the corresponding trapezoidal or triangular velocity profile and position trajectory.
The controller determines a new command position along the trajectory every sample period until the
specified profile is complete. Motion is complete when the last position command is sent by the
DMC-2x00 profiler.
NOTE: The actual motor motion may not be complete when the profile has been completed, however,
the next motion command may be specified.
The Begin (BG) command can be issued for all axes either simultaneously or independently. ABC or
D axis specifiers are required to select the axes for motion. When no axes are specified, this causes
motion to begin on all axes.
The speed (SP) and the acceleration (AC) can be changed at any time during motion; however, the
deceleration (DC) and position (PR or PA) cannot be changed until motion is complete. Remember,
motion is complete when the profiler is finished, not when the actual motor is in position. The Stop
command (ST) can be issued at any time to decelerate the motor to a stop before it reaches its final
position.
An incremental position movement (IP) may be specified during motion as long as the additional move
is in the same direction. Here, the user specifies the desired position increment, n. The new target is
equal to the old target plus the increment, n. Upon receiving the IP command, a revised profile will be
generated for motion towards the new end position. The IP command does not require a BG.
NOTE: If the motor is not moving, the IP command is equivalent to the PR and BG command
combination.
Command Summary - Independent Axis
COMMAND
PR A,B,C,D
PA A,B,C,D
SP A,B,C,D
AC A,B,C,D
DC A,B,C,D
BG ABCD
DESCRIPTION
Specifies relative distance
Specifies absolute position
Specifies slew speed
Specifies acceleration rate
Specifies deceleration rate
Starts motion
ST ABCD
Stops motion before end of move
Changes position target
IP A,B,C,D
IT A,B,C,D
AM ABCD
MC ABCD
Time constant for independent motion smoothing
Trip point for profiler complete
Trip point for "in position"
The DMC-2x00 also allows use of single axis specifiers such as PRB=2000
Operand Summary - Independent Axis
OPERAND
DESCRIPTION
_ACx
Return acceleration rate for the axis specified by ‘x’
Return deceleration rate for the axis specified by ‘x’
Returns the speed for the axis specified by ‘x’
_DCx
_SPx
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_PAx
_PRx
Returns current destination if ‘x’ axis is moving, otherwise returns the current commanded
position if in a move.
Returns current incremental distance specified for the ‘x’ axis
Examples
Absolute Position Movement
Instruction
Interpretation
PA 10000,20000
AC 1000000,1000000
DC 1000000,1000000
SP 50000,30000
BG AB
Specify absolute A,B position
Acceleration for A,B
Deceleration for A,B
Speeds for A,B
Begin motion
Multiple Move Sequence
Required Motion Profiles:
A-Axis
B-Axis
C-Axis
500 counts
Position
10000 count/sec
500000 counts/sec2
Speed
Acceleration
1000 counts
Position
15000 count/sec
500000 counts/sec2
Speed
Acceleration
100 counts
Position
5000 counts/sec
500000 counts/sec2
Speed
Acceleration
This example will specify a relative position movement on A, B and C axes. The movement on each
axis will be separated by 20 msec. Fig. 6.1 shows the velocity profiles for the A,B and C axis.
Instruction
#A
Interpretation
Begin Program
PR 2000,500,100
Specify relative position movement of 2000, 500 and 100 counts
for A,B and C axes.
SP 15000,10000,5000
Specify speed of 10000, 15000, and 5000 counts / sec
Specify acceleration of 500000 counts / sec2 for all axes
Specify deceleration of 500000 counts / sec2 for all axes
Begin motion on the A axis
AC 500000,500000,500000
DC 500000,500000,500000
BG A
WT 20
BG B
WT 20
BG C
EN
Wait 20 msec
Begin motion on the B axis
Wait 20 msec
Begin motion on C axis
End Program
DMC-2X00
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VELOCITY
(COUNTS/SEC)
A axis velocity profile
20000
15000
10000
B axis velocity profile
C axis velocity profile
5000
TIME (ms)
100
0
20
80
40
60
Figure 6.1 - Velocity Profiles of ABC
Notes on fig 6.1: The A and B axis have a ‘trapezoidal’ velocity profile, while the C axis has a
‘triangular’ velocity profile. The A and B axes accelerate to the specified speed, move at this constant
speed, and then decelerate such that the final position agrees with the command position, PR. The C
axis accelerates, but before the specified speed is achieved, must begin deceleration such that the axis
will stop at the commanded position. All 3 axes have the same acceleration and deceleration rate,
hence, the slope of the rising and falling edges of all 3 velocity profiles are the same.
Position Tracking
The Galil controller may be placed in the position tracking mode to support changing the target of an
absolute position move on the fly. New targets may be given in the same direction or the opposite
direction of the current position target. The controller will then calculate a new trajectory based upon
the new target and the acceleration, deceleration, and speed parameters that have been set. The motion
profile in this mode is trapezoidal. There is not a set limit governing the rate at which the end point
may be changed, however at the standard TM rate, the controller updates the position information at
the rate of 1msec. The controller generates a profiled point every other sample, and linearly
interpolates one sample between each profiled point. Some examples of applications that may use this
mode are satellite tracking, missile tracking, random pattern polishing of mirrors or lenses, or any
application that requires the ability to change the endpoint without completing the previous move.
The PA command is typically used to command an axis or multiple axes to a specific absolute position.
For some applications such as tracking an object, the controller must proceed towards a target and have
the ability to change the target during the move. In a tracking application, this could occur at any time
during the move or at regularly scheduled intervals. For example if a robot was designed to follow a
moving object at a specified distance and the path of the object wasn’t known the robot would be
required to constantly monitor the motion of the object that it was following. To remain within a
specified distance it would also need to constantly update the position target it is moving towards.
Galil motion controllers support this type of motion with the position tracking mode. This mode will
allow scheduled or random updates to the current position target on the fly. Based on the new target
the controller will either continue in the direction it is heading, change the direction it is moving, or
decelerate to a stop.
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The position tracking mode shouldn’t be confused with the contour mode. The contour mode allows
the user to generate custom profiles by updating the reference position at a specific time rate. In this
mode, the position can be updated randomly or at a fixed time rate, but the velocity profile will always
be trapezoidal with the parameters specified by AC, DC, and SP. Updating the position target at a
specific rate will not allow the user to create a custom profile.
The following example will demonstrate the possible different motions that may be commanded by the
controller in the position tracking mode. In this example, there is a host program that will generate the
absolute position targets. The absolute target is determined based on the current information the host
program has gathered on the object that it is tracking. The position tracking mode does allow for all of
the axes on the controller to be in this mode, but for the sake of discussion, it is assumed that the robot
is tracking only in the X dimension.
The controller must be placed in the position tracking mode to allow on the fly absolute position
changes. This is performed with the PT command. To place the X axis in this mode, the host would
issue PT1 to the controller if both X and Y axes were desired the command would be PT 1,1. The next
step is to begin issuing PA command to the controller. The BG command isn’t required in this mode,
the SP, AC, and DC commands determine the shape of the trapezoidal velocity profile that the
controller will use.
Example Motion 1:
The host program determines that the first target for the controller to move to is located at 5000
encoder counts. The acceleration and deceleration should be set to 150,000 cts/sec2 and the velocity is
set to 50,000 cts/sec. The command sequence to perform this is listed below.
COMMAND DESCRIPTION
PT1
Place the X axis in Position tracking mode
Set the X axis acceleration to 150000 cts/sec2
Set the X axis deceleration to 150000 cts/sec2
Set the X axis speed to 50000 cts/sec
AC150000
DC150000
SP50000
PA5000
Command the X axis to absolute position 5000 encoder counts
DMC-2X00
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Figure 1 Position vs Time (msec) Motion 1
Example
Motion 2:
The previous step showed the plot if the motion continued all the way to 5000, however partway
through the motion, the object that was being tracked changed direction, so the host program
determined that the actual target position should be 2000 cts at that time. Figure 2 shows what the
position profile would look like if the move was allowed to complete to 2000 cts. The position was
modified when the robot was at a position of 4200 cts. Note that the robot actually travels to a distance
of almost 5000 cts before it turns around. This is a function of the deceleration rate set by the DC
command. When a direction change is commanded, the controller decelerates at the rate specified by
the DC command. The controller then ramps the velocity in up to the value set with SP in the opposite
direction traveling to the new specified absolute position. In figure 3 the velocity profile is triangular
because the controller doesn’t have sufficient time to reach the set speed of 50000 cts/sec before it is
commanded to change direction.
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Figure 2: Position vs. Time (msec) Motion 2
Figure 3 Velocity vs Time (msec) Motion 2
Example
Motion 4
In this motion, the host program commands the controller to begin motion towards position 5000,
changes the target to -2000, and then changes it again to 8000. Figure 4 shows the plot of position vs.
time, Figure 5 plots velocity vs. time, and Figure 6 demonstrates the use of motion smoothing (IT) on
the velocity profile in this mode. The jerk in the system is also affected by the values set for AC and
DC.
DMC-2X00
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Figure 4 Position vs. Time (msec) Motion 4
Figure 5 Velocity vs.Time Motion 4
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Figure 6 Velocity cts/sec vs. Time (msec) with IT Motion 4
Note the controller treats the point where the velocity passes through zero as the end of one move, and
the beginning of another move. IT is allowed, however it will introduce some time delay.
Trip Points
Most trip points are valid for use while in the position tracking mode. There are a few exceptions to
this; the AM and MC commands may not be used while in this mode. It is recommended that MF,
MR, or AP be used, as they involve motion in a specified direction, or the passing of a specific
absolute position.
DMC-2X00
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Command Summary – Position Tracking Mode
COMMAND
DESCRIPTION
AC n,n,n,n,n,n,n,n
AP n,n,n,n,n,n,n,n
DC n,n,n,n,n,n,n,n
Acceleration settings for the specified axes
Trip point that holds up program execution until an absolute position has been reached
Deceleration settings for the specified axes
MF n,n,n,n,n,n,n,n Trip point to hold up program execution until n number of counts have passed in the
forward direction. Only one axis at a time may be specified.
MR n,n,n,n,n,n,n,n Trip point to hold up program execution until n number of counts have passed in the
reverse direction. Only one axis at a time may be specified.
PT n,n,n,n,n,n,n,n
PA n,n,n,n,n,n,n,n
SP n,n,n,n,n,n,n,n
Command used to enter and exit the Trajectory Modification Mode
Command Used to specify the absolute position target
Command used to enter and exit the Trajectory Modification Mode
Independent Jogging
The jog mode of motion is very flexible because speed, direction and acceleration can be changed
during motion. The user specifies the jog speed (JG), acceleration (AC), and the deceleration (DC)
rate for each axis. The direction of motion is specified by the sign of the JG parameters. When the
begin command is given (BG), the motor accelerates up to speed and continues to jog at that speed
until a new speed or stop (ST) command is issued. If the jog speed is changed during motion, the
controller will make an accelerated (or decelerated) change to the new speed.
An instant change to the motor position can be made with the use of the IP command. Upon receiving
this command, the controller commands the motor to a position which is equal to the specified
increment plus the current position. This command is useful when trying to synchronize the position
of two motors while they are moving.
Note that the controller operates as a closed-loop position controller while in the jog mode. The DMC-
2x00 converts the velocity profile into a position trajectory and a new position target is generated every
sample period. This method of control results in precise speed regulation with phase lock accuracy.
Command Summary - Jogging
COMMAND
DESCRIPTION
AC A,B,C,D
BG ABCD
Specifies acceleration rate
Begins motion
DC A,B,C,D
IP A,B,C,D
IT A,B,C,D
JG +/-A,B,C,D
ST ABCD
Specifies deceleration rate
Increments position instantly
Time constant for independent motion smoothing
Specifies jog speed and direction
Stops motion
Parameters can be set with individual axes specifiers such as JGB=2000 (set jog speed for B axis to
2000).
Operand Summary - Independent Axis
OPERAND
DESCRIPTION
_ACx
Return acceleration rate for the axis specified by ‘x’
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_DCx
_SPx
_TVx
Return deceleration rate for the axis specified by ‘x’
Returns the jog speed for the axis specified by ‘x’
Returns the actual velocity of the axis specified by ‘x’ (averaged over .25 sec)
Examples
Jog in X only
Jog A motor at 50000 count/s. After A motor is at its jog speed, begin jogging C in reverse direction at
25000 count/s.
Instruction
#A
Interpretation
Label
AC 20000,,20000
DC 20000,,20000
JG 50000,,-25000
BG A
Specify A,C acceleration of 20000 cts / sec
Specify A,C deceleration of 20000 cts / sec
Specify jog speed and direction for A and C axis
Begin A motion
AS A
Wait until A is at speed
BG C
Begin C motion
EN
Joystick Jogging
The jog speed can also be changed using an analog input such as a joystick. Assume that for a 10 volt
input the speed must be 50000 counts/sec.
Instruction
#JOY
Interpretation
Label
JG0
Set in Jog Mode
Begin motion
Label for loop
Read analog input
Compute speed
Change JG speed
Loop
BGA
#B
vl =@AN[1]
vel=v1*50000/10
JG vel
JP #B
DMC-2X00
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Linear Interpolation Mode
The DMC-2x00 provides a linear interpolation mode for 2 or more axes. In linear interpolation mode,
motion between the axes is coordinated to maintain the prescribed vector speed, acceleration, and
deceleration along the specified path. The motion path is described in terms of incremental distances
for each axis. An unlimited number of incremental segments may be given in a continuous move
sequence, making the linear interpolation mode ideal for following a piece-wise linear path. There is
no limit to the total move length.
The LM command selects the Linear Interpolation mode and axes for interpolation. For example, LM
BC selects only the B and C axes for linear interpolation.
When using the linear interpolation mode, the LM command only needs to be specified once unless the
axes for linear interpolation change.
Specifying the Coordinate Plane
The DMC-2x00 allows for 2 separate sets of coordinate axes for linear interpolation mode or vector
mode. These two sets are identified by the letters S and T.
To specify vector commands the coordinate plane must first be identified. This is done by issuing the
command CAS to identify the S plane or CAT to identify the T plane. All vector commands will be
applied to the active coordinate system until changed with the CA command.
Specifying Linear Segments
The command LI a,b,c,d,e,f,g,h specifies the incremental move distance for each axis. This means
motion is prescribed with respect to the current axis position. Up to 511 incremental move segments
may be given prior to the Begin Sequence (BGS) command. Once motion has begun, additional LI
segments may be sent to the controller.
The clear sequence (CS) command can be used to remove LI segments stored in the buffer prior to the
start of the motion. To stop the motion, use the instructions STS or AB. The command, ST, causes a
decelerated stop. The command, AB, causes an instantaneous stop and aborts the program, and the
command AB1 aborts the motion only.
The Linear End (LE) command must be used to specify the end of a linear move sequence. This
command tells the controller to decelerate to a stop following the last LI command. If an LE command
is not given, an Abort AB1 must be used to abort the motion sequence.
It is the responsibility of the user to keep enough LI segments in the DMC-2x00 sequence buffer to
ensure continuous motion. If the controller receives no additional LI segments and no LE command,
the controller will stop motion instantly at the last vector. There will be no controlled deceleration.
LM? or _LM returns the available spaces for LI segments that can be sent to the buffer. 511 returned
means the buffer is empty and 511 LI segments can be sent. A zero means the buffer is full and no
additional segments can be sent. As long as the buffer is not full, additional LI segments can be sent at
PC bus speeds.
The instruction _CS returns the segment counter. As the segments are processed, _CS increases,
starting at zero. This function allows the host computer to determine which segment is being
processed.
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Additional Commands
The commands VS n, VA n, and VD n are used to specify the vector speed, acceleration and
deceleration. The DMC-2x00 computes the vector speed based on the axes specified in the LM mode.
For example, LM ABC designates linear interpolation for the A,B and C axes. The vector speed for
this example would be computed using the equation:
2
2
2
2
VS =AS +BS +CS , where AS, BS and CS are the speed of the A,B and C axes.
The controller always uses the axis specifications from LM, not LI, to compute the speed.
VT is used to set the S-curve smoothing constant for coordinated moves. The command AV n is the
‘After Vector’ trip point, which halts program execution until the vector distance of n has been
reached.
Specifying Vector Speed for Each Segment
The instruction VS has an immediate effect and, therefore, must be given at the required time. In some
applications, such as CNC, it is necessary to attach various speeds to different motion segments. This
can be done by two functions: < n and > m
For example:
LI a,b,c,d < n >m
The first command, < n, is equivalent to commanding VSn at the start of the given segment and will
cause an acceleration toward the new commanded speeds, subjects to the other constraints.
The second function, > m, requires the vector speed to reach the value m at the end of the segment.
Note that the function > m may start the deceleration within the given segment or during previous
segments, as needed to meet the final speed requirement, under the given values of VA and VD.
Note, however, that the controller works with one > m command at a time. As a consequence, one
function may be masked by another. For example, if the function >100000 is followed by >5000, and
the distance for deceleration is not sufficient, the second condition will not be met. The controller will
attempt to lower the speed to 5000, but will reach that at a different point.
As an example, consider the following program.
Instruction
#ALT
Interpretation
Label for alternative program
Define Position of A and B axis to be 0
Define linear mode between A and B axes.
DP 0,0
LMAB
LI 4000,0 <4000 >1000
Specify first linear segment with a vector speed of 4000 and end
speed 1000
LI 1000,1000 < 4000 >1000
LI 0,5000 < 4000 >1000
Specify second linear segment with a vector speed of 4000 and end
speed 1000
Specify third linear segment with a vector speed of 4000 and end
speed 1000
LE
End linear segments
Begin motion sequence
Program end
BGS
EN
Changing Feed Rate:
The command VR n allows the feed rate, VS, to be scaled between 0 and 10 with a resolution of
0.0001. This command takes effect immediately and causes VS to be scaled. VR also applies when
the vector speed is specified with the ‘<’ operator. This is a useful feature for feed rate override. VR
does not ratio the accelerations. For example, VR 0.5 results in the specification VS 2000 to be
divided in half.
DMC-2X00
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Command Summary - Linear Interpolation
COMMAND
LM abcdefgh
LM?
DESCRIPTION
Specify axes for linear interpolation
Returns number of available spaces for linear segments in DMC-2x00 sequence
buffer. Zero means buffer full. 512 means buffer empty.
LI a,b,c,d,e,f,g,h < n
Specify incremental distances relative to current position, and assign vector speed n.
Specify vector speed
VS n
VA n
VD n
VR n
BGS
CS
Specify vector acceleration
Specify vector deceleration
Specify the vector speed ratio
Begin Linear Sequence
Clear sequence
LE
Linear End- Required at end of LI command sequence
Returns the length of the vector (resets after 2147483647)
Trip point for After Sequence complete
Trip point for After Relative Vector distance, n
S curve smoothing constant for vector moves
LE?
AMS
AV n
VT
Operand Summary - Linear Interpolation
OPERAND
DESCRIPTION
_AV
Return distance traveled
_CS
Segment counter - returns number of the segment in the sequence, starting at zero.
Returns length of vector (resets after 2147483647)
_LE
_LM
Returns number of available spaces for linear segments in DMC-2x00 sequence
buffer. Zero means buffer full. 512 means buffer empty.
_VPm
Return the absolute coordinate of the last data point along the trajectory.
(m= A,B,C,D,E,F,G or H)
To illustrate the ability to interrogate the motion status, consider the first motion segment of our
example, #LMOVE, where the A axis moves toward the point A=5000. Suppose that when A=3000,
the controller is interrogated using the command ‘MG _AV’. The returned value will be 3000. The
value of _CS, _VPA and _VPB will be zero.
Now suppose that the interrogation is repeated at the second segment when B=2000. The value of
_AV at this point is 7000, _CS equals 1, _VPA=5000 and _VPB=0.
Example
Linear Interpolation Motion
In this example, the AB system is required to perform a 90° turn. In order to slow the speed around
the corner, we use the AV 4000 trip point, which slows the speed to 1000 count/s. Once the motors
reach the corner, the speed is increased back to 4000 cts / s.
Instruction
Interpretation
#LMOVE
Label
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DP 0,0
LMAB
LI 5000,0
LI 0,5000
LE
Define position of A and B axes to be 0
Define linear mode between A and B axes.
Specify first linear segment
Specify second linear segment
End linear segments
VS 4000
BGS
Specify vector speed
Begin motion sequence
AV 4000
VS 1000
AV 5000
VS 4000
EN
Set trip point to wait until vector distance of 4000 is reached
Change vector speed
Set trip point to wait until vector distance of 5000 is reached
Change vector speed
Program end
Linear Move
Make a coordinated linear move in the CD plane. Move to coordinates 40000, 30000 counts at a
2
vector speed of 100000 counts/sec and vector acceleration of 1000000 counts/sec .
Instruction
LM CD
Interpretation
Specify axes for linear interpolation
Specify CD distances
Specify end move
LI,,40000,30000
LE
VS 100000
VA 1000000
VD 1000000
BGS
Specify vector speed
Specify vector acceleration
Specify vector deceleration
Begin sequence
Note that the above program specifies the vector speed, VS, and not the actual axis speeds VC and VD.
The axis speeds are determined by the DMC-2x00 from:
2
VC2 VD
=
+
VS
The resulting profile is shown in Figure 6.2.
DMC-2X00
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30000
27000
POSITION D
3000
0
0
4000
36000
40000
POSITION C
FEEDRATE
0
0.1
0.5
0.6
TIME (sec)
VELOCITY
C-AXIS
TIME (sec)
VELOCITY
D-AXIS
TIME (sec)
Figure 6.2 - Linear Interpolation
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Multiple Moves
This example makes a coordinated linear move in the AB plane. The Arrays VA and VB are used to
store 750 incremental distances which are filled by the program #LOAD.
Instruction
#LOAD
Interpretation
Load Program
DM VA [750],VB [750]
count=0
Define Array
Initialize Counter
n=10
Initialize position increment
LOOP
#LOOP
VA [count]=n
VB [count]=n
n=n+10
Fill Array VA
Fill Array VB
Increment position
Increment counter
Loop if array not full
Label
count = count +1
JP #LOOP, count <750
#A
LM AB
Specify linear mode for AB
Initialize array counter
If sequence buffer full, wait
Begin motion on 500th segment
Specify linear segment
Increment array counter
Repeat until array done
End Linear Move
count =0
#LOOP2;JP#LOOP2,_LM=0
JS#C, count =500
LI VA[count],VB[count]
count = count +1
JP #LOOP2, count <750
LE
AMS
After Move sequence done
Send Message
MG "DONE"
EN
End program
#C;BGS;EN
Begin Motion Subroutine
Vector Mode: Linear and Circular Interpolation Motion
The DMC-2x00 allows a long 2-D path consisting of linear and arc segments to be prescribed. Motion
along the path is continuous at the prescribed vector speed even at transitions between linear and
circular segments. The DMC-2x00 performs all the complex computations of linear and circular
interpolation, freeing the host PC from this time intensive task.
The coordinated motion mode is similar to the linear interpolation mode. Any pair of two axes may be
selected for coordinated motion consisting of linear and circular segments. In addition, a third axis can
be controlled such that it remains tangent to the motion of the selected pair of axes. Note that only one
pair of axes can be specified for coordinated motion at any given time.
The command VM m,n,p where ‘m’ and ‘n’ are the coordinated pair and p is the tangent axis.
NOTE: the commas which separate m,n and p are not necessary. For example, VM ABC selects the
AD axes for coordinated motion and the C-axis as the tangent.
Specifying the Coordinate Plane
The DMC-2x00 allows for 2 separate sets of coordinate axes for linear interpolation mode or vector
mode. These two sets are identified by the letters S and T.
DMC-2X00
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To specify vector commands the coordinate plane must first be identified. This is done by issuing the
command CAS to identify the S plane or CAT to identify the T plane. All vector commands will be
applied to the active coordinate system until changed with the CA command.
Specifying Vector Segments
The motion segments are described by two commands; VP for linear segments and CR for circular
segments. Once a set of linear segments and/or circular segments have been specified, the sequence is
ended with the command VE. This defines a sequence of commands for coordinated motion.
Immediately prior to the execution of the first coordinated movement, the controller defines the current
position to be zero for all movements in a sequence.
NOTE: This ‘local’ definition of zero does not affect the absolute coordinate system or subsequent
coordinated motion sequences.
The command, VP xy specifies the coordinates of the end points of the vector movement with respect
to the starting point. Non-sequential axes do not require comma delimitation. The command, CR r,q,d
define a circular arc with a radius r, starting angle of q, and a traversed angle d. The convention for q
is that zero corresponds to the positive horizontal direction and, for both q and d, the counter-clockwise
(CCW) rotation is positive.
Up to 511 segments of CR or VP may be specified in a single sequence and must be ended with the
command VE. The motion can be initiated with a Begin Sequence (BGS) command. Once motion
starts, additional segments may be added.
The Clear Sequence (CS) command can be used to remove previous VP and CR commands which
were stored in the buffer prior to the start of the motion. To stop the motion, use the instructions STS
or AB1. ST stops motion at the specified deceleration. AB1 aborts the motion instantaneously.
The Vector End (VE) command must be used to specify the end of the coordinated motion. This
command requires the controller to decelerate to a stop following the last motion requirement. If a VE
command is not given, an Abort (AB1) must be used to abort the coordinated motion sequence.
It is the responsibility of the user to keep enough motion segments in the DMC-2x00 sequence buffer
to ensure continuous motion. If the controller receives no additional motion segments and no VE
command, the controller will stop motion instantly at the last vector. There will be no controlled
deceleration. LM? or _LM returns the available spaces for motion segments that can be sent to the
buffer. 511 returned means the buffer is empty and 511 segments can be sent. A zero means the
buffer is full and no additional segments can be sent. As long as the buffer is not full, additional
segments can be sent at PC bus speeds.
The operand _CS can be used to determine the value of the segment counter.
Additional commands
The commands VS n, VA n and VD n are used for specifying the vector speed, acceleration, and
deceleration.
VT is the s curve smoothing constant used with coordinated motion.
Specifying Vector Speed for Each Segment:
The vector speed may be specified by the immediate command VS. It can also be attached to a motion
segment with the instructions
VP a,b < n >m
CR r,θ,δ < n >m
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The first command, <n, is equivalent to commanding VSn at the start of the given segment and will
cause an acceleration toward the new commanded speeds, subjects to the other constraints.
The second function, > m, requires the vector speed to reach the value m at the end of the segment.
Note that the function > m may start the deceleration within the given segment or during previous
segments, as needed to meet the final speed requirement, under the given values of VA and VD.
Note, however, that the controller works with one > m command at a time. As a consequence, one
function may be masked by another. For example, if the function >100000 is followed by >5000, and
the distance for deceleration is not sufficient, the second condition will not be met. The controller will
attempt to lower the speed to 5000, but will reach that at a different point.
Changing Feed rate:
The command VR n allows the feed rate, VS, to be scaled between 0 and 10 with a resolution of .0001.
This command takes effect immediately and causes VS scaled. VR also applies when the vector speed
is specified with the ‘<’ operator. This is a useful feature for feed rate override. VR does not ratio the
accelerations. For example, VR .5 results in the specification VS 2000 to be divided by two
Compensating for Differences in Encoder Resolution:
By default, the DMC-2x00 uses a scale factor of 1:1 for the encoder resolution when used in vector
mode. If this is not the case, the command, ES can be used to scale the encoder counts. The ES
command accepts two arguments which represent the number of counts for the two encoders used for
vector motion. The smaller ratio of the two numbers will be multiplied by the higher resolution
encoder. For more information, see ES command in Chapter 11, Command Summary.
Trippoints:
The AV n command is the After Vector , which waits for the vector relative distance of n to occur
before executing the next command in a program.
Tangent Motion:
Several applications, such as cutting, require a third axis (i.e. a knife blade), to remain tangent to the
coordinated motion path. To handle these applications, the DMC-2x00 allows one axis to be specified
as the tangent axis. The VM command provides parameter specifications for describing the
coordinated axes and the tangent axis.
VM m,n,p
m,n specifies coordinated axes p specifies tangent axis such as A,B,C or
D p=N turns off tangent axis
Before the tangent mode can operate, it is necessary to assign an axis via the VM command and define
its offset and scale factor via the TN m,n command. m defines the scale factor in counts/degree and n
defines the tangent position that equals zero degrees in the coordinated motion plane. The operand
_TN can be used to return the initial position of the tangent axis.
Command Summary - Coordinated Motion Sequence
Command
Description
VM m,n
Specifies the axes for the planar motion where m and n represent the planar axes and p is
the tangent axis.
VP m,n
Return coordinate of last point, where m=A,B,C or D.
CR r,Θ, ±ΔΘ
Specifies arc segment where r is the radius, Θ is the starting angle and ΔΘ is the travel
angle. Positive direction is CCW.
VS n
Specify vector speed or feed rate of sequence.
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VA n
VD n
VR n
BGS
CS
Specify vector acceleration along the sequence.
Specify vector deceleration along the sequence.
Specify vector speed ratio
Begin motion sequence.
Clear sequence.
AV n
AMS
TN m,n
ES m,n
VT
Trip point for After Relative Vector distance, n.
Holds execution of next command until Motion Sequence is complete.
Tangent scale and offset.
Ellipse scale factor.
S curve smoothing constant for coordinated moves
LM?
Return number of available spaces for linear and circular segments in DMC-2x00
sequence buffer. Zero means buffer is full. 512 means buffer is empty.
Operand Summary - Coordinated Motion Sequence
operand
_VPM
_AV
Description
The absolute coordinate of the axes at the last intersection along the sequence.
Distance traveled.
_LM
Number of available spaces for linear and circular segments in DMC-2x00 sequence
buffer. Zero means buffer is full. 512 means buffer is empty.
_CS
_VE
Segment counter - Number of the segment in the sequence, starting at zero.
Vector length of coordinated move sequence.
When AV is used as an operand, _AV returns the distance traveled along the sequence.
The operands _VPA and _VPB can be used to return the coordinates of the last point specified along
the path.
Example
Tangent Axis
Assume an AB table with the C-axis controlling a knife. The C-axis has a 2000 quad counts/rev
encoder and has been initialized after power-up to point the knife in the +B direction. A 180° circular
cut is desired, with a radius of 3000, center at the origin and a starting point at (3000,0). The motion is
CCW, ending at (-3000,0). Note that the 0° position in the AB plane is in the +A direction. This
corresponds to the position -500 in the Z-axis, and defines the offset. The motion has two parts. First,
A, B and C are driven to the starting point, and later, the cut is performed. Assume that the knife is
engaged with output bit 0.
Instruction
#EXAMPLE
VM ABC
Interpretation
Example program
AB coordinate with C as tangent
2000/360 counts/degree, position -500 is 0 degrees in AB plane
3000 count radius, start at 0 and go to 180 CCW
End vector
TN 2000/360,-500
CR 3000,0,180
VE
CB0
Disengage knife
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PA 3000,0,_TN
Move A and B to starting position, move C to initial tangent
position
BG ABC
AM ABC
SB0
Start the move to get into position
When the move is complete
Engage knife
WT50
Wait 50 msec for the knife to engage
Do the circular cut
BGS
AMS
After the coordinated move is complete
Disengage knife
CB0
MG "ALL DONE"
EN
End program
Coordinated Motion
Traverse the path shown in Fig. 6.3. Feed rate is 20000 counts/sec. Plane of motion is AB.
Instruction
VM AB
Interpretation
Specify motion plane
Specify vector speed
Specify vector acceleration
Specify vector deceleration
Segment AB
VS 20000
VA 1000000
VD 1000000
VP -4000,0
CR 1500,270,-180
VP 0,3000
CR 1500,90,-180
VE
Segment BC
Segment CD
Segment DA
End of sequence
Begin Sequence
BGS
The resulting motion starts at the point A and moves toward points B, C, D, A. Suppose that we
interrogate the controller when the motion is halfway between the points A and B.
The value of _AV is 2000
The value of _CS is 0
_VPA and _VPB contain the absolute coordinate of the point A
Suppose that the interrogation is repeated at a point, halfway between the points C and D.
The value of _AV is 4000+1500π+2000=10,712
The value of _CS is 2
_VPA,_VPB contain the coordinates of the point C
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C (-4000,3000)
D (0,3000)
R = 1500
B (-4000,0)
A (0,0)
Figure 6.3 - The Required Path
Electronic Gearing
This mode allows up to 8 axes to be electronically geared to some master axes. The masters may rotate
in both directions and the geared axes will follow at the specified gear ratio. The gear ratio may be
different for each axis and changed during motion.
The command GA ABCDEFGH specifies the master axes. GR a,b,c,d specifies the gear ratios for the
slaves where the ratio may be a number between +/-127.9999 with a fractional resolution of .0001.
There are two modes: standard gearing and gantry mode. The gantry mode is enabled with the
command GM. GR 0,0,0,0 turns off gearing in both modes. A limit switch or ST command disables
gearing in the standard mode but not in the gantry mode.
The command GM a,b,c,d select the axes to be controlled under the gantry mode. The parameter 1
enables gantry mode, and 0 disables it.
GR causes the specified axes to be geared to the actual position of the master. The master axis is
commanded with motion commands such as PR, PA or JG.
When the master axis is driven by the controller in the jog mode or an independent motion mode, it is
possible to define the master as the command position of that axis, rather than the actual position. The
designation of the commanded position master is by the letter, C. For example, GACA indicates that
the gearing is the commanded position of A.
An alternative gearing method is to synchronize the slave motor to the commanded vector motion of
several axes performed by GAS. For example, if the A and B motor form a circular motion, the C axis
may move in proportion to the vector move. Similarly, if A,B and C perform a linear interpolation
move, W can be geared to the vector move.
Electronic gearing allows the geared motor to perform a second independent or coordinated move in
addition to the gearing. For example, when a geared motor follows a master at a ratio of 1:1, it may be
advanced an additional distance with PR, or JG, commands, or VP, or LI.
Ramped Gearing
In some applications, especially when the master is traveling at high speeds, it is desirable to have the
gear ratio ramp gradually to minimize large changes in velocity on the slave axis when the gearing is
engaged. For example if the master axis is already traveling at 1,000,000 cts/sec and the slave will be
geared at a ratio of 1:1 when the gearing is engaged, the slave will instantly develop following error,
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and command maximum current to the motor. This can be a large shock to the system. For many
applications it is acceptable to slowly ramp the engagement of gearing over a greater time frame. Galil
allows the user to specify an interval of the master axis over which the gearing will be engaged. For
example, the same master X axis in this case travels at 1,000,000 counts/sec, and the gear ratio is 1:1,
but the gearing is slowly engaged over 30,000 cts of the master axis, greatly diminishing the initial
shock to the slave axis. Figure 1 below shows the velocity vs. time profile for instantaneous gearing.
Figure 2 shows the velocity vs. time profile for the gradual gearing engagement.
Figure 1 Velocity cts/sec vs. Time (msec) Instantaneous Gearing Engagement
Figure 2 Velocity (cts/sec) vs. Time (msec) Ramped Gearing
DMC-2X00
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The slave axis for each figure is shown in the bottom portion of the figure; the master axis is shown in
the top portion. The shock to the slave axis will be significantly less in figure 2 than in figure1. The
ramped gearing does have one consequence. There isn’t a true synchronization of the two axes, until
the gearing ramp is complete. The slave will lag behind the true ratio during the ramp period. If exact
position synchronization is required from the point gearing is initiated, then the position must be
commanded in addition to the gearing. The controller keeps track of this position phase lag with the
_GP operand. The following example will demonstrate how the command is used.
Example
Electronic Gearing Over a Specified Interval
Objective Run two geared motors at speeds of 1.132 and -.045 times the speed of an external master.
Because the master is traveling at high speeds, it is desirable for the speeds to change slowly.
Solution: Use a DMC-1730 or DMC-1830 controller where the Z-axis is the master and X and Y are
the geared axes. We will implement the gearing change over 6000 counts (3 revolutions) of the master
axis.
MO Z
Turn Z off, for external master
GA Z, Z
Specify Z as the master axis for both X and Y.
Specify ramped gearing over 6000 counts of the master axis.
Specify gear ratios
GD6000,6000
GR 1.132,-.045
Question: What is the effect of the ramped gearing?
Answer: Below, in the example titled Electronic Gearing, gearing would take effect immediately.
From the start of gearing if the master traveled 6000 counts, the slaves would travel 6792 counts and
270 counts.
Using the ramped gearing, the slave will engage gearing gradually. Since the gearing is engaged over
the interval of 6000 counts of the master, the slave will only travel ~3396 counts and ~135 counts
respectively. The difference between these two values is stored in the _GPn operand. If exact position
synchronization is required, the IP command is used to adjust for the difference.
Command Summary - Electronic Gearing
COMMAND
DESCRIPTION
GA n
Specifies master axes for gearing where:
n = X,Y,Z or W or A,B,C,D,E,F,G,H for main encoder as master
n = CX,CY,CZ, CW or CA, CB,CC,CD,CE,CF,CG,CH for commanded position.
n = DX,DY,DZ or DW or DA, DB, DC, DD, DE, DF,DG,DH for auxiliary encoders
n = S or T for gearing to coordinated motion.
GD a,b,c,d,e,f,g,h Sets the distance the master will travel for the gearing change to take full effect.
_GPn
This operand keeps track of the difference between the theoretical distance traveled if
gearing changes took effect immediately, and the distance traveled since gearing
changes take effect over a specified interval.
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GR a,b,c,d,e,f,g,h Sets gear ratio for slave axes. 0 disables electronic gearing for specified axis.
GM a,b,c,d,e,f,g,h X = 1 sets gantry mode, 0 disables gantry mode
MR x,y,z,w
MF x,y,z,w
Trippoint for reverse motion past specified value. Only one field may be used.
Trippoint for forward motion past specified value. Only one field may be used.
Example
Simple Master/Slave
Master axis moves 10000 counts at slew speed of 100000 counts/sec. B is defined as the master.
A,C,D are geared to master at ratios of 5,-.5 and 10 respectively.
Instruction
GA B,,B,B
GR 5,,-.5,10
PR ,10000
SP ,100000
BGB
Interpretation
Specify master axes as B
Set gear ratios
Specify B position
Specify B speed
Begin motion
Electronic Gearing
Objective: Run two geared motors at speeds of 1.132 and -0.045 times the speed of an external master.
The master is driven at speeds between 0 and 1800 RPM (2000 counts/rev encoder).
Solution: Use a DMC-2x30 controller, where the C-axis is the master and A and B are the geared
axes.
Instruction
MO C
Interpretation
Turn C off, for external master
Specify C as the master axis for both A and B.
Specify gear ratios
GA C,C
GR 1.132,-.045
Now suppose the gear ratio of the A-axis is to change on-the-fly to 2. This can be achieved by
commanding:
GR 2
Specify gear ratio for A axis to be 2
Gantry Mode
In applications where both the master and the follower are controlled by the DMC-2x00 controller, it
may be desired to synchronize the follower with the commanded position of the master, rather than the
actual position. This eliminates the coupling between the axes which may lead to oscillations.
For example, assume that a gantry is driven by two axes, A and B, on both sides. This requires the
gantry mode for strong coupling between the motors. The A-axis is the master and the B-axis is the
follower. To synchronize B with the commanded position of A, use the instructions:
Instruction
GA, CA
GR,1
Interpretation
Specify the commanded position of A as master for B.
Set gear ratio for Y as 1:1
Set gantry mode
GM,1
PR 3000
BG A
Command A motion
Start motion on A axis
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You may also perform profiled position corrections in the electronic gearing mode. Suppose, for
example, that you need to advance the slave 10 counts. Simply command
IP ,10
Specify an incremental position movement of 10 on B axis.
Under these conditions, this IP command is equivalent to:
PR,10
Specify position relative movement of 10 on B axis
BGB
Begin motion on B axis
Often the correction is quite large. Such requirements are common when synchronizing cutting knives
or conveyor belts.
Synchronize two conveyor belts with trapezoidal velocity correction.
Instruction
GA,A
Interpretation
Define A as the master axis for B.
Set gear ratio 2:1 for B
GR,2
PR,300
Specify correction distance
Specify correction speed
Specify correction acceleration
Specify correction deceleration
Start correction
SP,5000
AC,100000
DC,100000
BGB
Electronic Cam
The electronic cam is a motion control mode which enables the periodic synchronization of several
axes of motion. Up to 7 axes can be slaved to one master axis. The master axis encoder must be input
through a main encoder port.
The electronic cam is a more general type of electronic gearing which allows a table-based relationship
between the axes. It allows synchronizing all the controller axes. For example, the DMC-2x80
controller may have one master and up to seven slaves.
To illustrate the procedure of setting the cam mode, consider the cam relationship for the slave axis B,
when the master is A. Such a graphic relationship is shown in Figure 6.4.
Step 1. Selecting the master axis
The first step in the electronic cam mode is to select the master axis. This is done with the
instruction
EAp where p = A,B,C,D
p is the selected master axis
For the given example, since the master is x, we specify EAA
Step 2. Specify the master cycle and the change in the slave axes.
In the electronic cam mode, the position of the master is always expressed modulo one cycle.
In this example, the position of x is always expressed in the range between 0 and 6000.
Similarly, the slave position is also redefined such that it starts at zero and ends at 1500. At
the end of a cycle when the master is 6000 and the slave is 1500, the positions of both A and
B are redefined as zero. To specify the master cycle and the slave cycle change, we use the
instruction EM.
EM a,b,c,d
where a,b,c,d specify the cycle of the master and the total change of the slaves over one cycle.
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The cycle of the master is limited to 8,388,607 whereas the slave change per cycle is limited
to 2,147,483,647. If the change is a negative number, the absolute value is specified. For the
given example, the cycle of the master is 6000 counts and the change in the slave is 1500.
Therefore, we use the instruction:
EM 6000,1500
Step 3. Specify the master interval and starting point.
Next we need to construct the ECAM table. The table is specified at uniform intervals of
master positions. Up to 256 intervals are allowed. The size of the master interval and the
starting point are specified by the instruction:
EP m,n
where m is the interval width in counts, and n is the starting point.
For the given example, we can specify the table by specifying the position at the master points
of 0, 2000, 4000 and 6000. We can specify that by
EP 2000,0
Step 4. Specify the slave positions.
Next, we specify the slave positions with the instruction
ET[n]= a,b,c,d
where n indicates the order of the point.
The value, n, starts at zero and may go up to 256. The parameters A,B,C,D indicate the
corresponding slave position. For this example, the table may be specified by
ET[0]=,0
ET[1]=,3000
ET[2]=,2250
ET[3]=,1500
This specifies the ECAM table.
Step 5. Enable the ECAM
To enable the ECAM mode, use the command
EB n
where n=1 enables ECAM mode and n=0 disables ECAM mode.
Step 6. Engage the slave motion
To engage the slave motion, use the instruction
EG a,b,c,d
where a,b,c,d are the master positions at which the corresponding slaves must be engaged.
If the value of any parameter is outside the range of one cycle, the cam engages immediately.
When the cam is engaged, the slave position is redefined, modulo one cycle.
Step 7. Disengage the slave motion
To disengage the cam, use the command
EQ a,b,c,d
where a,b,c,d are the master positions at which the corresponding slave axes are disengaged.
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3000
2250
1500
0
2000
4000
6000
Master A
Figure 6.4: Electronic Cam Example
This disengages the slave axis at a specified master position. If the parameter is outside the master
cycle, the stopping is instantaneous.
Step 8. Create program to generate ECAM table
To illustrate the complete process, consider the cam relationship described by
the equation:
B = 0.5 A + 100 sin (0.18 A)
*
*
where A is the master, with a cycle of 2000 counts.
The cam table can be constructed manually, point by point, or automatically by a program. The
following program includes the set-up. The instruction EAA defines A as the master axis.
The cycle of the master is 2000. Over that cycle, B varies by 1000. This leads to the
instruction EM 2000,1000.
Suppose we want to define a table with 100 segments. This implies increments of 20 counts each.
If the master points are to start at zero, the required instruction is EP 20,0.
The following routine computes the table points. As the phase equals 0.18A and A varies in
increments of 20, the phase varies by increments of 3.6°. The program then computes the
values of B according to the equation and assigns the values to the table with the instruction
ET[N] = ,B.
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Instruction
Interpretation
#SETUP
EAA
Label
Select A as master
Cam cycles
EM 2000,1000
EP 20,0
n = 0
Master position increments
Index
#LOOP
Loop to construct table from equation
Note 3.6 = 0.18∗20
Define sine position
Define slave position
Define table
p = n∗3.6
s = @SIN [P] 100
*
b = n 10+s
*
ET [n] =, b
n = n+1
Update Counter
JP #LOOP, n<=100
EN
Repeat the process
End Program
Step 9. Create program to run ECAM mode
Now suppose that the slave axis is engaged with a start signal, input 1, but that both the
engagement and disengagement points must be done at the center of the cycle: A = 1000 and
B = 500. This implies that B must be driven to that point to avoid a jump.
This is done with the program:
Instruction
Interpretation
#RUN
EB1
Label
Enable cam
PA,500
SP,5000
BGB
starting position
B speed
Move B motor
After B moved
Wait for start signal
Engage slave
Wait for stop signal
Disengage slave
End
AM
AI1
EG,1000
AI - 1
EQ,1000
EN
Command Summary - Electronic CAM
Command
EA p
EB n
Description
Specifies master axes for electronic cam where:
Enables the ECAM
EC n
ECAM counter - sets the index into the ECAM table
Engages ECAM
EG a,b,c,d
EM a,b,c,d
EP m,n
EQ m,n
ET[n]
Specifies the change in position for each axis of the CAM cycle
Defines CAM table entry size and offset
Disengages ECAM at specified position
Defines the ECAM table entries
EW
Widen segment (see Application Note #2444)
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Operand Summary - Electronic CAM
command
description
_EB
Contains State of ECAM
_EC
Contains current ECAM index
Contains ECAM status for each axis
Contains size of cycle for each axis
Contains value of the ECAM table interval
Contains ECAM status for each axis
_EGa
_EM
_EP
_EQx
Example
Electronic CAM
The following example illustrates a cam program with a master axis, C, and two slaves, A and B
Instruction
Interpretation
#A;vl=0
Label; Initialize variable
PA 0,0;BGAB;AMAB
EA C
Go to position 0,0 on A and B axes
C axis as the Master for ECAM
Change for C is 4000, zero for A, B
ECAM interval is 400 counts with zero start
When master is at 0 position; 1st point.
2nd point in the ECAM table
3rd point in the ECAM table
4th point in the ECAM table
5th point in the ECAM table
6th point in the ECAM table
7th point in the ECAM table
8th point in the ECAM table
9th point in the ECAM table
10th point in the ECAM table
Starting point for next cycle
Enable ECAM mode
EM 0,0,4000
EP400,0
ET[0]=0,0
ET[1]=40,20
ET[2]=120,60
ET[3]=240,120
ET[4]=280,140
ET[5]=280,140
ET[6]=280,140
ET[7]=240,120
ET[8]=120,60
ET[9]=40,20
ET[10]=0,0
EB 1
JGC=4000
EG 0,0
Set C to jog at 4000
Engage both A and B when Master = 0
Begin jog on C axis
BGC
#LOOP;JP#LOOP,vl=0
EQ2000,2000
MF,, 2000
Loop until the variable is set
Disengage A and B when Master = 2000
Wait until the Master goes to 2000
Stop the C axis motion
ST C
EB 0
Exit the ECAM mode
EN
End of the program
The above example shows how the ECAM program is structured and how the commands can be given
to the controller. Figure 6.5 provides the results captured by the WSDK program. This shows how the
motion will be seen during the ECAM cycles. The first graph is for the A axis, the second graph
shows the cycle on the B axis and the third graph shows the cycle of the C axis.
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Figure 6.5 – Position Profiles of XYZ
Contour Mode
The DMC-2x00 also provides a contouring mode. This mode allows any arbitrary position curve to be
prescribed for 1 to 8 axes. This is ideal for following computer generated paths such as parabolic,
spherical or user-defined profiles. The path is not limited to straight line and arc segments and the path
length may be infinite.
Specifying Contour Segments
The Contour Mode is specified with the command, CM. For example, CMAC specifies contouring on
the A and C axes. Any axes that are not being used in the contouring mode may be operated in other
modes.
A contour is described by position increments which are described with the command, CD a,b,c,d over
n
a time interval, DT n. The parameter, n, specifies the time interval. The time interval is defined as 2
ms, where n is a number between 1 and 8. The controller performs linear interpolation between the
specified increments, where one point is generated for each millisecond.
Consider, for example, the trajectory shown in Fig. 6.6. The position A may be described by the
points:
Point 1
Point 2
Point 3
Point 4
A=0 at T=0ms
A=48 at T=4ms
A=288 at T=12ms
A=336 at T=28ms
The same trajectory may be represented by the increments
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Increment 1
Increment 2
Increment 3
DA=48
DA=240
DA=48
Time=4
Time=8
Time=16
DT=2
DT=3
DT=4
When the controller receives the command to generate a trajectory along these points, it interpolates
linearly between the points. The resulting interpolated points include the position 12 at 1 msec,
position 24 at 2 msec, etc.
The programmed commands to specify the above example are:
Instruction
#A
Interpretation
Label
CMA
Specifies A axis for contour mode
Specifies first time interval, 22 ms
Specifies first position increment
Specifies second time interval, 23 ms
Specifies second position increment
Specifies the third time interval, 24 ms
Specifies the third position increment
Exits contour mode
DT 2
CD 48;WC
DT 3
CD 240;WC
DT 4
CD 48;WC
DT0;CD0
EN
POSITION
(COUNTS)
336
288
240
192
96
48
TIME (ms)
0
4
8
28
12
20
24
16
SEGMENT 1
SEGMENT 2
SEGMENT 3
Figure 6.6 - The Required Trajectory
Additional Commands
The command, WC, is used as a trip point "When Complete". This allows the DMC-2x00 to use the
next increment only when it is finished with the previous one. Zero parameters for DT followed by
zero parameters for CD exit the contour mode.
If no new data record is found and the controller is still in the contour mode, the controller waits for
new data. No new motion commands are generated while waiting. If bad data is received, the
controller responds with a ?.
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Command Summary - Contour Mode
COMMAND
DESCRIPTION
CM ABCDEFGH
Specifies which axes for contouring mode. Any non-contouring axes may be
operated in other modes.
CD a,b,c,d,e,f,g,h
DT n
Specifies position increment over time interval. Range is +/-32,000. (Zero ends
contour mode, when issued following DT0)
Specifies time interval 2n msec for position increment, where n is an integer
between 1 and 8. Zero ends contour mode. If n does not change, it does not need
to be specified with each CD.
WC
Waits for previous time interval to be complete before next data record is
processed.
General Velocity Profiles
The Contour Mode is ideal for generating any arbitrary velocity profiles. The velocity profile can be
specified as a mathematical function or as a collection of points.
The design includes two parts: Generating an array with data points and running the program.
Example
Generating an Array
Consider the velocity and position profiles shown in Fig. 6.7. The objective is to rotate a motor a
distance of 6000 counts in 120 ms. The velocity profile is sinusoidal to reduce the jerk and the system
vibration. If we describe the position displacement in terms of A counts in B milliseconds, we can
describe the motion in the following manner:
Α
Β
ω =
Χ =
(
1− cos(2πΤ / Β)
)
AT
B
A
−
sin(2πΤ/ Β)
2π
NOTE: ω is the angular velocity; A is the position; and T is the variable, time, in milliseconds.
In the given example, A=6000 and B=120, the position and velocity profiles are:
A = 50T - (6000/2π) sin (2π T/120)
Note that the velocity, ω, in count/ms, is
ω = 50 [1 - cos 2π T/120]
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Figure 6.7 - Velocity Profile with Sinusoidal Acceleration
The DMC-2x00 can compute trigonometric functions. However, the argument must be expressed in
degrees. Using our example, the equation for A is written as:
A = 50T - 955 sin 3T
A complete program to generate the contour movement in this example is given below. To generate an
array, we compute the position value at intervals of 8 ms. This is stored at the array pos. Then, the
difference between the positions is computed and is stored in the array dir. Finally the motors are run
in the contour mode.
Contour Mode
Instruction
#POINTS
DM pos[16]
DM dir[15]
c=0;d=0
d=0
Interpretation
Program defines A points
Allocate memory
Set initial conditions, c is index
t is time in ms
t=0
#A
v1=50*t
v2=3*t
Argument in degrees
Compute position
Integer value of v3
Store in array pos
v3=-955*@SIN[v2]+v1
v4=@INT[v3]
pos[c]=v4
t=t+8
c=c+1
JP #A,c<16
#B
Program to find position differences
Compute the difference and store
c=0
#c
d=c+1
dir[c]=pos[d]- pos[c]
c=c+1
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JP #c,c<15
EN
End first program
Program to run motor
Contour Mode
#RUN
CMA
DT3
4 millisecond intervals
c=0
#E
CD dif[c]
WC
Contour Distance is in dif
Wait for completion
c=c+1
JP #E,c<15
DT0
CD0
Stop Contour
EN
End the program
Teach (Record and Play-Back)
Several applications require teaching the machine a motion trajectory. Teaching can be accomplished
using the DMC-2x00 automatic array capture feature to capture position data. The captured data may
then be played back in the contour mode. The following array commands are used:
DM C[n]
Dimension array
RA C[]
Specify array for automatic record (up to 4 for DMC-2x40)
RD _TPA
RC n,m
Specify data for capturing (such as _TPA or _TPC)
Specify capture time interval where n is 2n samples, m is number of records
to be captured
RC? or _RC
Returns a 1 if recording
Record and Playback Example
Instruction
#RECORD
DP0
Interpretation
Begin Program
Define position for A axis to be 0
De-allocate all arrays
DA*[ ]
DM xpos [501]
RA xpos [ ]
RD_TPA
Dimension 501 element array called xpos
Record Elements into xpos array
Element to be recorded is encoder position of A axis
Motor off for A axis
MOA
RC2
Begin Recording with a sample rate of 22 msec
Loop until all elements have been recorded
Routine to determine the difference between consecutive points
Dimension a 500 element array to hold contour points
Set loop counter
#LOOP1;JP#LOOP1,_RC=1
#COMPUTE
DM dx [500]
i = 0
#LOOP2
Loop to calculate the difference
Calculate difference
DX[I]= xpos [i+1]- xpos [i]
i=i+1
Update loop counter
JP#LOOP2,i<500
#PLAYBK
Continue looping until dx is full
Routine to play back motion that was recorded
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SHA
Servo Here
WT1000
CMA
Wait 1 sec (1000 msec)
Specify contour mode on A axis
Set contour data rate to be 22 msec
Set array index to 0
DT2
i=0
#LOOP3
CD dx[i];WC
i=i+1
Subroutine to execute contour points
Contour data command; Wait for next contour point
Update index
JP#LOOP3,i<500
DT0
Continue until all array elements have been executed
Set contour update rate to 0
CD0
Disable the contour mode (combination of DT0 and CD0)
End program
EN
For additional information about automatic array capture, see Chapter 7, Arrays.
Virtual Axis
The DMC-2x00 controller has an additional virtual axis designated as the N axis. This axis has no
encoder and no DAC. However, it can be commanded by the commands:
AC, DC, JG, SP, PR, PA, BG, IT, GA, VM, VP, CR, ST, DP, RP, EA.
The main use of the virtual axis is to serve as a virtual master in ECAM modes, and to perform an
unnecessary part of a vector mode. These applications are illustrated by the following examples.
Ecam master example
Suppose that the motion of the AB axes is constrained along a path that can be described by an
electronic cam table. Further assume that the ecam master is not an external encoder but has to be a
controlled variable.
This can be achieved by defining the N axis as the master with the command EAN and setting the
modulo of the master with a command such as EMN= 4000. Next, the table is constructed. To move
the constrained axes, simply command the N axis in the jog mode or with the PR and PA commands.
For example,
PAN = 2000
BGN
will cause the AB axes to move to the corresponding points on the motion cycle.
Sinusoidal Motion Example
The x axis must perform a sinusoidal motion of 10 cycles with an amplitude of 1000 counts and a
frequency of 20 Hz.
This can be performed by commanding the A and N axes to perform circular motion. Note that the
value of VS must be
VS = 2π * R * F
where R is the radius, (amplitude) and F is the frequency in Hz.
Set VA and VD to maximum values for the fastest acceleration.
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Instruction
VMAN
Interpretation
Select Axes
VA 68000000
VD 68000000
VS 125664
CR 1000, -90, 3600
VE
Maximum Acceleration
Maximum Deceleration
VS for 20 Hz
Ten Cycles
BGS
Stepper Motor Operation
When configured for stepper motor operation, several commands are interpreted differently than from
servo mode. The following describes operation with stepper motors.
Specifying Stepper Motor Operation
In order to command stepper motor operation, the appropriate stepper mode jumpers must be installed.
See chapter 2 for this installation.
Stepper motor operation is specified by the command MT. The argument for MT is as follows:
2
specifies a stepper motor with active low step output pulses
-2
specifies a stepper motor with active high step output pulses
2.5
-2.5
specifies a stepper motor with active low step output pulses and reversed direction
specifies a stepper motor with active high step output pulse and reversed direction
Stepper Motor Smoothing
The command, KS, provides stepper motor smoothing. The effect of the smoothing can be thought of
as a simple Resistor-Capacitor (single pole) filter. The filter occurs after the motion profiler and has
the effect of smoothing out the spacing of pulses for a more smooth operation of the stepper motor.
Use of KS is most applicable when operating in full step or half step operation. KS will cause the step
pulses to be delayed in accordance with the time constant specified.
When operating with stepper motors, you will always have some amount of stepper motor smoothing,
KS. Since this filtering effect occurs after the profiler, the profiler may be ready for additional moves
before all of the step pulses have gone through the filter. It is important to consider this effect since
steps may be lost if the controller is commanded to generate an additional move before the previous
move has been completed. See the discussion below, Monitoring Generated Pulses vs. Commanded
Pulses.
The general motion smoothing command, IT, can also be used. The purpose of the command, IT, is to
smooth out the motion profile and decrease 'jerk' due to acceleration.
Monitoring Generated Pulses vs. Commanded Pulses
For proper controller operation, it is necessary to make sure that the controller has completed
generating all step pulses before making additional moves. This is most particularly important if you
are moving back and forth. For example, when operating with servo motors, the trip point AM (After
Motion) is used to determine when the motion profiler is complete and is prepared to execute a new
motion command. However when operating in stepper mode, the controller may still be generating
step pulses when the motion profiler is complete. This is caused by the stepper motor smoothing filter,
KS. To understand this, consider the steps the controller executes to generate step pulses:
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First, the controller generates a motion profile in accordance with the motion commands.
Second, the profiler generates pulses as prescribed by the motion profile. The pulses that are generated
by the motion profiler can be monitored by the command, RP (Reference Position). RP gives the
absolute value of the position as determined by the motion profiler. The command, DP, can be used to
set the value of the reference position. For example, DP 0, defines the reference position of the A axis
to be zero.
Third, the output of the motion profiler is filtered by the stepper smoothing filter. This filter adds a
delay in the output of the stepper motor pulses. The amount of delay depends on the parameter which
is specified by the command, KS. As mentioned earlier, there will always be some amount of stepper
motor smoothing. The default value for KS is 1.313 which corresponds to a time constant of 3.939
sample periods.
Fourth, the output of the stepper smoothing filter is buffered and is available for input to the stepper
motor driver. The pulses which are generated by the smoothing filter can be monitored by the
command, TD (Tell Dual). TD gives the absolute value of the position as determined by actual output
of the buffer. The command, DP sets the value of the step count register as well as the value of the
reference position. For example, DP 0, defines the reference position of the A axis to be zero.
Stepper Smoothing Filter
(Adds a Delay)
Output
(To Stepper Driver)
Motion Profiler
Output Buffer
Reference Position (RP)
Step Count Register (TD)
Figure 6.8 - Velocity Profiles of ABC
Motion Complete Trip point
When used in stepper mode, the MC command will hold up execution of the proceeding commands
until the controller has generated the same number of steps out of the step count register as specified in
the commanded position. The MC trip point (Motion Complete) is generally more useful than AM trip
point (After Motion) since the step pulses can be delayed from the commanded position due to stepper
motor smoothing.
Using an Encoder with Stepper Motors
An encoder may be used on a stepper motor to check the actual motor position with the commanded
position. If an encoder is used, it must be connected to the main encoder input.
NOTE: The auxiliary encoder is not available while operating with stepper motors. The position of
the encoder can be interrogated by using the command, TP. The position value can be defined by
using the command, DE.
NOTE: Closed loop operation with a stepper motor is not possible without special firmware. Contact
Galil for more information.
Command Summary - Stepper Motor Operation
command
description
DE
DP
IT
Define Encoder Position (When using an encoder)
Define Reference Position and Step Count Register
Motion Profile Smoothing - Independent Time Constant
Stepper Motor Smoothing
KS
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MT
RP
TD
TP
Motor Type (2,-2,2.5 or -2.5 for stepper motors)
Report Commanded Position
Report number of step pulses generated by controller
Tell Position of Encoder
Operand Summary - Stepper Motor Operation
operand
_DEa
_DPa
Description
Contains the value of the step count register for the ‘a’ axis
Contains the value of the main encoder for the ‘a’ axis
Contains the value of the Independent Time constant for the 'a' axis
Contains the value of the Stepper Motor Smoothing Constant for the 'a' axis
Contains the motor type value for the 'a' axis
_ITa
_KSa
_MTa
_RPa
Contains the commanded position generated by the profiler for the ‘a’ axis
Contains the value of the step count register for the ‘a’ axis
Contains the value of the main encoder for the ‘a’ axis
_TDa
_TPa
Stepper Position Maintenance Mode (SPM)
The Galil controller can be set into the Stepper Position Maintenance (SPM) mode to handle the event
of stepper motor position error. The mode looks at position feedback from the main encoder and
compares it to the commanded step pulses. The position information is used to determine if there is
any significant difference between the commanded and the actual motor positions. If such error is
detected, it is updated into a command value for operator use. In addition, the SPM mode can be used
as a method to correct for friction at the end of a microstepping move. This capability provides closed-
loop control at the application program level. SPM mode can be used with Galil and non-Galil step
drives.
SPM mode is configured, executed, and managed with seven commands. This mode also utilizes the
#POSERR automatic subroutine allowing for automatic user-defined handling of an error event.
Internal Controller Commands (user can query):
QS
Error Magnitude (pulses)
User Configurable Commands (user can query & change):
OE
YA
YB
YC
YR
YS
Profiler Off-On Error
Step Drive Resolution (pulses / full motor step)
Step Motor Resolution (full motor steps / revolution)
Encoder Resolution (counts / revolution)
Error Correction (pulses)
Stepper Position Maintenance enable, status
A pulse is defined by the resolution of the step drive being used. Therefore, one pulse could be a full
step, a half step or a microstep.
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When a Galil controller is configured for step motor operation, the step pulse output by the controller
is internally fed back to the auxiliary encoder register. For SPM the feedback encoder on the stepper
will connect to the main encoder port. Enabling the SPM mode on a controller with YS=1 executes an
internal monitoring of the auxiliary and main encoder registers for that axis or axes. Position error is
then tracked in step pulses between these two registers (QS command).
TP × YA × YB
QS = TD −
YC
Where TD is the auxiliary encoder register(step pulses) and TP is the main encoder register(feedback
encoder). Additionally, YA defines the step drive resolution where YA = 1 for full stepping or YA = 2
for half stepping. The full range of YA is up to YA = 9999 for microstepping drives.
Error Limit
The value of QS is internally monitored to determine if it exceeds a preset limit of three full motor
steps. Once the value of QS exceeds this limit, the controller then performs the following actions:
1. The motion is maintained or is stopped, depending on the setting of the OE command. If OE=0
the axis stays in motion, if OE=1 the axis is stopped.
2. YS is set to 2, which causes the automatic subroutine labeled #POSERR to be executed.
Correction
A correction move can be commanded by assigning the value of QS to the YR correction move
command. The correction move is issued only after the axis has been stopped. After an error
correction move has completed and QS is less than three full motor steps, the YS error status bit is
automatically reset back to 1; indicating a cleared error.
Example: SPM Mode Setup
The following code demonstrates what is necessary to set up SPM mode for a full step drive, a half
step drive, and a 1/64th microstepping drive for an axis with a 1.8o step motor and 4000 count/rev
encoder. Note the necessary difference is with the YA command.
Full-Stepping Drive, X axis:
#SETUP
OE1;
Set the profiler to stop axis upon error
Set step smoothing
KS16;
MT-2;
YA1;
Motor type set to stepper
Step resolution of the full-step drive
Motor resolution (full steps per revolution)
Encoder resolution (counts per revolution)
Enable axis
YB200;
YC4000;
SHX;
WT50;
YS1;
Allow slight settle time
Enable SPM mode
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Half-Stepping Drive, X axis:
#SETUP
OE1;
Set the profiler to stop axis upon error
Set step smoothing
KS16;
MT-2;
YA2;
Motor type set to stepper
Step resolution of the half-step drive
Motor resolution (full steps per revolution)
Encoder resolution (counts per revolution)
Enable axis
YB200;
YC4000;
SHX;
WT50;
YS1;
Allow slight settle time
Enable SPM mode
1/64th Step Microstepping Drive, X axis:
#SETUP
OE1;
Set the profiler to stop axis upon error
KS16;
MT-2;
YA64;
YB200;
YC4000;
SHX;
Set step smoothing
Motor type set to stepper
Step resolution of the microstepping drive
Motor resolution (full steps per revolution)
Encoder resolution (counts per revolution)
Enable axis
WT50;
YS1;
Allow slight settle time
Enable SPM mode
Example: Error Correction
The following code demonstrates what is necessary to set up SPM mode for the X axis, detect error,
stop the motor, correct the error, and return to the main code. The drive is a full step drive, with a 1.8o
step motor and 4000 count/rev encoder.
#SETUP
OE1;
Set the profiler to stop axis upon error
Set step smoothing
KS16;
MT-2,-2,-2,-2;
YA2;
Motor type set to stepper
Step resolution of the drive
Motor resolution (full steps per revolution)
Encoder resolution (counts per revolution)
Enable axis
YB200;
YC4000;
SHX;
WT100;
Allow slight settle time
Perform motion
#MOTION
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SP512;
Set the speed
PR1000;
Prepare mode of motion
Begin motion
BGX;
#LOOP;JP#LOOP;
Keep thread zero alive for #POSERR to run in
REM When error occurs, the axis will stop due to OE1. In REM #POSERR, query
the status YS and the error QS, correct, REM and return to the main code.
Automatic subroutine is called when YS=2
#POSERR;
WT100;
Wait helps user see the correction
Save current speed setting
spsave=_SPX;
JP#RETURN,_YSX<>2;
SP64;
Return to thread zero if invalid error
Set slow speed setting for correction
MG”ERROR= “,_QSX
YRX=_QSX;
MCX;
Else, error is valid, use QS for correction
Wait for motion to complete
MG”CORRECTED, ERROR NOW= “,_QSX
WT100;
Wait helps user see the correction
#RETURN
SPX=spsave;
REO;
Return the speed to previous setting
Return from #POSERR
Example: Friction Correction
The following example illustrates how the SPM mode can be useful in correcting for X axis friction
after each move when conducting a reciprocating motion. The drive is a 1/64th microstepping drive
with a 1.8o step motor and 4000 count/rev encoder.
Set the profiler to continue upon error
#SETUP;
KS16;
Set step smoothing
MT-2,-2,-2,-2;
YA64;
Motor type set to stepper
Step resolution of the microstepping drive
Motor resolution (full steps per revolution)
Encoder resolution (counts per revolution)
Enable axis
YB200;
YC4000;
SHX;
WT50;
Allow slight settle time
YS1;
Enable SPM mode
Perform motion
#MOTION;
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SP16384;
PR10000;
BGX;
Set the speed
Prepare mode of motion
Begin motion
MCX
JS#CORRECT;
#MOTION2
SP16384;
PR-10000;
BGX;
Move to correction
Set the speed
Prepare mode of motion
Begin motion
MCX
JS#CORRECT;
JP#MOTION
#CORRECT;
spx=_SPX
#LOOP;
Move to correction
Correction code
Save speed value
SP2048;
Set a new slow correction speed
Stabilize
WT100;
JP#END,@ABS[_QSX]<10; End correction if error is within defined tolerance
YRX=_QSX;
MCX
Correction move
WT100;
JP#LOOP;
#END;
Stabilize
Keep correcting until error is within tolerance
End #CORRECT subroutine, returning to code
SPX=spx
EN
Dual Loop (Auxiliary Encoder)
The DMC-2x00 provides an interface for a second encoder for each axis except for axes configured for
stepper motor operation and any axis used in circular compare. When used, the second encoder is
typically mounted on the motor or the load, but may be mounted in any position. The most common
use for the second encoder is backlash compensation, described below.
The second encoder may be a standard quadrature type, or it may provide pulse and direction. The
controller also offers the provision for inverting the direction of the encoder rotation. The main and
the auxiliary encoders are configured with the CE command. The command form is CE a,b,c,d (or
a,b,c,d,e,f,g,h for controllers with more than 4 axes) where the parameters a,b,c,d each equal the sum
of two integers m and n. m configures the main encoder and n configures the auxiliary encoder.
NOTE: This operation is not available for axes configured for stepper motors.
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Using the CE Command
m= Main Encoder
n=
Second Encoder
0
1
2
3
Normal quadrature
Pulse & direction
0
Normal quadrature
4
Pulse & direction
Reverse quadrature
Reverse pulse & direction
8
Reversed quadrature
Reversed pulse & direction
12
For example, to configure the main encoder for reversed quadrature, m=2, and a second encoder of
pulse and direction, n=4, the total is 6, and the command for the A axis is
CE 6
Additional Commands for the Auxiliary Encoder
The command, DE a,b,c,d can be used to define the position of the auxiliary encoders. For example,
DE 0,500,-30,300
sets their initial values.
The positions of the auxiliary encoders may be interrogated with the command, DE?. For example
DE ?,,?
returns the value of the A and C auxiliary encoders.
The auxiliary encoder position may be assigned to variables with the instructions
V1= _DEA
The command, TD a,b,c,d, returns the current position of the auxiliary encoder.
The command, DV a,b,c,d, configures the auxiliary encoder to be used for backlash compensation.
Backlash Compensation
There are two methods for backlash compensation using the auxiliary encoders:
1. Continuous dual loop
2. Sampled dual loop
To illustrate the problem, consider a situation in which the coupling between the motor and the load
has a backlash. To compensate for the backlash, position encoders are mounted on both the motor and
the load.
The continuous dual loop combines the two feedback signals to achieve stability. This method
requires careful system tuning, and depends on the magnitude of the backlash. However, once
successful, this method compensates for the backlash continuously.
The second method, the sampled dual loop, reads the load encoder only at the end point and performs a
correction. This method is independent of the size of the backlash. However, it is effective only in
point-to-point motion systems which require position accuracy only at the endpoint.
Example
Continuous Dual Loop
The motor (aux) encoder needs a finer resolution than load (main) encoder. Connect the load encoder
to the main encoder port and connect the motor encoder to the dual encoder port. The dual loop
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method splits the filter function between the two encoders. It applies the KP (proportional) and KI
(integral) terms to the position error, based on the load encoder, and applies the KD (derivative) term
to the motor encoder. This method results in a stable system.
The dual loop method is activated with the instruction DV (Dual Velocity), where
DV
activates the dual loop for the four axes and
DV 0,0,0,0
1,1,1,1
disables the dual loop.
Note that the dual loop compensation depends on the backlash magnitude, and in extreme cases will
not stabilize the loop. The proposed compensation procedure is to start with KP=0, KI=0 and to
maximize the value of KD under the condition DV1. Once KD is found, increase KP gradually to a
maximum value, and finally, increase KI, if necessary.
Sampled Dual Loop
In this example, we consider a linear slide which is run by a rotary motor via a lead screw. Since the
lead screw has a backlash, it is necessary to use a linear encoder to monitor the position of the slide.
For stability reasons, it is best to use a rotary encoder on the motor.
Connect the rotary encoder to the A-axis and connect the linear encoder to the auxiliary encoder of A.
Assume that the required motion distance is one inch, and that this corresponds to 40,000 counts of the
rotary encoder and 10,000 counts of the linear encoder.
The design approach is to drive the motor a distance, which corresponds to 40,000 rotary counts. Once
the motion is complete, the controller monitors the position of the linear encoder and performs position
corrections.
This is done by the following program.
Instruction
#DUALOOP
CE 0
Interpretation
Label
Configure encoder
Set initial value
Main move
DE0
PR 40000
BGA
Start motion
#CORRECT
AMA
Correction loop
Wait for motion completion
Find linear encoder error
Compensate for motor error
Exit if error is small
Correction move
Start correction
Repeat
v1=10000-_DEA
v2=-_TEA/4+v1
JP#END,@ABS[v2]<2
PR v2*4
BGA
JP#CORRECT
#END
EN
Motion Smoothing
The DMC-2x00 controller allows the smoothing of the velocity profile to reduce the mechanical
vibration of the system.
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Trapezoidal velocity profiles have acceleration rates which change abruptly from zero to maximum
value. The discontinuous acceleration results in jerk which causes vibration. The smoothing of the
acceleration profile leads to a continuous acceleration profile and reduces the mechanical shock and
vibration.
Using the IT and VT Commands:
When operating with servo motors, motion smoothing can be accomplished with the IT and VT
command. These commands filter the acceleration and deceleration functions to produce a smooth
velocity profile. The resulting velocity profile has continuous acceleration and results in reduced
mechanical vibrations.
The smoothing function is specified by the following commands:
IT a,b,c,d
Independent time constant
VT n
Vector time constant
The command, IT, is used for smoothing independent moves of the type JG, PR, PA and the command,
VT, is used to smooth vector moves of the type VM and LM.
The smoothing parameters, a,b,c,d and n are numbers between 0 and 1 and determine the degree of
filtering. The maximum value of 1 implies no filtering, resulting in trapezoidal velocity profiles.
Smaller values of the smoothing parameters imply heavier filtering and smoother moves.
The following example illustrates the effect of smoothing. Fig. 6.9 shows the trapezoidal velocity
profile and the modified acceleration and velocity.
Note that the smoothing process results in longer motion time.
Example
Instruction
PR 20000
AC 100000
DC 100000
SP 5000
Interpretation
Position
Acceleration
Deceleration
Speed
IT .5
Filter for smoothing
Begin
BG A
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ACCELERATION
TIME
TIME
TIME
TIME
VELOCITY
ACCELERATION WITH
SMOOTHING
VELOCITY WITH
SMOOTHING
Figure 6.9 - Trapezoidal velocity and smooth velocity profiles
Using the KS Command (Step Motor Smoothing):
When operating with step motors, motion smoothing can be accomplished with the command, KS.
The KS command smoothes the frequency of step motor pulses. Similar to the commands, IT and VT,
this produces a smooth velocity profile.
The step motor smoothing is specified by the following command:
KS a,b,c,d
where a,b,c,d is an integer from 0.5 to 8 and represents the
amount of smoothing
The command, IT, is used for smoothing independent moves of the type JG, PR, PA and the command,
VT, is used to smooth vector moves of the type VM and LM.
The smoothing parameters, a,b,c,d and n are numbers between 0.5 and 8 and determine the degree of
filtering. The minimum value of 0.5 implies no filtering, resulting in trapezoidal velocity profiles.
Larger values of the smoothing parameters imply heavier filtering and smoother moves.
Note that KS is valid only for step motors.
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Homing
The Find Edge (FE) and Home (HM) instructions may be used to home the motor to a mechanical
reference. This reference is connected to the Home input line. The HM command initializes the motor
to the encoder index pulse in addition to the Home input. The configure command (CN) is used to
define the polarity of the home input.
The Find Edge (FE) instruction is useful for initializing the motor to a home switch. The home switch
is connected to the Homing Input. When the Find Edge command and Begin is used, the motor will
accelerate up to the slew speed and slew until a transition is detected on the Homing line. The motor
will then decelerate to a stop. A high deceleration value must be input before the find edge command
is issued for the motor to decelerate rapidly after sensing the home switch. The velocity profile
generated is shown in Fig. 6.10.
The Home (HM) command can be used to position the motor on the index pulse after the home switch
is detected. This allows for finer positioning on initialization. The command sequence HM and BG
causes the following sequence of events to occur.
1. Upon begin, motor accelerates to the slew speed. The direction of its motion is determined by
the state of the homing input. A zero (GND) will cause the motor to start in the forward
direction; +5V will cause it to start in the reverse direction. The CN command is used to
define the polarity of the home input.
2. Upon detecting the home switch changing state, the motor begins decelerating to a stop.
3. The motor then traverses very slowly back until the home switch toggles again.
4. The motor then traverses forward until the encoder index pulse is detected.
5. The DMC-2x00 defines the home position (0) as the position at which the index was detected.
Example
Instruction
#HOME
AC 1000000
DC 1000000
SP 5000
Interpretation
Label
Acceleration Rate
Deceleration Rate
Speed for Home Search
Home A
HM A
BG A
Begin Motion
After Complete
Send Message
End
AM A
MG "AT HOME"
EN
#EDGE
Label
AC 2000000
DC 2000000
SP 8000
Acceleration rate
Deceleration rate
Speed
FE B
Find edge command
Begin motion
After complete
Send message
Define position as 0
End
BG B
AM B
MG "FOUND HOME"
DP,0
EN
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HOMESENSOR
_HMA=1
_HMX=0
POSITION
HOME SWITCH
VELOCITY
MOTION BEGINS
TOWARD HOME
DIRECTION
(1)
POSITION
POSITION
VELOCITY
MOTION REVERSE
TOWARD HOME
DIRECTION
(2)
VELOCITY
MOTION TOWARD
INDEX
(3)
DIRECTION
POSITION
INDEX PULSES
POSITION
Figure 6.10 - Motion intervals in the Home sequence
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Command Summary - Homing Operation
command
FE ABCD
FI ABCD
Description
Find Edge Routine. This routine monitors the Home Input
Find Index Routine - This routine monitors the Index Input
Home Routine - This routine combines FE and FI as Described Above
Stop Code
HM ABCD
SC ABCD
TS ABCD
Tell Status of Switches and Inputs
Operand Summary - Homing Operation
Operand
Description
_HMa
Contains the value of the state of the Home Input
Contains stop code
_SCa
_TSa
Contains status of switches and inputs
High Speed Position Capture (The Latch Function)
Often it is desirable to capture the position precisely for registration applications. The DMC-2x00
provides a position latch feature. This feature allows the position of the main or auxiliary encoders of
A,B,C or D to be captured when the latch input changes state. This function can be setup such that the
position is captured when the latch input goes high or low. When the latch function is enabled for
active low operation, the position will be captured within 12 microseconds. When the latch function is
enabled for active high operation, the position will be captured within 35 microseconds. Each axis has
one general input associated to the axis for position capture:
Input
IN1
Function
Input
IN9
Function
A Axis Latch
B Axis Latch
C Axis Latch
D Axis Latch
E Axis Latch
F Axis Latch
G Axis Latch
H Axis Latch
IN2
IN10
IN11
IN12
IN3
IN4
The DMC-2x00 software commands, AL and RL, are used to arm the latch and report the latched
position. The steps to use the latch are as follows:
1. Give the AL ABCD command to arm the latch for the main encoder and ALSASBSCSD for
the auxiliary encoders.
2. Test to see if the latch has occurred (Input goes low) by using the _AL A or B or C or D
command. Example, V1=_ALA returns the state of the A latch into V1. V1 is 1 if the latch
has not occurred.
3. After the latch has occurred, read the captured position with the RL ABCD command or _RL
ABCD.
NOTE: The latch must be re-armed after each latching event.
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Example
Instruction
Interpretation
#LATCH
JG,5000
BG B
Latch program
Jog B
Begin motion on B axis
Arm Latch for B axis
AL B
#WAIT
#Wait label for loop
JP #WAIT,_ALB=1
Result=_RLB
Result=
Jump to #Wait label if latch has not occurred
Set ‘Result’ equal to the reported position of y axis
Print result
EN
End
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Chapter 7 Application Programming
Overview
The DMC-2x00 provides a powerful programming language that allows users to customize the
controller for their particular application. Programs can be downloaded into the DMC-2x00 memory
freeing the host computer for other tasks. However, the host computer can send commands to the
controller at any time, even while a program is being executed. Only ASCII commands can be used
for application programming.
In addition to standard motion commands, the DMC-2x00 provides commands that allow the DMC-
2x00 to make its own decisions. These commands include conditional jumps, event triggers and
subroutines. For example, the command JP#LOOP, n<10 causes a jump to the label #LOOP if the
variable n is less than 10.
For greater programming flexibility, the DMC-2x00 provides user-defined variables, arrays and
arithmetic functions. For example, with a cut-to-length operation, the length can be specified as a
variable in a program which the operator can change as necessary.
The following sections in this chapter discuss all aspects of creating applications programs. The
program memory size is 80 characters x 1000 lines.
Using the DOS Editor to Enter Programs (DMC-2000
only)
The DMC-2000 has an internal editor which may be used to create and edit programs in the controller's
memory. The internal editor is opened by the command ED. Note that the command ED will not open
the internal editor if issued from Galil's Window based software - in this case, a Windows based editor
will be automatically opened. The Windows based editor provides much more functionality and ease-
of-use, therefore, the internal editor is most useful when using a simple terminal with the controller and
a Windows based editor is not available.
Once the ED command has been given, each program line is automatically numbered sequentially
starting with 000. If no parameter follows the ED command, the editor prompter will default to the last
line of the last program in memory. If desired, the user can edit a specific line number or label by
specifying a line number or label following ED.
NOTE: ED command only accepts a parameter (such as #BEGIN) in DOS Window. For general
purposes, the editing features in this section are not applicable when not in DOS mode.
Instruction
Interpretation
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:ED
Puts Editor at end of last program
Puts Editor at line 5
:ED 5
:ED #BEGIN
Puts Editor at label #BEGIN
Line numbers appear as 000,001,002 and so on. Program commands are entered following the line
numbers. Multiple commands may be given on a single line as long as the total number of characters
doesn't exceed 80 characters per line.
While in the Edit Mode, the programmer has access to special instructions for saving, inserting and
deleting program lines. These special instructions are listed below:
Edit Mode Commands
<RETURN>
Typing the return key causes the current line of entered instructions to be saved. The editor will
automatically advance to the next line. Thus, hitting a series of <RETURN> will cause the editor to
advance a series of lines. Note, changes on a program line will not be saved unless a <return> is given.
<cntrl>P
The <cntrl>P command moves the editor to the previous line.
<cntrl>I
The <cntrl>I command inserts a line above the current line. For example, if the editor is at line
number 2 and <cntrl>I is applied, a new line will be inserted between lines 1 and 2. This new line will
be labeled line 2. The old line number 2 is renumbered as line 3.
<cntrl>D
The <cntrl>D command deletes the line currently being edited. For example, if the editor is at line
number 2 and <cntrl>D is applied, line 2 will be deleted. The previous line number 3 is now
renumbered as line number 2.
<cntrl>Q
The <cntrl>Q quits the editor mode. In response, the DMC-2000 will return a colon.
After the Edit session is over, the user may list the entered program using the LS command. If no
operand follows the LS command, the entire program will be listed. The user can start listing at a
specific line or label using the operand n. A command and new line number or label following the
start listing operand specifies the location at which listing is to stop.
Example
Instruction
:LS
Interpretation
List entire program
:LS 5
Begin listing at line 5
:LS 5,9
List lines 5 thru 9
:LS #A,9
:LS #A, #A +5
List line label #A thru line 9
List line label #A and additional 5 lines
NOTE: Editor is not available for DMC-2100, however, any terminal may be used (i.e. Telnet)
DMC-2X00
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Program Format
A DMC program consists of DMC-2x00 instructions combined to solve a machine control application.
Action instructions, such as starting and stopping motion, are combined with Program Flow
instructions to form the complete program. Program Flow instructions evaluate real-time conditions,
such as elapsed time or motion complete, and alter program flow accordingly.
Each DMC-2x00 instruction in a program must be separated by a delimiter. Valid delimiters are the
semicolon (;) or carriage return. The semicolon is used to separate multiple instructions on a single
program line where the maximum number of instructions on a line is limited by 80 characters. A
carriage return enters the final command on a program line.
Using Labels in Programs
All DMC-2x00 programs must begin with a label and end with an End (EN) statement. Labels start
with the pound (#) sign followed by a maximum of seven characters. The first character must be a
letter; after that, numbers are permitted. Spaces are not permitted.
The maximum number of labels which may be defined is 510, for firmware 1.0c and higher.
Valid labels
#BEGIN
#SQUARE
#X1
#BEGIN1
Invalid labels
#1Square
#123
Example
Instruction
#START
PR 10000,20000
BG AB
Interpretation
Beginning of the Program
Specify relative distances on A and B axes
Begin Motion
AM
Wait for motion complete
Wait 2 sec
WT 2000
JP #START
EN
Jump to label START
End of Program
The above program moves A and B 10000 and 20000 units. After the motion is complete, the motors
rest for 2 seconds. The cycle repeats indefinitely until the stop command is issued.
Special Labels
The DMC-2x00 has some special labels, which are used to define input interrupt subroutines, limit
switch subroutines, error handling subroutines, and command error subroutines. See section on Auto-
Start Routine
The DMC-2x00 has a special label for automatic program execution. A program which has been saved
into the controller’s non-volatile memory can be automatically executed upon power up or reset by
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beginning the program with the label #AUTO. The program must be saved into non-volatile memory
using the command, BP.
Automatic Subroutines for Monitoring Conditions on page 91.
#ININT
Label for Input Interrupt subroutine
#LIMSWI
#POSERR
#MCTIME
#CMDERR
#COMINT
#TCPERR
Label for Limit Switch subroutine
Label for excess Position Error subroutine
Label for timeout on Motion Complete trip point
Label for incorrect command subroutine
Label for communication interrupt on the aux. serial port
Label for TCP/IP communication error (2100 and 2200 only)
Commenting Programs
There are two methods for commenting programs. The first method uses the NO command and allows
for comments to be embedded into Galil programs. The second method used the REM statement and
requires the use of Galil software.
NO Command
The DMC-2x00 provides a command, NO, for commenting programs. This command allows the user
to include up to 78 characters on a single line after the NO command and can be used to include
comments from the programmer as in the following example:
Instruction
Interpretation
Label
#PATH
NO 2-D CIRCULAR PATH
VMAB
Comment - No Operation
Vector Mode
NO VECTOR MOTION ON A AND B
VS 10000
Comment - No Operation
Vector Speed
NO VECTOR SPEED IS 10000
VP -4000,0
Comment - No Operation
Vector Position
NO BOTTOM LINE
CR 1500,270,-180
NO HALF CIRCLE MOTION
VP 0,3000
Comment - No Operation
Circle Motion
Comment - No Operation
Vector Position
NO TOP LINE
Comment - No Operation
Circle
CR 1500,90,-180
NO HALF CIRCLE MOTION
VE
Comment - No Operation
Vector End
NO END VECTOR SEQUENCE
BGS
Comment - No Operation
Begin Sequence
NO BEGIN SEQUENCE MOTION
EN
Comment - No Operation
End of Program
NO END OF PROGRAM
Comment - No Operation
NOTE: The NO command is an actual controller command. Therefore, inclusion of the NO
commands will require process time by the controller.
HINT: Some users annotate their programs using the word “NOTE:”; everything after the “NO” is a
comment.
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REM Command
If you are using Galil software to communicate with the DMC-2x00 controller, you may also include
REM statements. ‘REM’ statements begin with the word ‘REM’ and may be followed by any
comments which are on the same line. The Galil terminal software will remove these statements when
the program is downloaded to the controller. For example:
#PATH
REM 2-D CIRCULAR PATH
VMAB
REM VECTOR MOTION ON A AND B
VS 10000
REM VECTOR SPEED IS 10000
VP -4000,0
REM BOTTOM LINE
CR 1500,270,-180
REM HALF CIRCLE MOTION
VP 0,3000
REM TOP LINE
CR 1500,90,-180
REM HALF CIRCLE MOTION
VE
REM END VECTOR SEQUENCE
BGS
REM BEGIN SEQUENCE MOTION
EN
REM END OF PROGRAM
These REM statements will be removed when this program is downloaded to the controller.
Executing Programs - Multitasking
The DMC-2x00 can run up to 8 independent programs simultaneously. These programs are called
threads and are numbered 0 through 7, where 0 is the main thread. Multitasking is useful for executing
independent operations such as PLC functions that occur independently of motion.
The main thread differs from the others in the following ways:
1. Only the main thread, thread 0, may use the input command, IN.
2. When automatic subroutines are implemented for limit switches, position errors or command errors,
they are executed in thread 0.
To begin execution of the various programs, use the following instruction:
XQ #A, n
Where n indicates the thread number. To halt the execution of any thread, use the instruction
HX n
where n is the thread number.
Note that both the XQ and HX commands can be performed by an executing program.
The example below produces a waveform on Output 1 independent of a move.
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Instruction
#TASK1
AT0
Interpretation
Task1 label
Initialize reference time
Clear Output 1
CB1
#LOOP1
AT 10
Loop1 label
Wait 10 msec from reference time
Set Output 1
SB1
AT -40
Wait 40 msec from reference, then initialize reference
Clear Output 1
CB1
JP #LOOP1
#TASK2
XQ #TASK1,1
#LOOP2
PR 1000
BGX
Repeat Loop1
Task2 label
Execute Task1
Loop2 label
Define relative distance
Begin motion
AMX
After motion done
Wait 10 msec
WT 10
JP #LOOP2,@IN[2]=1
HX
Repeat motion unless Input 2 is low
Halt all tasks
The program above is executed with the instruction XQ #TASK2,0 which designates TASK2 as the
main thread (i.e. Thread 0). #TASK1 is executed within TASK2.
Debugging Programs
The DMC-2x00 provides commands and operands which are useful in debugging application
programs. These commands include interrogation commands to monitor program execution,
determine the state of the controller and the contents of the controllers program, array, and variable
space. Operands also contain important status information which can help to debug a program.
Trace Commands ( DMC-2100/2200 only)
The trace command causes the controller to send each line in a program to the host computer
immediately prior to execution. Tracing is enabled with the command, TR1. TR0 turns the trace
function off.
NOTE: When the trace function is enabled, the line numbers as well as the command line will be
displayed as each command line is executed.
Data which is output from the controller is stored in the output UART. The UART buffer can store up
to 128 characters of information. In normal operation, the controller places output into the FIFO
buffer. When the trace mode is enabled, the controller will send information to the UART buffer at a
very high rate. In general, the UART will become full because the hardware handshake line will halt
serial data until the correct data is read. When the UART becomes full, program execution will be
delayed until it is cleared. If the user wants to avoid this delay, the command CW,1 can be given.
This command causes the controller to throw away the data which can not be placed into the FIFO. In
this case, the controller does not delay program execution.
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Error Code Command
When there is a program error, the DMC-2x00 halts the program execution at the point where the error
occurs. To display the last line number of program execution, issue the command, MG _ED.
The user can obtain information about the type of error condition that occurred by using the command,
TC1. This command reports back a number and a text message which describes the error condition.
The command, TC0 or TC, will return the error code without the text message. For more information
about the command, TC, see the Command Reference.
Stop Code Command
The status of motion for each axis can be determined by using the stop code command, SC. This can
be useful when motion on an axis has stopped unexpectedly. The command SC will return a number
representing the motion status. See the command reference for further information.
RAM Memory Interrogation Commands
For debugging the status of the program memory, array memory, or variable memory, the DMC-2x00
has several useful commands. The command, DM ?, will return the number of array elements
currently available. The command, DA ?, will return the number of arrays which can be currently
defined. For example, a standard DMC-2x10 will have a maximum of 8000 array elements in up to 30
arrays. If an array of 100 elements is defined, the command DM ? will return the value 7900 and the
command DA ? will return 29.
To list the contents of the variable space, use the interrogation command LV (List Variables). To list
the contents of array space, use the interrogation command, LA (List Arrays). To list the contents of
the Program space, use the interrogation command, LS (List). To list the application program labels
only, use the interrogation command, LL (List Labels).
Operands
In general, all operands provide information which may be useful in debugging an application
program. Below is a list of operands which are particularly valuable for program debugging. To
display the value of an operand, the message command may be used. For example, since the operand,
_ED contains the last line of program execution, the command MG _ED will display this line number.
_ED contains the last line of program execution. Useful to determine where program stopped.
_DL contains the number of available labels.
_UL contains the number of available variables.
_DA contains the number of available arrays.
_DM contains the number of available array elements.
_AB contains the state of the Abort Input
_LFa contains the state of the forward limit switch for the 'a' axis
_LRa contains the state of the reverse limit switch for the 'a' axis
Example
The following program has an error. It attempts to specify a relative movement while the A-axis is
already in motion. When the program is executed, the controller stops at line 003. The user can then
query the controller using the command, TC1. The controller responds with the corresponding
explanation:
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Instruction
Interpretation
Edit Mode
:ED
000 #A
Program Label
Position Relative 1000
Begin
001 PR1000
002 BGA
003 PR5000
Position Relative 5000
End
004 EN
<cntrl> Q
Quit Edit Mode
Execute #A
:XQ #A
?003 PR5000
Error on Line 3
Tell Error Code
Command not valid while running
Edit Line 3
:TC1
?7 Command not valid while running.
:ED 3
003 AMX;PR5000;BGA
<cntrl> Q
Add After Motion Done
Quit Edit Mode
Execute #A
:XQ #A
Program Flow Commands
The DMC-2x00 provides instructions to control program flow. The DMC-2x00 program sequencer
normally executes program instructions sequentially. The program flow can be altered with the use of
event triggers, trippoints, and conditional jump statements.
Event Triggers & Trippoints
To function independently from the host computer, the DMC-2x00 can be programmed to make
decisions based on the occurrence of an event. Such events include waiting for motion to be complete,
waiting for a specified amount of time to elapse, or waiting for an input to change logic levels.
The DMC-2x00 provides several event triggers that cause the program sequencer to halt until the
specified event occurs. Normally, a program is automatically executed sequentially one line at a time.
When an event trigger instruction is decoded, however, the actual program sequence is halted. The
program sequence does not continue until the event trigger is "tripped". For example, the motion
complete trigger can be used to separate two move sequences in a program. The commands for the
second move sequence will not be executed until the motion is complete on the first motion sequence.
In this way, the DMC-2x00 can make decisions based on its own status or external events without
intervention from a host computer.
NOTE: It is not recommended to send trip point commands (e.g. AM) from the PC to a DMC-
2100/2200. The buffer becomes filled easily when using event triggers which would halt
communications between the host and the controller.
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DMC-2x00 Event Triggers
Command
Function
AM A B C D E FG H or S
Halts program execution until motion is complete on
the specified axes or motion sequence(s). AM with no
parameter tests for motion complete on all axes. This
command is useful for separating motion sequences in
a program.
AD A or B or C or D or E or F or G or H
AR A or B or C or D or E or F or G or H
Halts program execution until position command has
reached the specified relative distance from the start of
the move. Only one axis may be specified at a time.
Halts program execution until after specified distance
from the last AR or AD command has elapsed. Only
one axis may be specified at a time.
AP A or B or C or D or E or F or G or H
MF A or B or C or D or E or F or G or H
Halts program execution until after absolute position
occurs. Only one axis may be specified at a time.
Halt program execution until after forward motion
reached absolute position. Only one axis may be
specified. If position is already past the point, then
MF will trip immediately. Will function on geared
axis or aux. inputs.
MR A or B or C or D or E or F or G or H
MC A or B or C or D or E or F or G or H
Halt program execution until after reverse motion
reached absolute position. Only one axis may be
specified. If position is already past the point, then
MR will trip immediately. Will function on geared
axis or aux. inputs.
Halt program execution until after the motion profile
has been completed and the encoder has entered or
passed the specified position. TW A,B,C,D sets
timeout to declare an error if not in position. If
timeout occurs, then the trip point will clear and the
stop code will be set to 99. An application program
will jump to label #MCTIME.
AI +/- n
Halts program execution until after specified input is
at specified logic level. n specifies input line.
Positive is high logic level, negative is low level. n=1
through 8 for DMC-2x10, 2x20, 2x30, 2x40. n=1
through 16 for DMC-2x50, 2x60, 2x70, 2x80. n=17
through 80 for DMC-2xx0.
AS A B C D E F G H
AT +/-n
Halts program execution until specified axis has
reached its slew speed.
Halts program execution until n msec from reference
time. AT 0 sets reference. AT n waits n msec from
reference. AT -n waits n msec from reference and sets
new reference after elapsed time.
AV n
WT n
Halts program execution until specified distance along
a coordinated path has occurred.
Halts program execution until specified time in msec
has elapsed.
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Example- Multiple Move Sequence
The AM trip point is used to separate the two PR moves. If AM is not used, the controller returns a ?
for the second PR command because a new PR cannot be given until motion is complete.
Instruction
#TWOMOVE
PR 2000
BGA
Interpretation
Label
Position Command
Begin Motion
AMA
Wait for Motion Complete
Next Position Move
Begin 2nd move
End program
PR 4000
BGA
EN
Example- Set Output after Distance
Set output bit 1 after a distance of 1000 counts from the start of the move. The accuracy of the trip
point is the speed multiplied by the sample period.
Instruction
#SETBIT
SP 10000
PA 20000
BGA
Interpretation
Label
Speed is 10000
Specify Absolute position
Begin motion
AD 1000
SB1
Wait until 1000 counts
Set output bit 1
End program
EN
Example- Repetitive Position Trigger
To set the output bit every 10000 counts during a move, the AR is used as shown in the next example.
Instruction
#TRIP
Interpretation
Label
JG 50000
BGA;n=0
#REPEAT
AR 10000
TPA
Specify Jog Speed
Begin Motion
# Repeat Loop
Wait 10000 counts
Tell Position
Set output 1
Wait 50 msec
Clear output 1
Increment counter
Repeat 5 times
Stop
SB1
WT50
CB1
n=n+1
JP #REPEAT,n<5
STA
EN
End
Example - Start Motion on Input
This example waits for input 1 to go low and then starts motion.
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NOTE: The AI command actually halts execution of the program until the input occurs. If you do not
want to halt the program sequences, you can use the Input Interrupt function (II) or use a conditional
jump on an input, such as JP #GO,@IN[1] =1.
Instruction
#INPUT
AI-1
Interpretation
Program Label
Wait for input 1 low
Position command
Begin motion
PR 10000
BGA
EN
End program
Example - Set Output when At Speed
Instruction
#ATSPEED
JG 50000
AC 10000
BGA
Interpretation
Program Label
Specify jog speed
Acceleration rate
Begin motion
ASA
Wait for at slew speed 50000
Set output 1
SB1
EN
End program
Example - Change Speed along Vector Path
The following program changes the or vector speed at the specified distance along the vector. The
vector distance is measured from the start of the move or from the last AV command.
Instruction
#VECTOR
VMAB;VS 5000
VP 10000,20000
VP 20000,30000
VE
Interpretation
Label
Coordinated path
Vector position
Vector position
End vector
BGS
Begin sequence
After vector distance
Reduce speed
End
AV 5000
VS 1000
EN
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Example - Multiple Move with Wait
This example makes multiple relative distance moves by waiting for each to be complete before
executing new moves.
Instruction
#MOVES
PR 12000
SP 20000
AC 100000
BGA
Interpretation
Label
Distance
Speed
Acceleration
Start Motion
AD 10000
SP 5000
AMA
Wait a distance of 10,000 counts
New Speed
Wait until motion is completed
Wait 200 ms
WT 200
PR -10000
SP 30000
AC 150000
BGA
New Position
New Speed
New Acceleration
Start Motion
EN
End
Example- Define Output Waveform Using AT
The following program causes Output 1 to be high for 10 msec and low for 40 msec. The cycle repeats
every 50 msec.
Instruction
#OUTPUT
AT0
Interpretation
Program label
Initialize time reference
SB1
Set Output 1
#LOOP
AT 10
Loop
After 10 msec from reference,
CB1
Clear Output 1
AT -40
SB1
Wait 40 msec from reference and reset reference
Set Output 1
Loop
JP #LOOP
EN
Conditional Jumps
The DMC-2x00 provides Conditional Jump (JP) and Conditional Jump to Subroutine (JS) instructions
for branching to a new program location based on a specified condition. The conditional jump
determines if a condition is satisfied and then branches to a new location or subroutine. Unlike event
triggers, the conditional jump instruction does not halt the program sequence. Conditional jumps are
useful for testing events in real-time. They allow the DMC-2x00 to make decisions without a host
computer. For example, the DMC-2x00 can decide between two motion profiles based on the state of
an input line.
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Command Format - JP and JS
FORMAT:
DESCRIPTION
JS destination, logical condition Jump to subroutine if logical condition is satisfied
JP destination, logical condition Jump to location if logical condition is satisfied
The destination is a program line number or label where the program sequencer will jump if the
specified condition is satisfied. Note that the line number of the first line of program memory is 0.
The comma designates "IF". The logical condition tests two operands with logical operators.
Logical operators:
OPERATOR
DESCRIPTION
less than
<
>
greater than
=
equal to
<=
>=
<>
less than or equal to
greater than or equal to
not equal
Conditional Statements
The conditional statement is satisfied if it evaluates to any value other than zero. The conditional
statement can be any valid DMC-2x00 numeric operand, including variables, array elements, numeric
values, functions, keywords, and arithmetic expressions. If no conditional statement is given, the jump
will always occur.
Number
V1=6
Numeric Expression
V1=V7*6
@ABS[V1]>10
V1<Count[2]
V1<V2
Array Element
Variable
Internal Variable
_TPA=0
_TVA>500
V1>@AN[2]
@IN[1]=0
I/O
Multiple Conditional Statements
The DMC-2x00 will accept multiple conditions in a single jump statement. The conditional statements
are combined in pairs using the operands “&” and “|”. The “&” operand between any two conditions,
requires that both statements must be true for the combined statement to be true. The “|” operand
between any two conditions, requires that only one statement be true for the combined statement to be
true.
NOTE: Each condition must be placed in parentheses for proper evaluation by the controller. In
addition, the DMC-2x00 executes operations from left to right. For further information on
Mathematical Expressions and the bit-wise operators ‘&’ and ‘|’, see pg 97.
For example, using variables named V1, V2, V3 and V4:
JP #TEST, (V1<V2) & (V3<V4)
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In this example, this statement will cause the program to jump to the label #TEST if V1 is less than V2
and V3 is less than V4. To illustrate this further, consider this same example with an additional
condition:
JP #TEST, ((V1<V2) & (V3<V4)) | (V5<V6)
This statement will cause the program to jump to the label #TEST under two conditions; 1. If V1 is
less than V2 and V3 is less than V4. OR 2. If V5 is less than V6.
Examples
If the condition for the JP command is satisfied, the controller branches to the specified label or line
number and continues executing commands from this point. If the condition is not satisfied, the
controller continues to execute the next commands in sequence.
Instruction
Interpretation
JP #LOOP,count<10
JS #MOVE2,@IN[1]=1
Jump to #LOOP if the variable, count, is less than 10
Jump to subroutine #MOVE2 if input 1 is logic level high. After
the subroutine MOVE2 is executed, the program sequencer
returns to the main program location where the subroutine was
called.
JP #BLUE,@ABS[v2]>2
JP #C,v1*v7<=v8*v2
JP#A
Jump to #BLUE if the absolute value of variable, v2, is greater
than 2
Jump to #C if the value of v1 times v7 is less than or equal to the
value of v8*v2
Jump to #A
Move the A motor to absolute position 1000 counts and back to zero ten times. Wait 100 msec
between moves.
Instruction
#BEGIN
count=10
#LOOP
Interpretation
Begin Program
Initialize loop counter
Begin loop
PA 1000
BGA
Position absolute 1000
Begin move
AMA
Wait for motion complete
Wait 100 msec
WT 100
PA 0
Position absolute 0
Begin move
BGA
AMA
Wait for motion complete
Wait 100 msec
WT 100
count = count -1
JP #LOOP, count >0
EN
Decrement loop counter
Test for 10 times thru loop
End Program
If, Else, and Endif
The DMC-2x00 provides a structured approach to conditional statements using IF, ELSE and ENDIF
commands.
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Using the IF and ENDIF Commands
An IF conditional statement is formed by the combination of an IF and ENDIF command. The IF
command has as its arguments one or more conditional statements. If the conditional statement(s)
evaluates true, the command interpreter will continue executing commands which follow the IF
command. If the conditional statement evaluates false, the controller will ignore commands until the
associated ENDIF command is executed OR an ELSE command occurs in the program (see discussion
of ELSE command below).
NOTE: An ENDIF command must always be executed for every IF command that has been executed.
It is recommended that the user not include jump commands inside IF conditional statements since this
causes redirection of command execution. In this case, the command interpreter may not execute an
ENDIF command.
Using the ELSE Command
The ELSE command is an optional part of an IF conditional statement and allows for the execution of
command only when the argument of the IF command evaluates False. The ELSE command must
occur after an IF command and has no arguments. If the argument of the IF command evaluates false,
the controller will skip commands until the ELSE command. If the argument for the IF command
evaluates true, the controller will execute the commands between the IF and ELSE command.
Nesting IF Conditional Statements
The DMC-2x00 allows for IF conditional statements to be included within other IF conditional
statements. This technique is known as 'nesting' and the DMC-2x00 allows up to 255 IF conditional
statements to be nested. This is a very powerful technique allowing the user to specify a variety of
different cases for branching.
Command Format - IF, ELSE and ENDIF
Format:
description
IF conditional statement(s)
Execute commands proceeding IF command (up to ELSE command) if
conditional statement(s) is true, otherwise continue executing at ENDIF
command or optional ELSE command.
ELSE
Optional command. Allows for commands to be executed when argument
of IF command evaluates not true. Can only be used with IF command.
ENDIF
Command to end IF conditional statement. Program must have an ENDIF
command for every IF command.
Instruction
#TEST
Interpretation
Begin Main Program "TEST"
Enable interrupts on input 1 and input 2
II,,3
MG "WAITING FOR INPUT 1, INPUT 2"
Output message
#LOOP
Label to be used for endless loop
Endless loop
JP #LOOP
EN
End of main program
#ININT
Input Interrupt Subroutine
IF conditional statement based on input 1
2nd IF executed if 1st IF conditional true
Message executed if 2nd IF is true
IF (@IN[1]=0)
IF (@IN[2]=0)
MG "INPUT 1 AND INPUT 2 ARE ACTIVE"
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ELSE
ELSE command for 2nd IF statement
Message executed if 2nd IF is false
End of 2nd conditional statement
ELSE command for 1st IF statement
Message executed if 1st IF statement
End of 1st conditional statement
Label to be used for a loop
MG "ONLY INPUT 1 IS ACTIVE
ENDIF
ELSE
MG"ONLY INPUT 2 IS ACTIVE"
ENDIF
#WAIT
JP#WAIT,(@IN[1]=0) | (@IN[2]=0)
RI0
Loop until Input 1& 2 are not active
End Input Interrupt Routine without restoring
trippoints
Subroutines
A subroutine is a group of instructions beginning with a label and ending with an End command (EN).
Subroutines are called from the main program with the jump subroutine instruction JS, followed by a
label or line number, and conditional statement. Up to 8 subroutines can be nested. After the
subroutine is executed, the program sequencer returns to the program location where the subroutine
was called unless the subroutine stack is manipulated as described in the following section.
An example of a subroutine to draw a square of 500 counts per side is given below. The square is
drawn at vector position 1000, 1000.
Instruction
#M
Interpretation
Begin Main Program
CB1
Clear Output Bit 1 (pick up pen)
Define vector position; move pen
Wait for after motion trip point
Set Output Bit 1 (put down pen)
Jump to SQUARE subroutine
End Main Program
VP 1000,1000;LE;BGS
AMS
SB1
JS #SQUARE;CB1
EN
# SQUARE
v1=500;JS #L
v1=-v1;JS #L
EN
SQUARE subroutine
Define length of side
Switch direction
End subroutine
#L;PR v1,v1;BGA
AMA;BGB;AMB
EN
Define A,B; Begin A
After motion on A, Begin B
End subroutine
Stack Manipulation
It is possible to manipulate the subroutine stack by using the ZS command. Every time a JS
instruction, interrupt or automatic routine (such as #POSERR or #LIMSWI) is executed, the subroutine
stack is incremented by 1. Normally the stack is restored with an EN instruction. Occasionally it is
desirable not to return back to the program line where the subroutine or interrupt was called. The ZS1
command clears 1 level of the stack. This allows the program sequencer to continue to the next line.
The ZS0 command resets the stack to its initial value. For example, if a limit occurs and the #LIMSWI
routine is executed, it is often desirable to restart the program sequence instead of returning to the
location where the limit occurred. To do this, give a ZS command at the end of the #LIMSWI routine.
Auto-Start Routine
The DMC-2x00 has a special label for automatic program execution. A program which has been saved
into the controller’s non-volatile memory can be automatically executed upon power up or reset by
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beginning the program with the label #AUTO. The program must be saved into non-volatile memory
using the command, BP.
Automatic Subroutines for Monitoring Conditions
Often it is desirable to monitor certain conditions continuously without tying up the host or DMC-2x00
program sequences. The DMC-2x00 can monitor several important conditions in the background.
These conditions include checking for the occurrence of a limit switch, a defined input, position error,
or a command error. Automatic monitoring is enabled by inserting a special, predefined label in the
applications program. The pre-defined labels are:
SUBROUTINE
#LIMSWI
DESCRIPTION
Limit switch on any axis goes low
Input specified by II goes low
#ININT
#POSERR
#MCTIME
#CMDERR
Position error exceeds limit specified by ER
Motion Complete timeout occurred. Timeout period set by TW command
Bad command given
#COMINT (DMC-2000 only) Communication Interrupt Routine
#TCPERR
TCP/IP communication error (2100 and 2200 only)
For example, the #POSERR subroutine will automatically be executed when any axis exceeds its
position error limit. The commands in the #POSERR subroutine could decode which axis is in error
and take the appropriate action. In another example, the #ININT label could be used to designate an
input interrupt subroutine. When the specified input occurs, the program will be executed
automatically.
NOTE: An application program must be running for automatic monitoring to function.
Example - Limit Switch:
This program prints a message upon the occurrence of a limit switch. Note, for the #LIMSWI routine
to function, the DMC-2x00 must be executing an applications program from memory. This can be a
very simple program that does nothing but loop on a statement, such as #LOOP;JP #LOOP;EN.
Motion commands, such as JG 5000 can still be sent from the PC even while the "dummy"
applications program is being executed.
Instruction
:ED
Interpretation
Edit Mode
000 #LOOP
001 JP #LOOP;EN
002 #LIMSWI
003 MG "LIMIT OCCURRED"
004 RE
Dummy Program
Jump to Loop
Limit Switch Label
Print Message
Return to main program
Quit Edit Mode
Execute Dummy Program
Jog
<control> Q
:XQ #LOOP
:JG 5000
:BGA
Begin Motion
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Now, when a forward limit switch occurs on the A axis, the #LIMSWI subroutine will be executed
Notes regarding the #LIMSWI Routine:
1) The RE command is used to return from the #LIMSWI subroutine.
2) The #LIMSWI subroutine will be re-executed if the limit switch remains active.
The #LIMSWI routine is only executed when the motor is being commanded to move.
Example - Position Error
Instruction
Interpretation
Edit Mode
:ED
000 #LOOP
Dummy Program
Loop
001 JP #LOOP;EN
002 #POSERR
003 v1=_TEA
004 MG "EXCESS POSITION ERROR"
005 MG "ERROR=",v1=
006 RE
Position Error Routine
Read Position Error
Print Message
Print Error
Return from Error
Quit Edit Mode
Execute Dummy Program
Jog at High Speed
Begin Motion
<control> Q
:XQ #LOOP
:JG 100000
:BGX
Example - Input Interrupt
Instruction
Interpretation
Label
#A
II1
Input Interrupt on 1
Jog
JG 30000,,,60000
BGAD
Begin Motion
Loop
#LOOP;JP#LOOP;EN
#ININT
Input Interrupt
Stop Motion
Test for Input 1 still low
Restore Velocities
Begin motion
STAD;AM
#TEST;JP #TEST, @IN[1]=0
JG 30000,,,6000
BGAD
RI0
Return from interrupt routine to Main Program and do not re-
enable trippoints
Example - Motion Complete Timeout
Instruction
Interpretation
#BEGIN
Begin main program
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TW 1000
PA 10000
BGA
Set the time out to 1000 ms
Position Absolute command
Begin motion
MCA
Motion Complete trip point
End main program
EN
#MCTIME
MG “A fell short”
EN
Motion Complete Subroutine
Send out a message
End subroutine
This simple program will issue the message “A fell short” if the A axis does not reach the commanded
position within 1 second of the end of the profiled move.
Example - Command Error
Instruction
#BEGIN
Interpretation
Begin main program
Prompt for speed
Begin motion
IN "ENTER SPEED", speed
JG speed;BGA
JP #BEGIN
Repeat
EN
End main program
Command error utility
Check if error on line 2
Check if out of range
Send message
#CMDERR
JP#DONE,_ED<>2
JP#DONE,_TC<>6
MG "SPEED TOO HIGH"
MG "TRY AGAIN"
ZS1
Send message
Adjust stack
JP #BEGIN
Return to main program
End program if other error
Zero stack
#DONE
ZS0
EN
End program
The above program prompts the operator to enter a jog speed. If the operator enters a number out of
range (greater than 8 million), the #CMDERR routine will be executed prompting the operator to enter
a new number.
In multitasking applications, there is an alternate method for handling command errors from different
threads. Using the XQ command along with the special operands described below allows the
controller to either skip or retry invalid commands.
OPERAND
_ED1
FUNCTION
Returns the number of the thread that generated an error
Retry failed command (operand contains the location of the failed command)
_ED2
_ED3
Skip failed command (operand contains the location of the command after the failed
command)
The operands are used with the XQ command in the following format:
XQ _ED2 (or _ED3),_ED1,1
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Where the “,1” at the end of the command line indicates a restart; therefore, the existing program stack
will not be removed when the above format executes.
The following example shows an error correction routine which uses the operands.
Example - Command Error w/Multitasking
Instruction
Interpretation
#A
Begin thread 0 (continuous loop)
JP#A
EN
End of thread 0
#B
Begin thread 1
n=-1
Create new variable
KP n
Set KP to value of N, an invalid value
Issue invalid command
End of thread 1
TY
EN
#CMDERR
IF (_TC=6)
N=1
Begin command error subroutine
If error is out of range (KP -1)
Set N to a valid number
Retry KP N command
XQ _ED2,_ED1,1
ENDIF
IF (_TC=1)
XQ _ED3,_ED1,1
ENDIF
If error is invalid command (TY)
Skip invalid command
EN
End of command error routine
Example - Communication Interrupt
A DMC-2x10 is used to move the A axis back and forth from 0 to 10000. This motion can be paused,
resumed and stopped via input from an auxiliary port terminal.
Instruction
#BEGIN
Interpretation
Label for beginning of program
CC 9600,0,0,0
Setup communication configuration for auxiliary serial
port
CI 2
Setup communication interrupt for auxiliary serial port
Message out of auxiliary port
Message out of auxiliary port
Message out of auxiliary port
Variable to remember speed
Set speed of A axis motion
MG {P2}"Type 0 to stop motion"
MG {P2}"Type 1 to pause motion"
MG {P2}"Type 2 to resume motion"
rate=2000
SPA=rate
#LOOP
PAA=10000
BGA
Label for Loop
Move to absolute position 10000
Begin Motion on A axis
AMA
Wait for motion to be complete
Move to absolute position 0
PAA=0
BGA
Begin Motion on A axis
AMA
Wait for motion to be complete
Continually loop to make back and forth motion
JP #LOOP
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EN
End main program
#COMINT
Interrupt Routine
JP #STOP,P2CH="0"
JP #PAUSE,P2CH="1"
JP #RESUME,P2CH="2"
EN1,1
Check for S (stop motion)
Check for P (pause motion)
Check for R (resume motion)
Do nothing
#STOP
Routine for stopping motion
STA;ZS;EN
Stop motion on A axis; Zero program stack; End
Program
#PAUSE
rate=_SPA
SPA=0
Routine for pausing motion
Save current speed setting of A axis motion
Set speed of A axis to zero (allows for pause)
Re-enable trip-point and communication interrupt
Routine for resuming motion
EN1,1
#RESUME
SPA=rate
EN1,1
Set speed on A axis to original speed
Re-enable trip-point and communication interrupt
For additional information, see section on page.
Example – Ethernet Communication Error
This simple program executes in the DMC-2100/2200 and indicates (via the serial port) when a
communication handle fails. By monitoring the serial port, the user can re-establish communication if
needed.
Instruction
#LOOP
Interpretation
Simple program loop
JP#LOOP
EN
#TCPERR
MG {P1}_IA4
Ethernet communication error auto routine
Send message to serial port indicating which handle
did not receive proper acknowledgment.
RE
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Mathematical and Functional Expressions
Mathematical Operators
For manipulation of data, the DMC-2x00 provides the use of the following mathematical operators:
Operator
Function
+
-
Addition
Subtraction
*
/
Multiplication
Division
&
|
Logical And (Bit-wise)
Logical Or (On some computers, a solid vertical line appears as a broken line)
Parenthesis
()
The numeric range for addition, subtraction and multiplication operations is +/-2,147,483,647.9999.
The precision for division is 1/65,000.
Mathematical operations are executed from left to right. Calculations within parentheses have
precedence.
speed=7.5*v1/2
The variable, speed, is equal to 7.5 multiplied by v1 and
divided by 2
count= count +2
The variable, count, is equal to the current value plus 2.
result=_TPA-(@COS[45]*40)
Puts the position of A - 28.28 in result. 40 * cosine of 45°
is 28.28
temp=@IN[1]&@IN[2]
temp is equal to 1 only if Input 1 and Input 2 are high
Bit-Wise Operators
The mathematical operators & and | are bit-wise operators. The operator, &, is a Logical And. The
operator, |, is a Logical Or. These operators allow for bit-wise operations on any valid DMC-2x00
numeric operand, including variables, array elements, numeric values, functions, keywords and
arithmetic expressions. The bit-wise operators may also be used with strings. This is useful for
separating characters from an input string. When using the input command for string input, the input
variable will hold up to 6 characters. These characters are combined into a single value which is
represented as 32 bits of integer and 16 bits of fraction. Each ASCII character is represented as one
byte (8 bits), therefore the input variable can hold up to six characters. The first character of the string
will be placed in the top byte of the variable and the last character will be placed in the lowest
significant byte of the fraction. The characters can be individually separated by using bit-wise
operations as illustrated in the following example:
Instruction
#TEST
Interpretation
Begin main program
IN "ENTER",len{S6}
Input character string of up to 6 characters into
variable ‘len’
flen=@FRAC[len]
Define variable ‘flen’ as fractional part of variable
‘len’
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flen=$10000* flen
Shift flen by 32 bits (IE - convert fraction, flen, to
integer)
len1=( flen &$00FF)
Mask top byte of flen and set this value to variable
‘len1’
len2=( flen &$FF00)/$100
len3= len &$000000FF
len4=( len &$0000FF00)/$100
len5=( len &$00FF0000)/$10000
len6=( len &$FF000000)/$1000000
MG len6 {S4}
Let variable, ‘len2’ = top byte of flen
Let variable, ‘len3’ = bottom byte of len
Let variable, ‘len4’ = second byte of len
Let variable, ‘len5’ = third byte of len
Let variable, ‘len6’ = fourth byte of len
Display ‘len6’ as string message of up to 4 chars
Display ‘len5’ as string message of up to 4 chars
Display ‘len4’ as string message of up to 4 chars
Display ‘len3’ as string message of up to 4 chars
Display ‘len2’ as string message of up to 4 chars
Display ‘len1’ as string message of up to 4 chars
MG len5 {S4}
MG len4 {S4}
MG len3 {S4}
MG len2 {S4}
MG len1 {S4}
EN
This program will accept a string input of up to 6 characters, parse each character, and then display
each character. Notice also that the values used for masking are represented in hexadecimal (as
denoted by the preceding ‘$’). For more information, see section Sending Messages.
To illustrate further, if the user types in the string “TESTME” at the input prompt, the controller will
respond with the following:
T
E
S
Response from command MG len6 {S4}
Response from command MG len5 {S4}
Response from command MG len4 {S4}
Response from command MG len3 {S4}
Response from command MG len2 {S4}
Response from command MG len1 {S4}
T
M
E
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Functions
FUNCTION
DESCRIPTION
@SIN[n]
Sine of n (n in degrees, with range of -32768 to 32767 and 16-bit fractional resolution)
Cosine of n (n in degrees, with range of -32768 to 32767 and 16-bit fractional resolution)
Tangent of n (n in degrees, with range of -32768 to 32767 and 16-bit fractional resolution)
Arc Sine of n, between -90° and +90°. Angle resolution in 1/64000 degrees.
Arc Cosine of n, between 0 and 180°. Angle resolution in 1/64000 degrees.
Arc Tangent of n, between -90° and +90°. Angle resolution in 1/64000 degrees
1’s Complement of n
@COS[n]
@TAN[n]
@ASIN*[n]
@ACOS* [n}
@ATAN* [n]
@COM[n]
@ABS[n]
@FRAC[n]
@INT[n]
Absolute value of n
Fraction portion of n
Integer portion of n
@RND[n]
@SQR[n]
@IN[n]
Round of n (Rounds up if the fractional part of n is .5 or greater)
Square root of n (Accuracy is +/-.0001)
Return digital input at general input n (where n starts at 1)
Return digital output at general output n (where n starts at 1)
Return analog input at general analog in n (where n starts at 1)
@OUT[n]
@AN[n]
* Note that these functions are multi-valued. An application program may be used to find the correct
band.
Functions may be combined with mathematical expressions. The order of execution of mathematical
expressions is from left to right and can be over-ridden by using parentheses.
Instruction
Interpretation
v1=@ABS[v7]
v2=5*@SIN[pos]
The variable, v1, is equal to the absolute value of variable v7.
The variable, v2, is equal to five times the sine of the variable,
pos.
v3=@IN[1]
The variable, v3, is equal to the digital value of input 1.
v4=2*(5+@AN[5])
The variable, v4, is equal to the value of analog input 5 plus 5,
then multiplied by 2.
Variables
For applications that require a parameter that is variable, the DMC-2x00 provides 254 variables.
These variables can be numbers or strings. A program can be written in which certain parameters,
such as position or speed, are defined as variables. The variables can later be assigned by the operator
or determined by program calculations. For example, a cut-to-length application may require that a cut
length be variable.
Instruction
PR posa
Interpretation
Assigns variable posa to PR command
Assigns variable rpmb multiplied by 70 to JG command.
JG rpmb*70
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Programmable Variables
The DMC-2x00 allows the user to create up to 254 variables. Each variable is defines by a name
which can be up to eight characters. The name must start with an alphabetic character; however,
numbers are permitted in the rest of the name. Spaces are not permitted. Variable can be upper or
lowercase, or any combination. Variables are case sensitive; SPEEDC ≠ speedC. Variable names
should not be the same as DMC-2x00 instructions. For example, PR is not a good choice for a variable
name.
Examples of valid and invalid variable names are:
Valid Variable Names
POSA
pos1
speedC
Invalid Variable Names
REALLONGNAME
123
; Cannot have more than 8 characters
; Cannot begin variable name with a number
; Cannot have spaces in the name
SPEED C
Assigning Values to Variables
Assigned values can be numbers, internal variables and keywords, functions, controller parameters and
strings;
The range for numeric variable values is 4 bytes of integer (231) followed by two bytes of fraction
(+/-2,147,483,647.9999).
Numeric values can be assigned to programmable variables using the equal sign.
Any valid DMC-2x00 function can be used to assign a value to a variable. For example,
v1=@ABS[v2] or v2=@IN[1]. Arithmetic operations are also permitted.
To assign a string value, the string must be in quotations. String variables can contain up to six
characters which must be in quotation.
Instruction
posA=_TPA
SPEED=5.75
input=@IN[2]
v2=v1+v3*v4
Var="CAT"
Interpretation
Assigns returned value from TPA command to variable posA
Assigns value 5.75 to variable SPEED
Assigns logical value of input 2 to variable input
Assigns the value of v1 plus v3 times v4 to the variable v2.
Assign the string, CAT, to Var
Assigning Variable Values to Controller Parameters
Variable values may be assigned to controller parameters such as GN or PR.
PR v1
Assign v1 to PR command
SP _VSS*2000
Assign _VSS*2000 to SP command
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Displaying the value of variables at the terminal
Variables may be sent to the screen using the format, variable=. For example, v1= returns the value of
the variable v1.
Example - Using Variables for Joystick
The example below reads the voltage of an A-B joystick and assigns it to variables VA and VB to
drive the motors at proportional velocities, where
10 volts = 3000 rpm = 200000 c/sec
Speed/Analog input = 200000/10 = 20000
Instruction
#JOYSTIK
JG 0,0
Interpretation
Label
Set in Jog mode
Begin Motion
Loop
BGAB
#LOOP
va=@AN[1]*20000
vb=@AN[2]*20000
JG va,vb
Read joystick A
Read joystick B
Jog at variable va,vb
Repeat
JP#LOOP
EN
End
Operands
Operands allow motion or status parameters of the DMC-2x00 to be incorporated into programmable
variables and expressions. Most DMC-2x00 commands have an equivalent operand - which are
designated by adding an underscore (_) prior to the DMC-2x00 command. The command reference
indicates which commands have an associated operand.
Status commands such as Tell Position return actual values, whereas action commands such as KP or
SP return the values in the DMC-2x00 registers. The axis designation is required following the
command.
Instruction
Interpretation
posA=_TPA
Assigns value from Tell Position A to the variable posA.
Jump to #LOOP if the position error of A is greater than 5
Jump to #ERROR if the error code equals 1.
JP #LOOP,_TEA>5
JP #ERROR,_TC=1
Operands can be used in an expression and assigned to a programmable variable, but they cannot be
assigned a value. For example: _TPA=2 is invalid.
Special Operands (Keywords)
The DMC-2x00 provides a few additional operands which give access to internal variables that are not
accessible by standard DMC-2x00 commands.
Keyword
Function
BGn
BN
*Returns a 1 if motion on axis ‘n’ is complete, otherwise returns 0.
*Returns serial # of the board.
DA
*Returns the number of arrays available
DL
*Returns the number of available labels for programming
*Returns the available array memory
DM
HMn
LFn
*Returns status of Home Switch (equals 0 or 1)
Returns status of Forward Limit switch input of axis ‘n’ (equals 0 or 1)
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_LRn
Returns status of Reverse Limit switch input of axis ‘n’ (equals 0 or 1)
UL
*Returns the number of available variables
TIME
Free-Running Real Time Clock (off by 2.4% - Resets with power-on).
NOTE: TIME does not use an underscore character (_) as other keywords.
* These keywords have corresponding commands while the keywords _LF, _LR, and TIME do not
have any associated commands. All keywords are listed in the Command Summary.
v1=_LFA
v3=TIME
v4=_HMD
Assign v1 the state of the Forward Limit Switch on the A-axis
Assign v3 the current value of the time clock
Assign v4 the logical state of the Home input on the D-axis
Arrays
For storing and collecting numerical data, the DMC-2x00 provides array space for 8000 elements.
The arrays are one dimensional and up to 30 different arrays may be defined. Each array element has a
31
numeric range of 4 bytes of integer (2 ) followed by two bytes of fraction (+/-2,147,483,647.9999).
Arrays can be used to capture real-time data, such as position, torque and analog input values. In the
contouring mode, arrays are convenient for holding the points of a position trajectory in a record and
playback application.
Defining Arrays
An array is defined with the command DM. The user must specify a name and the number of entries
to be held in the array. An array name can contain up to eight characters, starting with an uppercase
alphabetic character. The number of entries in the defined array is enclosed in [ ].
DM posA[7]
DM speed[100]
DM posA[0]
Defines an array names posA with seven entries
Defines an array named speed with 100 entries
Frees array space
Assignment of Array Entries
Like variables, each array element can be assigned a value. Assigned values can be numbers or
returned values from instructions, functions and keywords.
Array elements are addressed starting at count 0. For example the first element in the posA array
(defined with the DM command, DM posA[7]) would be specified as posA[0].
Values are assigned to array entries using the equal sign. Assignments are made one element at a time
by specifying the element number with the associated array name.
NOTE: Arrays must be defined using the command, DM, before assigning entry values.
DM speed[10]
speed[1]=7650.2
speed[1]=
Dimension Speed Array
Assigns the first element of the array the value 7650.2
Returns array element value
posXA[10]=_TPA
Assigns the 10th element the position of A
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con[2]=@COS[POS]*2
timer[1]=TIME
Assigns the 2nd element of the array the cosine of POS * 2.
Assigns the 1st element of the array TIME
Using a Variable to Address Array Elements
An array element number can also be a variable. This allows array entries to be assigned sequentially
using a counter.
Instruction
#A
Interpretation
Begin Program
count=0;DM POS[10]
#LOOP
Initialize counter and define array
Begin loop
WT 10
Wait 10 msec
POS[count]=_TPA
POS[count]=
count = count +1
JP #LOOP, count <10
EN
Record position into array element
Report position
Increment counter
Loop until 10 elements have been stored
End Program
The above example records 10 position values at a rate of one value per 10 msec. The values are
stored in an array named POS. The variable, COUNT, is used to increment the array element counter.
The above example can also be executed with the automatic data capture feature described below.
Uploading and Downloading Arrays to On Board Memory
Arrays may be uploaded and downloaded using the QU and QD commands.
QU array[],start,end,delim
QD array[],start,end
where array is an array name such as A[].
Start is the first element of array (default=0)
End is the last element of array (default=last element)
Delim specifies whether the array data is separated by a comma (delim=1) or a carriage return
(delim=0).
The file is terminated using <control>Z, <control>Q, <control>D or \.
Automatic Data Capture into Arrays
The DMC-2x00 provides a special feature for automatic capture of data such as position, position
error, inputs or torque. This is useful for teaching motion trajectories or observing system
performance. Up to four types of data can be captured and stored in four arrays. The capture rate or
time interval may be specified. Recording can be done as a one time event or as a circular continuous
recording.
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Command Summary - Automatic Data Capture
command
description
RA n[],m[],o[],p[]
Selects up to four arrays for data capture. The arrays must be defined with the
DM command.
RD type1,type2,type3,type4 Selects the type of data to be recorded, where type1, type2, type3, and type 4
represent the various types of data (see table below). The order of data type is
important and corresponds with the order of n,m,o,p arrays in the RA command.
RC n,m
The RC command begins data collection. Sets data capture time interval where
n is an integer between 1 and 8 and designates 2n msec between data. m is
optional and specifies the number of elements to be captured. If m is not
defined, the number of elements defaults to the smallest array defined by DM.
When m is a negative number, the recording is done continuously in a circular
manner. _RD is the recording pointer and indicates the address of the next array
element. n=0 stops recording.
RC?
Returns a 0 or 1 where, 0 denotes not recording, 1 specifies recording in progress
Data Types for Recording:
data type
_DEA
_TPA
_TEA
_SHA
_RLA
_TI
description
2nd encoder position (dual encoder)
Encoder position
Position error
Commanded position
Latched position
Inputs
_OP
Output
_TSA
_SCA
_NOA
_TTA
_AFA
Switches (only bit 0-4 valid)
Stop code
Status bits
Torque (reports digital value +/-32544)
Analog Input (Letter corresponds to input, e.g. AFA = 1st Analog In, AFB=2nd
Analog In.)
NOTE: A may be replaced by B,C,D,E,F,G, or H for capturing data on other axes.
Operand Summary - Automatic Data Capture
_RC
Returns a 0 or 1 where, 0 denotes not recording, 1 specifies recording in progress
_RD
Returns address of next array element.
Example - Recording into an Array
Instruction
Interpretation
#RECORD
Begin program
DM apos[300],bpos[300]
DM aerr[300],berr[300]
RA apos [],aerr[],bpos[],berr[]
RD _TPA,_TEA,_TPB,_TEB
Define A,B position arrays
Define A,B error arrays
Select arrays for capture
Select data types
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PR 10000,20000
RC1
Specify move distance
Start recording now, at rate of 2 msec
Begin motion
BG AB
#A;JP #A,_RC=1
MG "DONE"
EN
Loop until done
Print message
End program
#PLAY
Play back
n=0
Initial Counter
Exit if done
JP# DONE,N>300
n=
Print Counter
apos [n]=
bpos [n]=
aerr[n]=
berr[n]=
n=n+1
Print X position
Print Y position
Print X error
Print Y error
Increment Counter
Done
#DONE
EN
End Program
Deallocating Array Space
Array space may be deallocated using the DA command followed by the array name. DA*[0]
deallocates all the arrays.
Input of Data (Numeric and String)
Input of Data
The command, IN, is used to prompt the user to input numeric or string data. Using the IN command,
the user may specify a message prompt by placing a message in quotations. When the controller
executes an IN command, the controller will wait for the input of data. The input data is assigned to
the specified variable or array element.
Example- Inputting Numeric Data
#A
IN "Enter Length",lenA
EN
In this example, the message “Enter Length” is displayed on the computer screen. The controller waits
for the operator to enter a value. The operator enters the numeric value which is assigned to the
variable, lenA. (NOTE: Do not include a space between the comma at the end of the input message
and the variable name.)
Example- Cut-to-Length
In this example, a length of material is to be advanced a specified distance. When the motion is
complete, a cutting head is activated to cut the material. The length is variable, and the operator is
prompted to input it in inches. Motion starts with a start button which is connected to input 1.
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The load is coupled with a 2 pitch lead screw. A 2000 count/rev encoder is on the motor, resulting in a
resolution of 4000 counts/inch. The program below uses the variable len, to length. The IN command
is used to prompt the operator to enter the length, and the entered value is assigned to the variable
LEN.
Instruction
#BEGIN
AC 800000
DC 800000
SP 5000
Interpretation
LABEL
Acceleration
Deceleration
Speed
len=3.4
Initial length in inches
Cut routine
#CUT
AI1
Wait for start signal
Prompt operator for length in inches
Specify position in counts
Begin motion to move material
Wait for motion done
Set output to cut
IN "enter Length(IN)", len
PR LEN *4000
BGA
AMA
SB1
WT100;CB1
JP #CUT
EN
Wait 100 msec, then turn off cutter
Repeat process
End program
Operator Data Entry Mode
The Operator Data Entry Mode provides for un-buffered data entry through the auxiliary RS-232 port.
In this mode, the DMC-2x00 provides a buffer for receiving characters. This mode may only be used
when executing an applications program.
The Operator Data Entry Mode may be specified for Port 2 only. This mode may be exited with the \
or <escape> key.
NOTE: Operator Data Entry Mode cannot be used for high rate data transfer.
Set the third field of the CC command to zero to set the Operator Data Entry Mode.
To capture and decode characters in the Operator Data Mode, the DMC-2x00 provides special the
following keywords:
Keyword
P2CH
Function
Contains the last character received
Contains the received string
Contains the received number
P2ST
P2NM
P2CD
Contains the status code:
-1 mode disabled
0 nothing received
1 received character, but not <enter>
2 received string, not a number
3 received number
NOTE: The value of P2CD returns to zero after the corresponding string or number is read.
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These keywords may be used in an applications program to decode data and they may also be used in
conditional statements with logical operators.
Example
Instruction
Interpretation
JP #LOOP,P2CD< >3
JP #P,P1CH="V"
PR P2NM
Checks to see if status code is 3 (number received)
Checks if last character received was a V
Assigns received number to position
Checks to see if received string is X
JS #XAXIS,P1ST="X"
Using Communication Interrupt
The DMC-2x00 provides a special interrupt for communication allowing the application program to be
interrupted by input from the user. The interrupt is enabled using the CI command. The syntax for the
command is CI n:
n = 0
n = 1
n = 2
n = -1
Don't interrupt Port 2
Interrupt on <enter> Port 2
Interrupt on any character Port 2
Clear any characters in buffer
The #COMINT label is used for the communication interrupt. For example, the DMC-2x00 can be
configured to interrupt on any character received on Port 2. The #COMINT subroutine is entered
when a character is received and the subroutine can decode the characters. At the end of the routine
the EN command is used. EN,1 will re-enable the interrupt and return to the line of the program where
the interrupt was called, EN will just return to the line of the program where it was called without re-
enabling the interrupt. As with any automatic subroutine, a program must be running in thread 0 at all
times for it to be enabled.
Example
A DMC-2x00 is used to jog the A and B axis. This program automatically begins upon power-up and
allows the user to input values from the main serial port terminal. The speed of either axis may be
changed during motion by specifying the axis letter followed by the new speed value. An S stops
motion on both axes.
Instruction
#AUTO
Interpretation
Label for Auto Execute
Initial A speed
speedA=10000
speedB=10000
CI 2
Initial B speed
Set Port 2 for Character Interrupt
Specify jog mode speed for A and B axis
Begin motion
JG speedA, speedB
BGXY
#PRINT
Routine to print message to terminal
Print message
MG{P2}"TO CHANGE SPEEDS"
MG{P2}"TYPE A OR B"
MG{P2}"TYPE S TO STOP"
#JOGLOOP
Loop to change Jog speeds
Set new jog speed
JG speedA, speedB
JP #JOGLOOP
EN
End of main program
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#COMINT
Interrupt routine
Check for A
JP #A,P2CH="A"
JP #B,P2CH="B"
JP #C,P2CH="S"
ZS1;CI2;JP#JOGLOOP
#A;JS#NUM
Check for B
Check for S
Jump if not X,Y,S
speedX=val
New X speed
Jump to Print
ZS1;CI2;JP#PRINT
#B;JS#NUM
speedY=val
New Y speed
Jump to Print
Stop motion on S
ZS1;CI2;JP#PRINT
#C;ST;AMX;CI-1
MG{^8}, "THE END"
ZS;EN,1
End-Re-enable interrupt
Routine for entering new jog speed
Prompt for value
#NUM
MG "ENTER",P2CH{S},"AXIS SPEED"
{N}
#NUMLOOP; CI-1
#NMLP
Check for enter
Routine to check input from terminal
Jump to error if string
Read value
JP #NMLP,P2CD<2
JP #ERROR,P2CD=2
val=P2NM
EN
End subroutine
Error Routine
Error message
#ERROR;CI-1
MG "INVALID-TRY AGAIN"
JP #NMLP
EN
End
Inputting String Variables
String variables with up to six characters may be input using the specifier, {Sn} where n represents the
number of string characters to be input. If n is not specified, six characters will be accepted. For
example, IN "Enter A,B or C", V{S} specifies a string variable to be input.
The DMC-2x00, stores all variables as 6 bytes of information. When a variable is specified as a
number, the value of the variable is represented as 4 bytes of integer and 2 bytes of fraction. When a
variable is specified as a string, the variable can hold up to 6 characters (each ASCII character is 1
byte). When using the IN command for string input, the first input character will be placed in the top
byte of the variable and the last character will be placed in the lowest significant byte of the fraction.
The characters can be individually separated by using bit-wise operations, see section Bit-wise
Operators.
Output of Data (Numeric and String)
Numerical and string data can be output from the controller using several methods. The message
command, MG, can output string and numerical data. Also, the controller can be commanded to return
the values of variables and arrays, as well as other information using the interrogation commands (the
interrogation commands are described in chapter 5).
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Sending Messages
Messages may be sent to the bus using the message command, MG. This command sends specified
text and numerical or string data from variables or arrays to the screen.
Text strings are specified in quotes and variable or array data is designated by the name of the variable
or array. For example:
MG "The Final Value is", result
In addition to variables, functions and commands, responses can be used in the message command.
For example:
MG "Analog input is", @AN[1]
MG "The Position of A is", _TPA
Specifying the Port for Messages:
By default, messages will be sent through the port specified by the USB/Ethernet Dip Switch - the state
of this switch upon power up will determine if messages will be sent to USB port (DMC-2000), or
Ethernet (DMC-2100/2200) the Main Serial Port. However, the port can be specified with the
specifier, {P1} for the main serial port {P2} for auxiliary serial port, {U} for the USB port , or {E} for
the Ethernet port.
MG {P2} "Hello World"
Sends message to Auxiliary Port
Formatting Messages
String variables can be formatted using the specifier, {Sn} where n is the number of characters, 1 thru
6. For example:
MG STR {S3}
This statement returns 3 characters of the string variable named STR.
Numeric data may be formatted using the {Fn.m} expression following the completed MG statement.
{$n.m} formats data in HEX instead of decimal. The actual numerical value will be formatted with n
characters to the left of the decimal and m characters to the right of the decimal. Leading zeros will be
used to display specified format.
For example:
MG "The Final Value is", result {F5.2}
If the value of the variable result is equal to 4.1, this statement returns the following:
The Final Value is 00004.10
If the value of the variable result is equal to 999999.999, the above message statement returns the
following:
The Final Value is 99999.99
The message command normally sends a carriage return and line feed following the statement. The
carriage return and the line feed may be suppressed by sending {N} at the end of the statement. This is
useful when a text string needs to surround a numeric value.
Example:
#A
JG 50000;BGA;ASA
MG "The Speed is", _TVA {F5.1} {N}
MG "counts/sec"
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EN
When #A is executed, the above example will appear on the screen as:
The speed is 50000 counts/sec
Using the MG Command to Configure Terminals
The MG command can be used to configure a terminal. Any ASCII character can be sent by using the
format {^n} where n is any integer between 1 and 255.
Example:
MG {^07} {^255}
sends the ASCII characters represented by 7 and 255 to the bus.
Summary of Message Functions
function
description
" "
Surrounds text string
{Fn.m}
Formats numeric values in decimal n digits to the left of the decimal point and
m digits to the right
{P1}, {P2}, {U} or {E}
Send message to Main Serial Port, Auxiliary Serial Port, USB Port or Ethernet
Port
{$n.m}
{^n}
Formats numeric values in hexadecimal
Sends ASCII character specified by integer n
Suppresses carriage return/line feed
{N}
{Sn}
Sends the first n characters of a string variable, where n is 1 thru 6.
Displaying Variables and Arrays
Variables and arrays may be sent to the screen using the format, variable= or array[x]=. For example,
v1= returns the value of v1.
Example - Printing a Variable and an Array element
Instruction
#DISPLAY
DM posA[7]
PR 1000
Interpretation
Label
Define Array POSA with 7 entries
Position Command
Begin
BGX
AMX
After Motion
v1=_TPA
posA[1]=_TPA
v1=
Assign Variable v1
Assign the first entry
Print v1
Interrogation Commands
The DMC-2x00 has a set of commands that directly interrogate the controller. When these command
are entered, the requested data is returned in decimal format on the next line followed by a carriage
return and line feed. The format of the returned data can be changed using the Position Format (PF),
and Leading Zeros (LZ) command. For a complete description of interrogation commands, see Ch 5.
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Using the PF Command to Format Response from Interrogation
Commands
The command, PF, can change format of the values returned by theses interrogation commands:
BL ?
DE ?
DP ?
EM ?
FL ?
IP ?
LE ?
PA ?
PR ?
TN ?
VE ?
TE
TP
The numeric values may be formatted in decimal or hexadecimal with a specified number of digits to
the right and left of the decimal point using the PF command.
Position Format is specified by:
PF m.n
where m is the number of digits to the left of the decimal point (0 thru 10) and n is the number of digits
to the right of the decimal point (0 thru 4) A negative sign for m specifies hexadecimal format.
Hex values are returned preceded by a $ and in 2's complement. Hex values should be input as signed
2's complement, where negative numbers have a negative sign. The default format is PF 10.0.
If the number of decimal places specified by PF is less than the actual value, a nine appears in all the
decimal places.
Example
Instruction
:DP21
:TPA
Interpretation
Define position
Tell position
0000000021
:PF4
Default format
Change format to 4 places
Tell position
:TPA
0021
New format
:PF-4
Change to hexadecimal format
Tell Position
:TPA
$0015
:PF2
Hexadecimal value
Format 2 places
:TPA
Tell Position
99
Returns 99 if position greater than 99
Removing Leading Zeros from Response to Interrogation Commands
The leading zeros on data returned as a response to interrogation commands can be removed by the use
of the command, LZ.
LZ0
TP
Disables the LZ function
Tell Position Interrogation Command
Response (With Leading Zeros)
-0000000009, 0000000005
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LZ1
TP
Enables the LZ function
Tell Position Interrogation Command
Response (Without Leading Zeros)
-9, 5
Local Formatting of Response of Interrogation Commands
The response of interrogation commands may be formatted locally. To format locally, use the
command, {Fn.m} or {$n.m} on the same line as the interrogation command. The symbol F specifies
that the response should be returned in decimal format and $ specifies hexadecimal. n is the number of
digits to the left of the decimal, and m is the number of digits to the right of the decimal.
TP {F2.2}
Tell Position in decimal format 2.2
-05.00, 05.00, 00.00, 07.00
TP {$4.2}
Response from Interrogation Command
Tell Position in hexadecimal format 4.2
Response from Interrogation Command
FFFB.00,$0005.00,$0000.00,$0007.00
Formatting Variables and Array Elements
The Variable Format (VF) command is used to format variables and array elements. The VF
command is specified by:
VF m.n
where m is the number of digits to the left of the decimal point (0 thru 10) and n is the number of
digits to the right of the decimal point (0 thru 4).
A negative sign for m specifies hexadecimal format. The default format for VF is VF 10.4
Hex values are returned preceded by a $ and in 2's complement.
Instruction
Interpretation
Assign v1
v1=10
v1=
Return v1
:0000000010.0000
Response - Default format
Change format
Return v1
VF2.2
v1=
:10.00
vF-2.2
v1=
Response - New format
Specify hex format
Return v1
$0A.00
VF1
Response - Hex value
Change format
Return v1
v1=
:9
Response - Overflow
Local Formatting of Variables
PF and VF commands are global format commands that affect the format of all relevant returned
values and variables. Variables may also be formatted locally. To format locally, use the command,
{Fn.m} or {$n.m} following the variable name and the ‘=’ symbol. F specifies decimal and $ specifies
hexadecimal. n is the number of digits to the left of the decimal, and m is the number of digits to the
right of the decimal.
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Instruction
v1=10
Interpretation
Assign v1
v1=
Return v1
:0000000010.0000
v1={F4.2}
:0010.00
Default Format
Specify local format
New format
v1={$4.2}
:$000A.00
v1="ALPHA"
v1={S4}
Specify hex format
Hex value
Assign string "ALPHA" to v1
Specify string format first 4 characters
:ALPH
The local format is also used with the MG command.
Converting to User Units
Variables and arithmetic operations make it easy to input data in desired user units such as inches or
RPM.
The DMC-2x00 position parameters such as PR, PA and VP have units of quadrature counts. Speed
parameters such as SP, JG and VS have units of counts/sec. Acceleration parameters such as AC, DC,
2
VA and VD have units of counts/sec . The controller interprets time in milliseconds.
All input parameters must be converted into these units. For example, an operator can be prompted to
input a number in revolutions. A program could be used such that the input number is converted into
counts by multiplying it by the number of counts/revolution.
Instruction
Interpretation
Label
#RUN
IN "ENTER # OF REVOLUTIONS",n1
Prompt for revs
Convert to counts
Prompt for RPMs
Convert to counts/sec
Prompt for ACCEL
Convert to counts/sec2
Begin motion
PR n1*2000
IN "ENTER SPEED IN RPM",s1
SP s1*2000/60
IN "ENTER ACCEL IN RAD/SEC2",a1
AC a1*2000/(2*3.14)
BG
EN
End program
Hardware I/O
Digital Outputs
The DMC-2x00 has an 8-bit uncommitted output port and an additional 64 I/O which may be
configured as inputs or outputs with the CO command for controlling external events. The DMC-
2x50 through DMC-2x80 has an additional 8 outputs. Each bit on the output port may be set and
cleared with the software instructions SB (Set Bit) and CB (Clear Bit), or OB (define output bit).
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Example- Set Bit and Clear Bit
Instruction
Interpretation
SB6
Sets bit 6 of output port
Clears bit 4 of output port
CB4
Example- Output Bit
The Output Bit (OB) instruction is useful for setting or clearing outputs depending on the value of a
variable, array, input or expression. Any non-zero value results in a set bit.
Instruction
Interpretation
OB1, POS
Set Output 1 if the variable POS is non-zero. Clear Output 1 if
POS equals 0.
OB 2, @IN [1]
Set Output 2 if Input 1 is high. If Input 1 is low, clear Output 2.
Set Output 3 only if Input 1 and Input 2 are high.
OB 3, @IN [1]&@IN [2]
OB 4, COUNT [1]
Set Output 4 if element 1 in the array COUNT is non-zero.
The output port can be set by specifying an 8-bit word using the instruction OP (Output Port). This
0
instruction allows a single command to define the state of the entire 8-bit output port, where 2 is
1
output 1, 2 is output 2 and so on. A 1 designates that the output is on.
Example- Output Port
Instruction
Interpretation
OP6
1
2
Sets outputs 2 and 3 of output port to high. All other bits are 0. (2 + 2 =
6)
OP0
Clears all bits of output port to zero
Sets all bits of output port to one.
OP 255
2
1
2
3
4
5
6
7
(2 + 2 + 2 + 2 + 2 + 2 + 2 + 2 )
The output port is useful for setting relays or controlling external switches and events during a motion
sequence.
Example - Turn on output after move
Instruction
Interpretation
#OUTPUT
Label
PR 2000
BG
Position Command
Begin
AM
After move
Set Output 1
Wait 1000 msec
Clear Output 1
End
SB1
WT 1000
CB1
EN
Digital Inputs
The general digital inputs for are accessed by using the @IN[n] function or the TI command. The
@IN[n] function returns the logic level of the specified input, n, where n is a number 1 through 96..
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Example - Using Inputs to control program flow
Instruction
JP #A,@IN[1]=0
JP #B,@IN[2]=1
AI 7
Interpretation
Jump to A if input 1 is low
Jump to B if input 2 is high
Wait until input 7 is high
Wait until input 6 is low
AI -6
Example - Start Motion on Switch
Motor A must turn at 4000 counts/sec when the user flips a panel switch to on. When panel switch is
turned to off position, motor A must stop turning.
Solution: Connect panel switch to input 1 of DMC-2x00. High on input 1 means switch is in on
position.
Instruction
#S;JG 4000
AI 1;BGA
AI -1;STA
AMA;JP #S
EN;
Interpretation
Set speed
Begin after input 1 goes high
Stop after input 1 goes low
After motion, repeat
The Auxiliary Encoder Inputs
The auxiliary encoder inputs can be used for general use. For each axis, the controller has one
auxiliary encoder and each auxiliary encoder consists of two inputs, channel A and channel B. The
auxiliary encoder inputs are mapped to the inputs 81-96.
Each input from the auxiliary encoder is a differential line receiver and can accept voltage levels
between +/- 12 volts. The inputs have been configured to accept TTL level signals. To connect TTL
signals, simply connect the signal to the + input and leave the - input disconnected. For other signal
levels, the - input should be connected to a voltage that is ½ of the full voltage range (for example,
connect the - input to 6 volts if the signal is a 0 - 12 volt logic).
Example:
A DMC-2x10 has one auxiliary encoder. This encoder has two inputs (channel A and channel B).
Channel A input is mapped to input 81 and Channel B input is mapped to input 82. To use this input
for 2 TTL signals, the first signal will be connected to AA+ and the second to AB+. AA- and AB-
will be left unconnected. To access this input, use the function @IN[81] and @IN[82].
NOTE: The auxiliary encoder inputs are not available for any axis that is configured for stepper
motor.
Input Interrupt Function
The DMC-2x00 provides an input interrupt function which causes the program to automatically
execute the instructions following the #ININT label. This function is enabled using the II m,n,o
command. The m specifies the beginning input and n specifies the final input in the range. The
parameter o is an interrupt mask. If m and n are unused, o contains a number with the mask. A 1
designates that input to be enabled for an interrupt, where 20 is bit 1, 21 is bit 2 and so on. For
example, II,,5 enables inputs 1 and 3 (20 + 22 = 5).
A low input on any of the specified inputs will cause automatic execution of the #ININT subroutine.
The Return from Interrupt (RI) command is used to return from this subroutine to the place in the
program where the interrupt had occurred. If it is desired to return to somewhere else in the program
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after the execution of the #ININT subroutine, the Zero Stack (ZS) command is used followed by
unconditional jump statements.
Important: Use the RI command (not EN) to return from the #ININT subroutine.
Example - Input Interrupt
Instruction
Interpretation
#A
Label #A
II 1
Enable input 1 for interrupt function
Set speeds on A and B axes
Begin motion on A and B axes
Label #B
JG 30000,-20000
BG AB
#B
TP AB
Report A and B axes positions
Wait 1000 milliseconds
Jump to #B
WT 1000
JP #B
EN
End of program
#ININT
Interrupt subroutine
MG "Interrupt has occurred"
Displays the message
Stops motion on A and B axes
Loop until Interrupt cleared
Specify new speeds
ST AB
#LOOP;JP #LOOP,@IN[1]=0
JG 15000,10000
WT 300
BG AB
Wait 300 milliseconds
Begin motion on A and B axes
Return from Interrupt subroutine
RI
Analog Inputs
The DMC-2x00 provides eight analog inputs. The value of these inputs in volts may be read using the
@AN[n] function where n is the analog input 1 through 8. The resolution of the Analog-to-Digital
conversion is 12 bits (16-bit ADC is available as an option). Analog inputs are useful for reading
special sensors such as temperature, tension or pressure.
The following examples show programs which cause the motor to follow an analog signal. The first
example is a point-to-point move. The second example shows a continuous move.
Example - Position Follower (Point-to-Point)
Objective - The motor must follow an analog signal. When the analog signal varies by 10V, motor
must move 10000 counts.
Method: Read the analog input and command A to move to that point.
Instruction
#POINTS
Interpretation
Label
SP 7000
Speed
AC 80000;DC 80000
#LOOP
Acceleration
VP=@AN[1]*1000
Read and analog input, compute position
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PA VP
BGA
Command position
Start motion
After completion
Repeat
AMA
JP #LOOP
EN
End
Example - Position Follower (Continuous Move)
Method: Read the analog input, compute the commanded position and the position error. Command
the motor to run at a speed in proportions to the position error.
Instruction
#CONT
Interpretation
Label
AC 80000;DC 80000
JG 0
Acceleration rate
Start job mode
Start motion
BGX
#LOOP
vp=@AN[1]*1000
ve=vp-_TPA
vel=ve*20
JG vel
Compute desired position
Find position error
Compute velocity
Change velocity
Change velocity
End
JP #LOOP
EN
Extended I/O of the DMC-2x00 Controller
The DMC-2x00 controller offers 64 extended I/O points which can be configured as inputs or outputs
in 8 bit increments through software. The I/O points are accessed through 1 80 pin high density
connector.
Configuring the I/O of the DMC-2x00
The 64 extended I/O points of the DMC-2x00 series controller can be configured in blocks of 8. The
extended I/O is denoted as blocks 2-9 or bits 17-80.
The command, CO, is used to configure the extended I/O as inputs or outputs. The CO command has
one field:
CO n
where n is a decimal value which represents a binary number. Each bit of the binary number
represents one block of extended I/O. When set to 1, the corresponding block is configured as an
output.
The least significant bit represents block 2 and the most significant bit represents block 9. The decimal
value can be calculated by the following formula. n = n2 + 2*n3 + 4*n4 + 8*n5 +16* n6 +32* n7 +64*
n8 +128* n9 where nx represents the block. If the nx value is a one, then the block of 8 I/O points is to
be configured as an output. If the nx value is a zero, then the block of 8 I/O points will be configured
as an input. For example, if block 4 and 5 is to be configured as an output, CO 12 is issued.
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8-Bit I/O Block
Block
Binary
Representation
Decimal Value for
Block
17-24
25-32
20
2
1
3
1
2
21
33-40
41-48
49-56
57-64
65-72
73-80
4
5
6
7
8
9
22
23
24
25
26
27
4
8
16
32
64
128
The simplest method for determining n:
Step 1. Determine which 8-bit I/O blocks to be configured as outputs.
Step 2. From the table, determine the decimal value for each I/O block to be set as an output.
Step 3. Add up all of the values determined in step 2. This is the value to be used for n.
For example, if blocks 2 and 3 are to be outputs, then n is 3 and the command, CO3, should be issued.
NOTE: This calculation is identical to the formula: n = n2 + 2*n3 + 4*n4 + 8*n5 +16* n6 +32* n7 +64*
n8 +128* n9 where nx represents the block.
Saving the State of the Outputs in Non-Volatile Memory
The configuration of the extended I/O and the state of the outputs can be stored in the EEPROM with
the BN command. If no value has been set, the default of CO 0 is used (all blocks are inputs).
Accessing Extended I/O
When configured as an output, each I/O point may be defined with the SBn and CBn commands
(where n=1 through 8 and 17 through 80). Outputs may also be defined with the conditional
command, OBn (where n=1 through 8 and 17 through 80).
The command, OP, may also be used to set output bits, specified as blocks of data. The OP command
accepts 5 parameters. The first parameter sets the values of the main output port of the controller
(Outputs 1-8, block 0). The additional parameters set the value of the extended I/O as outlined:
OP m,a,b,c,d
where m is the decimal representation of the bits 1-8 (values from 0 to 255) and a,b,c,d represent the
extended I/O in consecutive groups of 16 bits (values from 0 to 65535). Arguments which are given for
I/O points which are configured as inputs will be ignored. The following table describes the arguments
used to set the state of outputs.
Argument
Blocks
0
Bits
1-8
Description
General Outputs
Extended I/O
Extended I/O
Extended I/O
Extended I/O
m
a
2,3
17-32
33-48
49-64
65-80
b
c
4,5
6,7
d
8,9
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For example, if block 8 is configured as an output, the following command may be issued:
OP 7,,,,7
This command will set bits 1,2,3 (block 0) and bits 65,66,67 (block 8) to 1. Bits 4 through 8 and bits
68 through 80 will be set to 0. All other bits are unaffected.
When accessing I/O blocks configured as inputs, use the TIn command. The argument 'n' refers to the
block to be read (n=0,2,3,4,5,6,7,8 or 9). The value returned will be a decimal representation of the
corresponding bits.
Individual bits can be queried using the @IN[n] function (where n=1 through 8 or 17 through 80). If
the following command is issued;
MG @IN[17]
the controller will return the state of the least significant bit of block 2 (assuming block 2 is configured
as an input).
Interfacing to Grayhill or OPTO-22 G4PB24
The DMC-2x00 controller uses one 80 Pin high density connector which requires connection to a 80
pin high density cable (Galil CABLE-80). This cable can be converted to 2 50 pin IDC connectors
which are compatible with I/O mounting racks such as Grayhill 70GRCM32-HL and OPTO-22
G4PB24. To convert the 80 pin cable, use the CB-50-80 adapter from Galil. The 50 pin ribbon cables
which connect to the CB-50-80 connect directly into the I/O mounting racks.
When using the OPTO-22 G4PB24 I/O mounting rack, the user will only have access to 48 of the 64
I/O points available on the controller. Block 5 and Block 9 must be configured as inputs and will be
grounded by the I/O rack.
Example Applications
Wire Cutter
An operator activates a start switch. This causes a motor to advance the wire a distance of 10". When
the motion stops, the controller generates an output signal which activates the cutter. Allowing 100 ms
for the cutting completes the cycle.
Suppose that the motor drives the wire by a roller with a 2" diameter. Also assume that the encoder
resolution is 1000 lines per revolution. Since the circumference of the roller equals 2π inches, and it
corresponds to 4000 quadrature, one inch of travel equals:
4000/2π = 637 count/inch
This implies that a distance of 10 inches equals 6370 counts, and a slew speed of 5 inches per second,
for example, equals 3185 count/sec.
The input signal may be applied to I1, for example, and the output signal is chosen as output 1. The
motor velocity profile and the related input and output signals are shown in Fig. 7.1.
The program starts at a state that we define as #A. Here the controller waits for the input pulse on I1.
As soon as the pulse is given, the controller starts the forward motion.
Upon completion of the forward move, the controller outputs a pulse for 20 ms and then waits an
additional 80 ms before returning to #A for a new cycle.
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Instruction
Interpretation
#A
Label
AI1
Wait for input 1
Distance
PR 6370
SP 3185
BGA
Speed
Start Motion
AMA
SB1
After motion is complete
Set output bit 1
Wait 20 ms
WT 20
CB1
Clear output bit 1
Wait 80 ms
WT 80
JP #A
Repeat the process
START PULSE I1
MOTOR VELOCITY
OUTPUT PULSE
output
TIME INTERVALS
move
wait
ready
move
Figure 7.1 - Motor Velocity and the Associated Input/Output signals
A-B Table Controller
An A-B-C system must cut the pattern shown in Fig. 7.2. The A-B table moves the plate while the C-
axis raises and lowers the cutting tool.
The solid curves in Fig. 7.2 indicate sections where cutting takes place. Those must be performed at a
feed rate of 1 inch per second. The dashed line corresponds to non-cutting moves and should be
performed at 5 inch per second. The acceleration rate is 0.1 g.
The motion starts at point A, with the C-axis raised. An A-B motion to point B is followed by
lowering the C-axis and performing a cut along the circle. Once the circular motion is completed, the
C-axis is raised and the motion continues to point C, etc.
Assume that all of the 3 axes are driven by lead screws with 10 turns-per-inch pitch. Also assume
encoder resolution of 1000 lines per revolution. This results in the relationship:
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1 inch = 40,000 counts
and the speeds of
1 in/sec = 40,000 count/sec
5 in/sec = 200,000 count/sec
an acceleration rate of 0.1g equals
2
0.1g = 38.6 in/s2 = 1,544,000 count/s
Note that the circular path has a radius of 2" or 80000 counts, and the motion starts at the angle of 270°
and traverses 360° in the CW (negative direction). Such a path is specified with the instruction
CR 80000,270,-360
Further assume that the C must move 2" at a linear speed of 2" per second. The required motion is
performed by the following instructions:
Instruction
Interpretation
#A
Label
VM AB
VP 160000,160000
VE
Circular interpolation for AB
Positions
End Vector Motion
Vector Speed
VS 200000
VA 1544000
BGS
Vector Acceleration
Start Motion
AMS
When motion is complete
Move C down
PR,,-80000
SP,,80000
BGC
C speed
Start C motion
AMC
Wait for completion of C motion
Circle
CR 80000,270,-360
VE
VS 40000
BGS
Feed rate
Start circular move
Wait for completion
Move C up
AMS
PR,,80000
BGC
Start C move
Wait for C completion
Move A
AMC
PR -21600
SP 20000
BGA
Speed A
Start A
AMA
Wait for A completion
Lower C
PR,,-80000
BGC
AMC
CR 80000,270,-360
VE
C second circle move
VS 40000
BGS
AMS
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PR,,80000
BGC
Raise C
AMC
VP -37600,-16000
VE
Return AB to start
VS 200000
BGS
AMS
EN
B
R=2
4
B
C
A
0
4
9.3
A
Figure 7.2 - Motor Velocity and the Associated Input/Output signals
Speed Control by Joystick
The speed of a motor is controlled by a joystick. The joystick produces a signal in the range between -
10V and +10V. The objective is to drive the motor at a speed proportional to the input voltage.
Assume that a full voltage of 10 volts must produce a motor speed of 3000 rpm with an encoder
resolution of 1000 lines or 4000 count/rev. This speed equals:
3000 rpm = 50 rev/sec = 200000 count/sec
The program reads the input voltage periodically and assigns its value to the variable vin. To get a
speed of 200,000 ct/sec for 10 volts, we select the speed as
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Speed = 20000 x vin
The corresponding velocity for the motor is assigned to the VEL variable.
Instruction
#A
JG0
BGA
#B
vin=@AN[1]
vel=vin*20000
JG vel
JP #B
EN
Position Control by Joystick
This system requires the position of the motor to be proportional to the joystick angle. Furthermore,
the ratio between the two positions must be programmable. For example, if the control ratio is 5:1, it
implies that when the joystick voltage is 5 volts, corresponding to 1024 counts, the required motor
position must be 5120 counts. The variable V3 changes the position ratio.
Instruction
#A
Interpretation
Label
v3=1024
DP0
Initial position ratio
Define the starting position
Set motor in jog mode as zero
Start
JG0
BGA
#B
v1=@AN[1]
v2=v1*v3
v4=v2-_TPA-_TEA
v5=v4*20
JG v5
Read analog input
Compute the desired position
Find the following error
Compute a proportional speed
Change the speed
JP #B
Repeat the process
End
EN
Backlash Compensation by Sampled Dual-Loop
The continuous dual loop, enabled by the DV1 function is an effective way to compensate for
backlash. In some cases, however, when the backlash magnitude is large, it may be difficult to
stabilize the system. In those cases, it may be easier to use the sampled dual loop method described
below.
This design example addresses the basic problems of backlash in motion control systems. The
objective is to control the position of a linear slide precisely. The slide is to be controlled by a rotary
motor, which is coupled to the slide by a lead screw. Such a lead screw has a backlash of 4 micron,
and the required position accuracy is for 0.5 micron.
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The basic dilemma is where to mount the sensor. If you use a rotary sensor, you get a 4 micron
backlash error. On the other hand, if you use a linear encoder, the backlash in the feedback loop will
cause oscillations due to instability.
An alternative approach is the dual-loop, where we use two sensors, rotary and linear. The rotary
sensor assures stability (because the position loop is closed before the backlash) whereas the linear
sensor provides accurate load position information. The operation principle is to drive the motor to a
given rotary position near the final point. Once there, the load position is read to find the position error
and the controller commands the motor to move to a new rotary position which eliminates the position
error.
Since the required accuracy is 0.5 micron, the resolution of the linear sensor should preferably be twice
finer. A linear sensor with a resolution of 0.25 micron allows a position error of +/-2 counts.
The dual-loop approach requires the resolution of the rotary sensor to be equal or better than that of the
linear system. Assuming that the pitch of the lead screw is 2.5mm (approximately 10 turns per inch), a
rotary encoder of 2500 lines per turn or 10,000 count per revolution results in a rotary resolution of
0.25 micron. This results in equal resolution on both linear and rotary sensors.
To illustrate the control method, assume that the rotary encoder is used as a feedback for the X-axis,
and that the linear sensor is read and stored in the variable LINPOS. Further assume that at the start,
both the position of X and the value of LINPOS are equal to zero. Now assume that the objective is to
move the linear load to the position of 1000.
The first step is to command the X motor to move to the rotary position of 1000. Once it arrives we
check the position of the load. If, for example, the load position is 980 counts, it implies that a
correction of 20 counts must be made. However, when the X-axis is commanded to be at the position
of 1000, suppose that the actual position is only 995, implying that X has a position error of 5 counts,
which will be eliminated once the motor settles. This implies that the correction needs to be only 15
counts, since 5 counts out of the 20 would be corrected by the X-axis. Accordingly, the motion
correction should be:
Correction = Load Position Error - Rotary Position Error
The correction can be performed a few times until the error drops below +/-2 counts. Often, this is
performed in one correction cycle.
Instruction
Interpretation
Label
#A
DP0
Define starting positions as zero
linpos=0
PR 1000
Required distance
Start motion
BGA
#B
AMA
Wait for completion
Wait 50 msec
WT 50
linpos = _DEA
Read linear position
Find the correction
Exit if error is small
Command correction
er=1000- linpos -_TEA
JP #C,@ABS[er]<2
PR er
BGA
JP #B
#C
Repeat the process
EN
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Chapter 8 Hardware & Software
Protection
Introduction
The DMC-2x00 provides several hardware and software features to check for error conditions and to
inhibit the motor on error. These features help protect the various system components from damage.
WARNING: Machinery in motion can be dangerous! It is the responsibility of the user to design
effective error handling and safety protection as part of the machine. Since the dmc-2x00 is an
integral part of the machine, the engineer should design his overall system with protection against
a possible component failure on the dmc-2x00. Galil shall not be liable or responsible for any
incidental or consequential damages.
Hardware Protection
The DMC-2x00 includes hardware input and output protection lines for various error and mechanical
limit conditions. These include:
Output Protection Lines
Amp Enable - This signal goes low when the motor off command is given, when the position
error exceeds the value specified by the Error Limit (ER) command, or when off-on-error
condition is enabled (OE1) and the abort command is given. Each axis amplifier has separate
amplifier enable lines. This signal also goes low when the watch-dog timer is activated, or
upon reset.
NOTE: The standard configuration of the AEN signal is TTL active low. Both the polarity
and the amplitude can be changed if you are using the ICM-2900 interface board. To make
these changes, see section entitled ‘Amplifier Interface’ pg 3-25.
Error Output - The error output is a TTL signal which indicates on error condition in the
controller. This signal is available on the interconnect module as ERROR. When the error
signal is low, this indicates on of the following error conditions.
1. At least one axis has a position error greater than the error limit. The error limit is set by
using the command ER.
2. The reset line on the controller is held low or is being affected by noise.
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3. There is a failure on the controller and the processor is resetting itself.
4. There is a failure with the output IC which drives the error signal.
Input Protection Lines
General Abort - A low input stops commanded motion instantly without a controlled
deceleration. For any axis in which the Off-On-Error function is enabled, the amplifiers will
be disabled. This could cause the motor to ‘coast’ to a stop. If the Off-On-Error function is
not enabled, the motor will instantaneously stop and servo at the current position. The Off-
On-Error function is further discussed in this chapter.
Selective Abort - The controller can be configured to provide an individual abort for each axis.
Activation of the selective abort signal will act the same as the Abort Input but only on the
specific axis. To configure the controller for selective abort, issue the command CN,,,1. This
configures the inputs 5,6,7,8,13,14,15,16 to act as selective aborts for axes A,B,C,D,E,F,G,H
respectively.
Forward Limit Switch - Low input inhibits motion in forward direction. If the motor is moving
in the forward direction when the limit switch is activated, the motion will decelerate and
stop. In addition, if the motor is moving in the forward direction, the controller will
automatically jump to the limit switch subroutine, #LIMSWI (if such a routine has been
written by the user). The CN command can be used to change the polarity of the limit
switches.
Reverse Limit Switch - Low input inhibits motion in reverse direction. If the motor is moving in
the reverse direction when the limit switch is activated, the motion will decelerate and stop.
In addition, if the motor is moving in the reverse direction, the controller will automatically
jump to the limit switch subroutine, #LIMSWI (if such a routine has been written by the user).
The CN command can be used to change the polarity of the limit switches.
Software Protection
The DMC-2x00 provides a programmable error limit. The error limit can be set for any number
between 1 and 32767 using the ER n command. The default value for ER is 16384.
ER 200,300,400,500
ER,1,,10
Set A-axis error limit for 200, B-axis error limit to 300, C-axis error limit to
400 counts, D-axis error limit to 500 counts
Set B-axis error limit to 1 count, set D-axis error limit to 10 counts.
The units of the error limit are quadrature counts. The error is the difference between the command
position and actual encoder position. If the absolute value of the error exceeds the value specified by
ER, the DMC-2x00 will generate several signals to warn the host system of the error condition. These
signals include:
SIGNAL OR FUNCTION
# POSERR
STATE IF ERROR OCCURS
Jumps to automatic excess position error subroutine
Turns on
Error Light
OE Function
Shuts motor off if OE1
Goes low
AEN Output Line
The Jump on Condition statement is useful for branching on a given error within a program. The
position error of A,B,C and D can be monitored during execution using the TE command.
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Programmable Position Limits
The DMC-2x00 provides programmable forward and reverse position limits. These are set by the BL
and FL software commands. Once a position limit is specified, the DMC-2x00 will not accept position
commands beyond the limit. Motion beyond the limit is also prevented.
Example
Instruction
Interpretation
Define Position
Set Reverse position limit
Set Forward position limit
Jog
DP0,0,0
BL -2000,-4000,-8000
FL 2000,4000,8000
JG 2000,2000,2000
BG ABC
Begin
(motion stops at forward limits)
Off-On-Error
The DMC-2x00 controller has a built in function which can turn off the motors under certain error
conditions. This function is know as ‘Off-On-Error”. To activate the OE function for each axis,
specify 1 for A,B,C and D axis. To disable this function, specify 0 for the axes. When this function is
enabled, the specified motor will be disabled under the following 3 conditions:
1. The position error for the specified axis exceeds the limit set with the command, ER
2. The abort command is given
3. The abort input is activated with a low signal.
NOTE: If the motors are disabled while they are moving, they may ‘coast’ to a stop because they are
no longer under servo control.
To re-enable the system, use the Reset (RS) or Servo Here (SH) command.
Example
OE 1,1,1,1
Enable off-on-error for A,B,C and D
OE 0,1,0,1
Enable off-on-error for B and D axes, Disable off-on-error for A and C
Automatic Error Routine
The #POSERR label causes the statements following to be automatically executed if error on any axis
exceeds the error limit specified by ER. The error routine must be closed with the RE command. The
RE command returns from the error subroutine to the main program.
NOTE: The Error Subroutine will be entered again unless the error condition is gone.
Example
Instruction
#A;JP #A;EN
#POSERR
MG "error"
SB 1
Interpretation
"Dummy" program
Start error routine on error
Send message
Fire relay
STA
Stop motor
AMA
After motor stops
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SHA
RE
Servo motor here to clear error
Return to main program
NOTE: An applications program must be executing for the #POSERR routine to function.
Limit Switch Routine
The DMC-2x00 provides forward and reverse limit switches which inhibit motion in the respective
direction. There is also a special label for automatic execution of a limit switch subroutine. The
#LIMSWI label specifies the start of the limit switch subroutine. This label causes the statements
following to be automatically executed if any limit switch is activated and that axis motor is moving in
that direction. The RE command ends the subroutine.
The state of the forward and reverse limit switches may also be tested during the jump-on-condition
statement. The _LR condition specifies the reverse limit and _LF specifies the forward limit. A,B,C,
or D following LR or LF specifies the axis. The CN command can be used to configure the polarity of
the limit switches.
Example
Instruction
#A;JP #A;EN
#LIMSWI
Interpretation
Dummy Program
Limit Switch Utility
Check if forward limit
Check if reverse limit
Jump to #LF if forward
Jump to #LR if reverse
Jump to end
v1=_LFA
v2=_LRA
JP#LF,v1=0
JP#LR,v2=0
JP#END
#LF
#LF
MG "FORWARD LIMIT"
STX;AMA
Send message
Stop motion
PR-1000;BGA;AMA
JP#END
Move in reverse
End
#LR
#LR
MG "REVERSE LIMIT"
STX;AMA
Send message
Stop motion
PR1000;BGA;AMA
#END
Move forward
End
RE
Return to main program
NOTE: An applications program must be executing for #LIMSWI to function.
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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 with
no additional inputs.
Amplifier offset too
large.
Adjust amplifier offset
Same as above, but offset adjustment does not stop
the motor.
Damaged amplifier.
Replace amplifier.
Controller does not read changes in encoder position. Wrong encoder
connections.
Check encoder wiring.
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.
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Communication
SYMPTOM
CAUSE
REMEDY
Using terminal emulator, cannot
Selected comm. port incorrect
Try another comport
communicate with controller.
Same as above
Selected baud rate incorrect
Check to be sure that baud rate
same as dip switch settings on
controller, change as necessary.
Stability
SYMPTOM
CAUSE
REMEDY
Motor runs away when the loop is
closed.
Wrong feedback polarity.
Invert the polarity of the loop by
inverting the motor leads (brush type)
or the encoder.
Motor oscillates.
Too high gain or too little
damping.
Decrease KI and KP. Increase KD.
Operation
SYMPTOM
CAUSE
REMEDY
Controller rejects command.
Responded with a ?
Anything.
Interrogate the cause with TC or
TC1.
Motor does not complete move.
Noise on limit switches stops the
motor.
To verify cause, check the stop
code (SC). If caused by limit
switch noise, reduce noise.
During a periodic operation, motor Encoder noise
drifts slowly.
Interrogate the position
periodically. If controller states
that the position is the same at
different locations it implies
encoder noise. Reduce noise. Use
differential encoder inputs.
Same as above.
Programming error.
Avoid resetting position error at
end of move with SH command.
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Chapter 10 Theory of Operation
Overview
The following discussion covers the operation of motion control systems. A typical motion control
system consists of the elements shown in Fig 10.1.
COMPUTER
CONTROLLER
DRIVER
ENCODER
MOTOR
Figure 10.1 - Elements of Servo Systems
The operation of such a system can be divided into three levels, as illustrated in Fig. 10.2. The levels
are:
1. Closing the Loop
2. Motion Profiling
3. Motion Programming
The first level, the closing of the loop, assures that the motor follows the commanded position. This is
done by closing the position loop using a sensor. The operation at the basic level of closing the loop
involves the subjects of modeling, analysis, and design. These subjects will be covered in the
following discussions.
The motion profiling is the generation of the desired position function. This function, R(t), describes
where the motor should be at every sampling period. Note that the profiling and the closing of the loop
are independent functions. The profiling function determines where the motor should be and the
closing of the loop forces the motor to follow the commanded position
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The highest level of control is the motion program. This can be stored in the host computer or in the
controller. This program describes the tasks in terms of the motors that need to be controlled, the
distances and the speed.
LEVEL
MOTION
PROGRAMMING
3
MOTION
PROFILING
2
CLOSED-LOOP
CONTROL
1
Figure 10.2 - Levels of Control Functions
The three levels of control may be viewed as different levels of management. The top manager, the
motion program, may specify the following instruction, for example.
PR 6000,4000
SP 20000,20000
AC 200000,00000
BG A
AD 2000
BG B
EN
This program corresponds to the velocity profiles shown in Fig. 10.3. Note that the profiled positions
show where the motors must be at any instant of time.
Finally, it remains up to the servo system to verify that the motor follows the profiled position by
closing the servo loop.
The following section explains the operation of the servo system. First, it is explained qualitatively,
and then the explanation is repeated using analytical tools for those who are more theoretically
inclined.
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X VELOCITY
Y VELOCITY
X POSITION
Y POSITION
TIME
Figure 10.3 - Velocity and Position Profiles
Operation of Closed-Loop Systems
To understand the operation of a servo system, we may compare it to a familiar closed-loop operation,
adjusting the water temperature in the shower. One control objective is to keep the temperature at a
comfortable level, say 90 degrees F. To achieve that, our skin serves as a temperature sensor and
reports to the brain (controller). The brain compares the actual temperature, which is called the
feedback signal, with the desired level of 90 degrees F. The difference between the two levels is called
the error signal. If the feedback temperature is too low, the error is positive, and it triggers an action
which raises the water temperature until the temperature error is reduced sufficiently.
The closing of the servo loop is very similar. Suppose that we want the motor position to be at 90
degrees. The motor position is measured by a position sensor, often an encoder, and the position
feedback is sent to the controller. Like the brain, the controller determines the position error, which is
the difference between the commanded position of 90 degrees and the position feedback. The
controller then outputs a signal that is proportional to the position error. This signal produces a
proportional current in the motor, which causes a motion until the error is reduced. Once the error
becomes small, the resulting current will be too small to overcome the friction, causing the motor to
stop.
The analogy between adjusting the water temperature and closing the position loop carries further. We
have all learned the hard way, that the hot water faucet should be turned at the "right" rate. If you turn
it too slowly, the temperature response will be slow, causing discomfort. Such a slow reaction is called
overdamped response.
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The results may be worse if we turn the faucet too fast. The overreaction results in temperature
oscillations. When the response of the system oscillates, we say that the system is unstable. Clearly,
unstable responses are bad when we want a constant level.
What causes the oscillations? The basic cause for the instability is a combination of delayed reaction
and high gain. In the case of the temperature control, the delay is due to the water flowing in the pipes.
When the human reaction is too strong, the response becomes unstable.
Servo systems also become unstable if their gain is too high. The delay in servo systems is between
the application of the current and its effect on the position. Note that the current must be applied long
enough to cause a significant effect on the velocity, and the velocity change must last long enough to
cause a position change. This delay, when coupled with high gain, causes instability.
This motion controller includes a special filter which is designed to help the stability and accuracy.
Typically, such a filter produces, in addition to the proportional gain, damping and integrator. The
combination of the three functions is referred to as a PID filter.
The filter parameters are represented by the three constants KP, KI and KD, which correspond to the
proportional, integral and derivative term respectively.
The damping element of the filter acts as a predictor, thereby reducing the delay associated with the
motor response.
The integrator function, represented by the parameter KI, improves the system accuracy. With the KI
parameter, the motor does not stop until it reaches the desired position exactly, regardless of the level
of friction or opposing torque.
The integrator also reduces the system stability. Therefore, it can be used only when the loop is stable
and has a high gain.
The output of the filter is applied to a digital-to-analog converter (DAC). The resulting output signal in
the range between +10 and -10 volts is then applied to the amplifier and the motor.
The motor position, whether rotary or linear is measured by a sensor. The resulting signal, called
position feedback, is returned to the controller for closing the loop.
The following section describes the operation in a detailed mathematical form, including modeling,
analysis and design.
System Modeling
The elements of a servo system include the motor, driver, encoder and the controller. These elements
are shown in Fig. 10.4. The mathematical model of the various components is given below.
CONTROLLER
X
Y
R
V
E
DIGITAL
FILTER
ZOH
DAC
AMP
MOTOR
P
Σ
C
ENCODER
Figure 10.4 - Functional Elements of a Motion Control System
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Motor-Amplifier
The motor amplifier may be configured in three modes:
1. Voltage Drive
2. Current Drive
3. Velocity Loop
The operation and modeling in the three modes is as follows:
Voltage Drive
The amplifier is a voltage source with a gain of Kv [V/V]. The transfer function relating the input
voltage, V, to the motor position, P, is
P V = KV K S ST +1 ST +1
)
]
[
t
m
e
where
and
Tm = RJ Kt2 [s]
Te = L R
[s]
and the motor parameters and units are
K
Torque constant [Nm/A]
t
R
J
Armature Resistance Ω
2
Combined inertia of motor and load [kg.m ]
Armature Inductance [H]
L
When the motor parameters are given in English units, it is necessary to convert the quantities to MKS
units. For example, consider a motor with the parameters:
K = 14.16 oz - in/A = 0.1 Nm/A
t
R = 2 Ω
2
-4
2
J = 0.0283 oz-in-s = 2.10 kg . m
L = 0.004 H
Then the corresponding time constants are
T
= 0.04 sec
m
and
T = 0.002 sec
e
Assuming that the amplifier gain is Kv = 4, the resulting transfer function is
P/V = 40/[s(0.04s+1)(0.002s+1)]
Current Drive
The current drive generates a current I, which is proportional to the input voltage, V, with a gain of Ka.
The resulting transfer function in this case is
2
P/V = K K / Js
a
t
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where Kt and J are as defined previously. For example, a current amplifier with K = 2 A/V with the
a
motor described by the previous example will have the transfer function:
2
P/V = 1000/s
[rad/V]
If the motor is a DC brushless motor, it is driven by an amplifier that performs the commutation. The
combined transfer function of motor amplifier combination is the same as that of a similar brush
motor, as described by the previous equations.
Velocity Loop
The motor driver system may include a velocity loop where the motor velocity is sensed by a
tachometer and is fed back to the amplifier. Such a system is illustrated in Fig. 10.5. Note that the
transfer function between the input voltage V and the velocity ω is:
ω /V = [K K /Js]/[1+K K K /Js] = 1/[K (sT +1)]
a
t
a
t
g
g
1
where the velocity time constant, T1, equals
T1 = J/K K K
a
t
g
This leads to the transfer function
P/V = 1/[K s(sT1+1)]
g
V
Ka
Kt/Js
Σ
Kg
Figure 10.5 - Elements of velocity loops
The resulting functions derived above are illustrated by the block diagram of Fig. 10.6.
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VOLTAGE SOURCE
E
W
W
W
P
P
P
V
1/Ke
1
Kv
(STm+1)(STe+1)
S
CURRENT SOURCE
I
V
Kt
1
Ka
JS
S
VELOCITY LOOP
V
1
1
Kg(ST1+1)
S
Figure 10.6 - Mathematical model of the motor and amplifier in three operational modes
Encoder
The encoder generates N pulses per revolution. It outputs two signals, Channel A and B, which are in
quadrature. Due to the quadrature relationship between the encoder channels, the position resolution is
increased to 4N quadrature counts/rev.
The model of the encoder can be represented by a gain of
K = 4N/2π
[count/rad]
f
For example, a 1000 lines/rev encoder is modeled as
K = 638
f
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DAC
The DAC or D-to-A converter converts a 16-bit number to an analog voltage. The input range of the
numbers is 65536 and the output voltage range is +/-10V or 20V. Therefore, the effective gain of the
DAC is
K= 20/65536 = 0.0003
[V/count]
Digital Filter
The digital filter has three elements in series: PID, low-pass and a notch filter. The transfer function of
the filter. The transfer function of the filter elements are:
K(Z − A) CZ
PID
D(z) =
L(z) =
+
Z
Z −1
1− B
Z − B
Low-pass
(Z − z)(Z − z)
(Z − p)(Z − p)
Notch
N(z) =
The filter parameters, K, A, C and B are selected by the instructions KP, KD, KI and PL, respectively.
The relationship between the filter coefficients and the instructions are:
K = (KP + KD)
⋅
4
A = KD/(KP + KD)
C = KI/2
B = PL
The PID and low-pass elements are equivalent to the continuous transfer function G(s).
G(s) = (P + sD + I/s) ∗ a/(S+a)
P = 4KP
D = 4T⋅ KD
I = KI/2T
a = 1/T ln (1/B)
where T is the sampling period.
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For example, if the filter parameters of the DMC-2x00 are
KP = 4
KD = 36
KI = 2
PL = 0.75
T = 0.001 s
the digital filter coefficients are
K = 160
A = 0.9
C = 1
a = 250 rad/s
and the equivalent continuous filter, G(s), is
G(s) = [16 + 0.144s + 1000/s} ∗ 250/ (s+250)
The notch filter has two complex zeros, Z and z, and two complex poles, P and p.
The effect of the notch filter is to cancel the resonance affect by placing the complex zeros on top of
the resonance poles. The notch poles, P and p, are programmable and are selected to have sufficient
damping. It is best to select the notch parameters by the frequency terms. The poles and zeros have a
frequency in Hz, selected by the command NF. The real part of the poles is set by NB and the real part
of the zeros is set by NZ.
The simplest procedure for setting the notch filter is to identify the resonance frequency and set NF to
the same value. Set NB to about one half of NF and set NZ to a low value between zero and 5.
ZOH
The ZOH, or zero-order-hold, represents the effect of the sampling process, where the motor command
is updated once per sampling period. The effect of the ZOH can be modeled by the transfer function
H(s) = 1/(1+sT/2)
If the sampling period is T = 0.001, for example, H(s) becomes:
H(s) = 2000/(s+2000)
However, in most applications, H(s) may be approximated as one.
This completes the modeling of the system elements. Next, we discuss the system analysis.
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System Analysis
To analyze the system, we start with a block diagram model of the system elements. The analysis
procedure is illustrated in terms of the following example.
Consider a position control system with the DMC-2x00 controller and the following parameters:
K = 0.1
Nm/A
Torque constant
t
-4
2
System moment of inertia
J = 2.10
R = 2
kg.m
Motor resistance
Ω
K = 4
a
A/V
Current amplifier gain
KP = 12.5
KD = 245
KI = 0
Digital filter gain
Digital filter zero
No integrator
N = 500
T = 1
Counts/rev
ms
Encoder line density
Sample period
The transfer function of the system elements are:
Motor
2
M(s) = P/I = Kt/Js2 = 500/s [rad/A]
Amp
K = 4 [Amp/V]
a
DAC
K = 0.0003 [V/count]
d
Encoder
K = 4N/2π = 318 [count/rad]
f
ZOH
2000/(s+2000)
Digital Filter
KP = 12.5, KD = 245, T = 0.001
Therefore,
D(z) = 1030 (z-0.95)/Z
Accordingly, the coefficients of the continuous filter are:
P = 50
D = 0.98
The filter equation may be written in the continuous equivalent form:
G(s) = 50 + 0.98s = .098 (s+51)
The system elements are shown in Fig. 10.7.
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AMP
4
FILTER
ZOH
DAC
MOTOR
V
2000
500
S2
50+0.980s
0.0003
Σ
S+2000
ENCODER
318
Figure 10.7 - Mathematical model of the control system
The open loop transfer function, A(s), is the product of all the elements in the loop.
2
A = 390,000 (s+51)/[s (s+2000)]
To analyze the system stability, determine the crossover frequency, ω at which A(j ω ) equals one.
c
c
This can be done by the Bode plot of A(j ω ), as shown in Fig. 10.8.
c
Magnitude
4
1
50
200
2000
W (rad/s)
0.1
Figure 10.8 - Bode plot of the open loop transfer function
For the given example, the crossover frequency was computed numerically resulting in 200 rad/s.
Next, we determine the phase of A(s) at the crossover frequency.
2
A(j200) = 390,000 (j200+51)/[(j200) . (j200 + 2000)]
-1
-1
α = Arg[A(j200)] = tan (200/51)-180° -tan (200/2000)
α = 76° - 180° - 6° = -110°
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Finally, the phase margin, PM, equals
PM = 180° + α = 70°
As long as PM is positive, the system is stable. However, for a well damped system, PM should be
between 30 degrees and 45 degrees. The phase margin of 70 degrees given above indicated
overdamped response.
Next, we discuss the design of control systems.
System Design and Compensation
The closed-loop control system can be stabilized by a digital filter, which is preprogrammed in the
DMC-2x00 controller. The filter parameters can be selected by the user for the best compensation.
The following discussion presents an analytical design method.
The Analytical Method
The analytical design method is aimed at closing the loop at a crossover frequency, ω , with a phase
c
margin PM. The system parameters are assumed known. The design procedure is best illustrated by a
design example.
Consider a system with the following parameters:
K
Nm/A
Torque constant
t
-4
2
System moment of inertia
J = 2.10
R = 2
kg.m
Motor resistance
Ω
K = 2
a
A/V
Current amplifier gain
N = 1000
Counts/rev
Encoder line density
The DAC of the DMC-2x00 outputs +/-10V for a 14-bit command of +/-8192 counts.
The design objective is to select the filter parameters in order to close a position loop with a crossover
frequency of ω = 500 rad/s and a phase margin of 45 degrees.
c
The first step is to develop a mathematical model of the system, as discussed in the previous system.
Motor
2
2
M(s) = P/I = K /Js = 1000/s
t
Amp
K = 2
[Amp/V]
a
DAC
K = 10/32768 = .0003
d
Encoder
ZOH
K = 4N/2π = 636
f
H(s) = 2000/(s+2000)
Compensation Filter
G(s) = P + sD
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The next step is to combine all the system elements, with the exception of G(s), into one function, L(s).
6
2
L(s) = M(s) K K K H(s) =3.17∗10 /[s (s+2000)]
a
d
f
Then the open loop transfer function, A(s), is
A(s) = L(s) G(s)
Now, determine the magnitude and phase of L(s) at the frequency ω = 500.
c
6
2
L(j500) = 3.17∗10 /[(j500) (j500+2000)]
This function has a magnitude of
|L(j500)| = 0.00625
and a phase
-1
Arg[L(j500)] = -180° - tan (500/2000) = -194°
G(s) is selected so that A(s) has a crossover frequency of 500 rad/s and a phase margin of 45 degrees.
This requires that
|A(j500)| = 1
Arg [A(j500)] = -135°
However, since
A(s) = L(s) G(s)
then it follows that G(s) must have magnitude of
|G(j500)| = |A(j500)/L(j500)| = 160
and a phase
arg [G(j500)] = arg [A(j500)] - arg [L(j500)] = -135° + 194° = 59°
In other words, we need to select a filter function G(s) of the form
G(s) = P + sD
so that at the frequency ω =500, the function would have a magnitude of 160 and a phase lead of 59
c
degrees.
These requirements may be expressed as:
|G(j500)| = |P + (j500D)| = 160
and
-1
arg [G(j500)] = tan [500D/P] = 59°
The solution of these equations leads to:
P = 160cos 59° = 82.4
500D = 160sin 59° = 137
Therefore,
D = 0.274
and
G = 82.4 + 0.2744s
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The function G is equivalent to a digital filter of the form:
-1
D(z) = 4KP + 4KD(1-z )
where
P = 4 ∗ KP
D = 4 ∗ KD ∗ T
and
4 ∗ KD = D/T
Assuming a sampling period of T=1ms, the parameters of the digital filter are:
KP = 20.6
KD = 68.6
The DMC-2x00 can be programmed with the instruction:
KP 20.6
KD 68.6
In a similar manner, other filters can be programmed. The procedure is simplified by the following
table, which summarizes the relationship between the various filters.
Equivalent Filter Form
DMC-2x00
Digital
D(z) =[K(z-A/z) + Cz/(z-1)]∗ (1-B)/(Z-B)
-1
-1
Digital
D(z) = [4 KP + 4 KD(1-z ) + KI/2(1-z )] ∗(1-B)/(Z-B)
KP, KD, KI, PL K = (KP + KD)
4
A = KD/(KP+KD)
C = KI/2
B = PL
Continuous
PID, T
G(s) = (P + Ds + I/s) ∗ a/S+a
P = 4 KP
D = 4 T*KD
I = KI/2T
a = 1/T ln (1/PL)
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Appendices
Electrical Specifications
Servo Control
ACMD Amplifier Command:
+/-10 volt analog signal. Resolution 16-bit DAC or
0.0003 volts. 3 mA maximum
A+,A-,B+,B-,IDX+,IDX- Encoder and
Auxiliary
TTL compatible, but can accept up to +/-12 volts.
Quadrature phase on CHA, CHB. Can accept single-
ended (A+,B+ only) or differential (A+,A-,B+,B-).
Maximum A, B edge rate: 12 MHz. Minimum IDX pulse
width: 80 nsec.
Stepper Control
Pulse
TTL (0-5 volts) level at 50% duty cycle. 3,000,000
pulses/sec maximum frequency
Direction
TTL (0-5 volts)
Input / Output
Limit Switch Inputs, Home Inputs.
2.2K ohm in series with opto-isolator. Active high or low
requires at least 1mA to activate. Once activated, the
input requires the current to go below 0.5ma. All Limit
Switch and Home inputs use one common voltage
(LSCOM) which can accept up to 24 volts. Voltages
above 24 volts require an additional resistor.
IN[1] thru IN[8] Uncommitted Inputs and
Abort Input
IN[9] thru IN[16] Uncommitted Inputs
(DMC-2x50 through DMC-2x80 only)
≥ 1 mA = ON; ≤ 0.5 mA = OFF
AN[1] thru AN[8] Analog Inputs:
Standard configuration is +/-10 volts. 12-Bit Analog-to-
Digital converter. 16-bit optional.
OUT[1] thru OUT[8] Outputs:
OUT[9] thru OUT[16] Outputs:
(DMC-2x50 through DMC-2x80 only)
IN[81], IN[82]
TTL
TTL
Auxiliary Encoder Inputs for A (X) axis. Line Receiver
Inputs - accepts differential or single ended voltages with
voltage range of +/- 12 volts.
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IN[83], IN[84]
Auxiliary Encoder Inputs for B (Y) axis. Line Receiver
Inputs - accepts differential or single ended voltages with
voltage range of +/- 12 volts.
(DMC-2x20 through DMC-2x80 only)
IN[85], IN[86]
Auxiliary Encoder Inputs for C (Z) axis. Line Receiver
Inputs - accepts differential or single ended voltages with
voltage range of +/- 12 volts.
(DMC-2x30 through DMC-2x80 only)
IN[87], IN[88]
Auxiliary Encoder Inputs for D (W) axis. Line Receiver
Inputs - accepts differential or single ended voltages with
voltage range of +/- 12 volts.
(DMC-2x40 through DMC-2x80 only)
IN[89], IN[90]
Auxiliary Encoder Inputs for E axis. Line Receiver
Inputs - accepts differential or single ended voltages with
voltage range of +/- 12 volts.
(DMC-2x50 through DMC-2x80 only)
IN[91], IN[92]
Auxiliary Encoder Inputs for F axis. Line Receiver Inputs
- accepts differential or single ended voltages with voltage
range of +/- 12 volts.
(DMC-2x60 through DMC-2x80 only)
IN[93], IN[94]
Auxiliary Encoder Inputs for G axis. Line Receiver
Inputs - accepts differential or single ended voltages with
voltage range of +/- 12 volts.
(DMC-2x70 through DMC-2x80 only)
IN[95], IN[96]
Auxiliary Encoder Inputs for H axis. Line Receiver
Inputs - accepts differential or single ended voltages with
voltage range of +/- 12 volts.
(DMC-2x80 only)
Power
+5V
1.1 A
+12V
-12V
40 mA
40 mA
Performance Specifications
Minimum Servo Loop Update Time:
Normal
Fast Firmware
DMC-2x10
DMC-2x20
DMC-2x30
DMC-2x40
DMC-2x50
DMC-2x60
DMC-2x70
DMC-2x80
250 μsec
250 μsec
375 μsec
375 μsec
500 μsec
500 μsec
625 μsec
625 μsec
125 μsec
125 μsec
250 μsec
250 μsec
375 μsec
375 μsec
500 μsec
500 μsec
Position Accuracy:
+/-1 quadrature count
DMC-2X00
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Velocity Accuracy:
Long Term
Phase-locked, better than .005%
System dependent
Short Term
Position Range:
Velocity Range:
+/-2147483647 counts per move
Up to 12,000,000 counts/sec
servo;
3,000,000 pulses/sec-stepper
2 counts/sec
Velocity Resolution:
Motor Command Resolution:
Variable Range:
16 bit or 0.0003 V
+/-2 billion
Variable Resolution:
-4
1 ⋅ 10
Array Size:
8000 elements, 30 arrays
1000 lines x 80 characters
Program Size:
Fast Update Rate Mode
The DMC-2x00 can operate with much faster servo update rates. This mode is known as 'fast mode'
and allows the controller to operate with the following update rates:
DMC-2x10, DMC-2x20
DMC-2x30, DMC-2x40
DMC-2x50, DMC-2x60
DMC-2x70, DMC-2x80
125 usec
250 usec
375 usec
500 usec
In order to run the DMC-2x00 motion controller in fast mode, the fast firmware must be uploaded.
This can be done through the Galil terminal software such as DMCTERM and WSDK. The fast
firmware is included with the original DMC-2x00 utilities. To set the update rate use command TM.
When the controller is operating with the fast firmware, the following functions are disabled:
Gearing mode
Ecam mode
Pole (PL)
Analog Feedback (AF)
Stepper Motor Operation (MT 2,-2,2.5,-2.5)
Trippoints in thread 2-8
DMA channel
Tell Velocity Interrogation Command (TV)
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Connectors for DMC-2x00 Main Board
DMC-2x00 Axes A-D High Density Connector
1
2
3
4
5
6
7
8
9
Analog Ground
gnd
5v
error output
reset
encoder-compare output
gnd
51 nc
52 gnd
53 5v
54 limit common
55 home W
56 reverse limit W
57 forward limit W
58 home Z
59 reverse limit Z
60 forward limit Z
61 home Y
62 reverse limit Y
63 forward limit Y
64 home X
65 reverse limit X
66 forward limit X
67 gnd
68 5v
69 input common
70 latch X
71 latch Y
72 latch Z
73 latch W
74 input 5
75 input 6
gnd
motor command W
10 sign W / dir W
11 pwm W / step W
12 motor command Z
13 sign Z / dir Z
14 pwm Z / step Y
15 motor command Y
16 sign Y / dir Y
17 pwm Y / step Y
18 motor command X
19 sign X / dir X
20 pwm X / step X
21 amp enable W
22 amp enable Z
23 amp enable y
24 amp enable X
25 A+X
26 A- X
76 input 7
27 B+X
77 input 8
28 B-X
78 abort
29 I+X
30 I-X
31 A+Y
32 A-Y
33 B+Y
34 B-Y
35 I+Y
36 I-Y
79 output 1
80 output 2
81 output 3
82 output 4
83 output 5
84 output 6
85 output 7
86 output 8
87 5v
37 A+Z
38 A-Z
88 gnd
39 B+Z
89 gnd
40 B-Z
90 gnd
41 I+Z
42 I-Z
43 A+W
44 A-W
91 analog in 1
92 analog in 2
93 analog in 3
94 analog in 4
95 analog in 5
45 B+W
DMC-2X00
Appendices y 149
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46 B-W
47 I+W
48 I-W
49 +12V
50 +12V
96 analog in 6
97 analog in 7
98 analog in 8
99 -12v
100 -12v
DMC-2x00 Axes E-H High Density Connector
1
2
3
4
5
6
7
8
9
nc
gnd
5v
51 nc
52 gnd
53 5v
error output
reset
encoder-compare output
gnd
54 limit common
55 home H
56 reverse limit H
57 forward limit H
58 home G
59 reverse limit G
60 forward limit G
61 home F
62 reverse limit F
63 forward limit F
64 home E
65 reverse limit E
66 forward limit E
67 gnd
gnd
motor command H
10 sign H / dir H
11 pwm H / step H
12 motor command G
13 sign G / dir G
14 pwm G / step G
15 motor command F
16 sign F / dir F
17 pwm F / step F
18 motor command E
19 sign E / dir E
20 pwm E / step E
21 amp enable H
22 amp enable G
23 amp enable F
24 amp enable E
25 A+E
68 5v
69 input common
70 latch E
71 latch F
72 latch G
73 latch H
74 input 13
75 input 14
76 input 15
77 input 16
78 abort
26 A- E
27 B+E
28 B-E
29 I+E
30 I-E
31 A+F
32 A-F
33 B+F
34 B-F
35 I+F
36 I-F
79 output 9
80 output 10
81 output 11
82 output 12
83 output 13
84 output 14
85 output 15
86 output 16
87 5v
37 A+G
38 A-G
88 gnd
39 B+G
89 gnd
40 B-G
90 gnd
41 I+G
91 nc
42 I-G
92 nc
150 • Appendices
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43 A+H
44 A-H
45 B+H
46 B-H
47 I+H
48 I-H
93 nc
94 nc
95 nc
96 nc
97 nc
98 nc
49 +12V
50 +12V
99 -12v
100 -12v
DMC-2x00 Auxiliary Encoder 36 Pin High Density Connector
1
2
3
4
5
6
7
8
9
5v
gnd
19 5v
20 gnd
+aaX
-aaX
+abX
-abX
+aaY
-aaY
+abY
21 +aaE
22 -aaE
23 +abE
24 -abE
25 +aaF
26 -aaF
27 +abF
28 -abF
29 +aaG
30 -aaG
31 +abG
32 -abG
33 +aaH
34 -aaH
35 +abH
36 -abH
10 -abY
11 +aaZ
12 -aaZ
13 +abZ
14 -abZ
15 +aaW
16 -aaW
17 +abW
18 -abW
DMC-2x00 Extended I/O 80 Pin High Density Connector
Pin
Signal
Block
Bit @IN[n], @OUT[n]
Bit No
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
GND
8
9
8
9
8
9
8
9
8
9
8
9
8
9
8
9
7
--
72
73
71
74
70
75
69
76
68
77
67
78
66
79
65
80
64
--
7
0
6
1
5
2
4
3
3
4
2
5
1
6
0
7
7
GND
DMC-2X00
Appendices y 151
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19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
I/O
GND
I/O
GND
I/O
GND
I/O
GND
I/O
GND
I/O
GND
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
+5V
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
GND
I/O
7
--
7
--
7
--
7
--
7
--
7
--
7
6
6
6
6
6
6
6
6
--
4
5
4
5
4
5
4
5
4
5
4
5
4
5
4
5
3
--
3
--
3
-
63
--
62
--
61
--
60
--
59
--
58
--
57
56
55
54
53
52
51
50
49
--
40
41
39
42
38
43
37
44
36
45
35
46
34
47
33
48
32
--
6
GND
5
GND
4
GND
3
GND
2
GND
1
GND
0
7
6
5
4
3
2
1
0
+5V
7
0
6
1
5
2
4
3
3
4
2
5
1
6
0
7
7
GND
6
GND
5
GND
4
GND
3
GND
2
GND
1
31
--
30
--
29
--
28
--
27
--
26
--
GND
I/O
GND
I/O
GND
I/O
GND
I/O
3
--
3
--
3
--
3
--
GND
I/O
GND
GND
152 • Appendices
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71
72
73
74
75
76
77
78
79
80
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
+5V
3
2
2
2
2
2
2
2
2
--
25
24
23
22
21
20
19
18
17
--
0
7
6
5
4
3
2
1
0
+5V
RS-232-Main Port
Standard connector and cable, 9Pin
Pin
Signal
1
CTS – OUTPUT
Transmit data-output
Receive data-input
RTS – input
Gnd
CTS – output
RTS – input
CTS – output
Nc
2
3
4
5
6
7
8
9
RS-232-Auxiliary Port
Standard connector and cable, 9Pin
Pin
1
Signal
CTS – input
Transmit data-input
Receive data-output
RTS – output
Gnd
2
3
4
5
6
CTS – input
RTS – output
CTS – input
5v
7
8
9
USB - In
USB - Out
Series B, 4 pos
Series A, 8 pos
Connector: Amp # 787780-1
Connector: Amp # 787617-1
DMC-2X00
Appendices y 153
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Ethernet
100 BASE-T/10 BASE-T - Kycon GS-NS-88-3.5
Pin
1
Signal
TXP
TXN
RXP
NC
2
3
4
5
NC
6
RXN
NC
7
8
NC
10 BASE-2- AMP 227161-7
10 BASE-F- HP HFBR-1414 (TX, Transmitter)
HP HFBR-2416 (RX, Receiver)
LED Status
F
Uses Fiber Link
C
Uses Full Duplex – will blink when a collision Uses Full Duplex – will blink when a collision occurs with half
duplex
L
Ethernet link established – will blink for any activity
Uses 100Base T speed Ethernet
100
Cable Connections for DMC-2x00
The DMC-2x00 requires the transmit, receive, and ground for slow communication rates. (i.e. 1200
baud) For faster rates the handshake lines are required. The connection tables below contain the
handshake lines. These descriptions and tables are for RS-232 only. RS-422 is available on request.
Standard RS-232 Specifications
25 pin Serial Connector (Male, D-type)
This table describes the pinout for standard serial ports found on most computers.
Pin Number
Function
1
NC
2
3
4
5
6
Transmitted Data
Received Data
Request to Send
Clear to Send
Data Set Ready
154 • Appendices
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7
Signal Ground
8
Carrier Detect
9
+Transmit Current Loop Return
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
NC
-Transmit Current Loop Data
NC
NC
NC
NC
NC
NC
+Receive Current Loop Data
NC
Data Terminal Ready
NC
Ring Indicator
NC
NC
-Receive Current Loop Return
9 Pin Serial Connector (Male, D-type)
Standard serial port connections found on most computers.
PIN NUMBER
FUNCTION
1
2
3
4
5
6
7
8
9
Carrier Detect
Receive Data
Transmit Data
Data Terminal Ready
Signal Ground
Data Set Ready
Request to Send
Clear to Send
Ring Indicator
DMC-2x00 Serial Cable Specifications
Cable to Connect Computer 25 pin to Main Serial Port
25 Pin (Male - computer)
8 (Carrier Detect)
9 Pin (female - controller)
1
2
3
4
3 (Receive Data)
2 (Transmit Data)
20 (Data Terminal Ready)
DMC-2X00
Appendices y 155
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7 (Signal Ground)
Controller Ground
5
9
Cable to Connect Computer 9 pin to Main Serial Port Cable (9 pin)
9 Pin (FEMALE - Computer)
9 Pin (FEMALE - Controller)
1 (Carrier Detect)
1
2 (Receive Data)
2
3
4
5
9
3 (Transmit Data)
4 (Data Terminal Ready)
5 (Signal Ground)
Controller Ground
Cable to Connect Computer 25 pin to Auxiliary Serial Port Cable (9
pin)
25 Pin (Male - terminal)
20 (Data Terminal Ready)
2 (Transmit Data)
9 Pin (male - controller)
1
2
3
4
5
9
3 (Receive Data)
8 (Carrier Detect)
7 (Signal Ground)
Controller +5V
Cable to Connect Computer 9 pin to Auxiliary Serial Port Cable (9 pin)
9 Pin (FEMALE - terminal)
4 (Data Terminal Ready)
3 (Transmit Data)
9 Pin (MALE - Controller)
1
2
3
4
5
9
2 (Receive Data)
1 (Carrier Detect)
5 (Signal Ground)
Controller +5V
156 • Appendices
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Pin-Out Description for DMC-2x00
Outputs
Analog Motor Command
+/- 10 volt range signal for driving amplifier. In servo mode,
motor command output is updated at the controller sample rate. In
the motor off mode, this output is held at the OF command level.
Amp Enable
Signal to disable and enable an amplifier. Amp Enable goes low
on Abort and OE1.
PWM/STEP OUT
PWM/STEP OUT is used for directly driving power bridges for
DC servo motors or for driving step motor amplifiers. For servo
motors: If you are using a conventional amplifier that accepts a
+/-10 volt analog signal, this pin is not used and should be left
open. The PWM output is available in two formats: Inverter and
Sign Magnitude. In the Inverter mode, the PWM signal is .2%
duty cycle for full negative voltage, 50% for 0 voltage and 99.8%
for full positive voltage (25kHz switching frequency). In the Sign
Magnitude Mode (Jumper SM), the PWM signal is 0% for 0
voltage, 99.6% for full voltage and the sign of the Motor
Command is available at the sign output (50kHz switching
frequency).
PWM/STEP OUT
For step motors: The STEP OUT pin produces a series of pulses
for input to a step motor driver. The pulses may either be low or
high. The pulse width is 50%. Upon Reset, the output will be low
if the SM jumper is on. If the SM jumper is not on, the output will
be tristate.
Sign/Direction
Error
Used with PWM signal to give the sign of the motor command for
servo amplifiers or direction for step motors.
The signal goes low when the position error on any axis exceeds
the value specified by the error limit command, ER.
Output 1-Output 8
Output 9-Output 16
(DMC-2x50 thru 2x80
These 8 TTL outputs are uncommitted and may be designated by
the user to toggle relays and trigger external events. The output
lines are toggled by Set Bit, SB, and Clear Bit, CB, instructions.
The OP instruction is used to define the state of all the bits of the
Output port.
Inputs
Encoder, A+, B+
Position feedback from incremental encoder with two channels in
quadrature, CHA and CHB. The encoder may be analog or TTL.
Any resolution encoder may be used as long as the maximum
frequency does not exceed 12,000,000 quadrature states/sec. The
controller performs quadrature decoding of the encoder signals
resulting in a resolution of quadrature counts (4 x encoder cycles).
NOTE: Encoders that produce outputs in the format of pulses and
direction may also be used by inputting the pulses into CHA and
direction into Channel B and using the CE command to configure
this mode.
DMC-2X00
Appendices y 157
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Encoder Index, I+
Encoder, A-, B-, I-
Once-Per-Revolution encoder pulse. Used in Homing sequence or
Find Index command to define home on an encoder index.
Differential inputs from encoder. May be input along with CHA,
CHB for noise immunity of encoder signals. The CHA- and CHB-
inputs are optional.
Auxiliary Encoder, Aux A+, Inputs for additional encoder. Used when an encoder on both the
Aux B+, Aux I+, Aux A-,
Aux B-, Aux I-
motor and the load is required. Not available on axes configured
for step motors.
Abort
A low input stops commanded motion instantly without a
controlled deceleration. Also aborts motion program.
Reset
A low input resets the state of the processor to its power-on
condition. The previously saved state of the controller, along with
parameter values, and saved sequences are restored.
Forward Limit Switch
Reverse Limit Switch
Home Switch
When active, inhibits motion in forward direction. Also causes
execution of limit switch subroutine, #LIMSWI. The polarity of
the limit switch may be set with the CN command.
When active, inhibits motion in reverse direction. Also causes
execution of limit switch subroutine, #LIMSWI. The polarity of
the limit switch may be set with the CN command.
Input for Homing (HM) and Find Edge (FE) instructions. Upon
BG following HM or FE, the motor accelerates to slew speed. A
transition on this input will cause the motor to decelerate to a stop.
The polarity of the Home Switch may be set with the CN
command.
Input 1 - Input 8 isolated
Input 9 - Input 16 isolated
Uncommitted inputs. May be defined by the user to trigger
events. Inputs are checked with the Conditional Jump instruction
and After Input instruction or Input Interrupt. Input 1 is latch A,
Input 2 is latch B, Input 3 is latch C and Input 4 is latch D if the
high speed position latch function is enabled.
Latch
High speed position latch to capture axis position on occurrence of
latch signal. AL command arms latch. Input 1 is latch A, Input 2
is latch B, Input 3 is latch C and Input 4 is latch D. Input 9 is latch
E, input 10 is latch F, input 11 is latch G, input 12 is latch H.
158 • Appendices
DMC-2X00
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Jumper Description for DMC-2x00
Jumper
Label
SMX
SMY
SMZ
Function (If jumpered)
JP5 MB
For each axis, the SM jumper selects the SM
magnitude mode for servo motors or selects
stepper motors. If you are using stepper
SMW
motors, SM must always be jumpered. The Analog
command is not valid with SM jumpered.
JP7 MB
JP1 MB
SM E
SM F
SM G
SM H
OPT
Reserved
MRST
Master Reset enable. Returns controller to factory default
settings and erases EEPROM. Requires power-on or RESET
to be activated.
JP 3 DB for DMC-2000
UPGRADE Used to upgrade controller firmware when resident firmware
is corrupt.
JP4 DB for DMC-2100/2200
JP4 DB for DMC-2000
JP 5 for DMC-2100/2200
AUX
Serial Port Configuration for RS-232/RS-422
JP3
MAIN
Main Serial Port configuration for RS-232/RS-422
NOTE: MB denotes motherboard. DB denotes daughter board.
DMC-2X00
Appendices y 159
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Dimensions for DMC-2x00
160 • Appendices
DMC-2X00
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Accessories and Options
DMC-20x0
-16
1- 8 axis motion controllers where x specifies the number of axes
16-Bit ADC Option for analog inputs
100-pin high density cable, 1 meter
100-pin high density cable, 4 meter
80-pin high density cable, 1 meter
80-pin high density cable, 4 meter
36-pin high density cable, 1 meter
36-pin high density cable, 4 meter
USB cable, 2 meter
USB cable, 3 meter
CABLE-100-1M
CABLE-100-4M
CABLE-80-1M
CABLE-80-4M
CABLE-36-1M
CABLE-36-4M
CABLE-USB-2M
CABLE-USB-3M
CB-50-100
50-pin to 100-pin converter board, includes two 50-pin ribbon cables
50-pin to 80-pin converter board, includes two 50-pin ribbon cables
Interconnect module
CB-50-80
ICM-1900
-LAEN
Option for ICM-1900
Provides Active Low Amplifier Enable Signal
-OPTO
-OPTOHC
AMP-19x0
-OPTO
Option for ICM-1900
Provides Opto0isolation for digital outputs
Option for ICM-1900
Provides High Current Opto-isolation for digital outputs
Interconnect module with 1 - 4 brush motor amplifiers where x specifies the number
of amplifiers.
Option for AMP-19x0
Provides Opto0isolation for digital outputs
-OPTOHC
Option for AMP-19x0
Provides High Current Opto-isolation for digital outputs
Interconnect module with detachable screw terminal
Option for ICM-2900
ICM-2900
-LAEN
Provides Active Low Amplifier Enable Signal
Option for ICM-2900 where the ICM-2900 includes flanges for rack mounting
ICM-2900 module with screw terminal
Option for AMP-19x0
-FL
-ST
-OPTO
Provides Opto-isolation for digital outputs
-OPTOHC
Option for AMP-19x0
Provides High Current Opto-isolation for digital outputs
Galil CD-ROM / Utilities.
Includes the following:
DMCWIN16
DMCWIN32
SETUP16
Windows 3.x Terminal
Windows 95 / 98 / NT Terminal
Setup Utility for Window 3.x
SETUP32
C KIT
Setup Utility for Windows 95/98/NT
C-Programmers Kit
WSDK-16
WSDK-32
VBX Tool Kit
CAD-to-DMC
MCS
Servo Design Kit for Windows 3.x
Servo Design Kit for Windows 95 / 98 / NT
Visual BasicTM Tool Kit (includes VBXs and OCXs)
AutoCADR DXF translator
Motion Control Selector. Utility for motor / amplifier sizing.
HPGL translator
HPGL
DMC-2X00
Appendices y 161
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ICM-2900 Interconnect Module
Mechanical Specifications
Description
-----------
Weight
Unit
----
lb
Specification
-------------
2.3
Length
in
12.25
Width
in
2.61
Height
in
2.37
Environmental Specifications
Description
Unit
----
C
Specification
-------------
-25 to +70
0 to +70
-----------
Storage Temperature
Operating Temperature
Operating Altitude
C
feet
10,000
Equipment Maintenance
The ICM-2900 does not require maintenance.
Description
The ICM-2900 interconnect module provides easy connections between the Optima series controllers
and other system elements, such as amplifiers, encoders, and external switches. The ICM- 2900
accepts the 100-pin main cable and provides terminal blocks for connections. Each terminal is labeled
for quick connection of system elements. The ICM-2900 provides access to the signals for up to 4
axes (Two required for 5 or more axes).
Block (4 PIN)
Label
I/O
Description
1
MOCMDZ
O
Z axis motor command to amp input (w / respect to
ground)
1
1
1
2
SIGNZ
PWMZ
GND
O
O
O
O
Z axis sign output for input to stepper motor amp
Z axis pulse output for input to stepper motor amp
Signal Ground
MOCMDW
W axis motor command to amp input (w / respect
to ground)
2
2
2
3
SIGNW
PWMW
GND
O
O
O
O
W axis sign output for input to stepper motor amp
W axis pulse output for input to stepper motor amp
Signal Ground
MOCMDX
X axis motor command to amp input (w / respect to
ground)
3
SIGNX
O
X axis sign output for input to stepper motor amp
162 • Appendices
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3
3
4
PWMX
GND
O
O
O
X axis pulse output for input to stepper motor amp
Signal Ground
MOCMDY
Y axis motor command to amp input (w / respect to
ground)
4
SIGNY
PWMY
GND
O
O
O
I
Y axis sign output for input to stepper motor amp
Y axis pulse output for input to stepper motor amp
Signal Ground
4
4
5
OUT PWR
ERROR
CMP
Isolated Power In for Opto-Isolation Option
Error output
5
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
I
5
Circular Compare Output
Isolated Ground for Opto-Isolation Option
W axis amplifier enable
Z axis amplifier enable
Y axis amplifier enable
X axis amplifier enable
General Output 5
5
OUT GND
AMPENW
AMPENZ
AMPENY
AMPENX
OUT5
6
6
6
6
7
7
OUT6
General Output 6
7
OUT7
General Output 7
7
OUT8
General Output 8
8
OUT1
General Output 1
8
OUT2
General Output 2
8
OUT3
General Output 3
8
OUT4
General Output 4
9
+5V
+ 5 volts
9
HOMEZ
RLSZ
Z axis home input
9
I
Z axis reverse limit switch input
Z axis forward limit switch input
Limit Switch Common Input
W axis home input
9
FLSZ
I
10
10
10
10
11
11
11
11
12
12
12
12
13
13
13
LSCOM
HOMEW
RLSW
FLSW
HOMEX
RLSX
I
I
I
W axis reverse limit switch input
W axis forward limit switch input
X axis home input
I
I
I
X axis reverse limit switch input
X axis forward limit switch input
Signal Ground
FLSX
I
GND
O
I
HOMEY
RLSY
Y axis home input
I
Y axis reverse limit switch input
Y axis forward limit switch input
Signal Ground
FLSY
I
GND
O
I
IN5
Input 5
IN6
I
Input 6
IN7
I
Input 7
DMC-2X00
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13
14
14
14
14
15
15
15
15
IN8
I
Input 8
XLATCH
YLATCH
ZLATCH
WLATCH
+5V
I
Input 1 (Used for X axis latch input)
Input 2 (Used for Y axis latch input)
Input 3 (Used for Z axis latch input)
Input 4 (Used for W axis latch input)
+ 5 volts
I
I
I
O
O
O
O
+12V
+12 volts
-12V
-12 volts
ANA GND
Isolated Analog Ground for Use with Analog
Inputs
16
16
16
16
17
17
17
17
18
18
18
18
19
19
19
19
20
20
20
20
21
21
21
21
22
22
22
22
23
23
23
23
INCOM
ABORT
RESET
GND
I
Input Common For General Use Inputs
Abort Input
I
I
Reset Input
O
I
Signal Ground
ANALOG5
ANALOG6
ANALOG7
ANALOG8
ANALOG1
ANALOG2
ANALOG3
ANALOG4
+5V
Analog Input 5
I
Analog Input 6
I
Analog Input 7
I
Analog Input 8
I
Analog Input 1
I
Analog Input 2
I
Analog Input 3
I
Analog Input 4
O
I
+ 5 volts
+INX
X Main encoder Index +
X Main encoder Index -
Signal Ground
-INX
I
GND
O
I
+MAX
-MAX
X Main encoder A+
X Main encoder A-
X Main encoder B+
X Main encoder B-
+ 5 volts
I
+MBX
-MBX
I
I
+5V
O
I
+INY
Y Main encoder Index +
Y Main encoder Index -
Signal Ground
-INY
I
GND
O
I
+MAY
-MAY
Y Main encoder A+
Y Main encoder A-
Y Main encoder B+
Y Main encoder B-
+ 5 volts
I
+MBY
-MBY
I
I
+5V
O
I
+INZ
Z Main encoder Index +
Z Main encoder Index -
Signal Ground
-INZ
I
GND
O
164 • Appendices
DMC-2X00
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24
24
24
24
25
25
25
25
26
26
26
26
+MAZ
-MAZ
+MBZ
-MBZ
+5V
I
Z Main encoder A+
Z Main encoder A-
Z Main encoder B+
Z Main encoder B-
+ 5 volts
I
I
I
O
I
+INW
-INW
W Main encoder Index +
W Main encoder Index -
Signal Ground
I
GND
O
I
+MAW
-MAW
+MBW
-MBW
W Main encoder A+
W Main encoder A-
W Main encoder B+
W Main encoder B-
I
I
I
DMC-2X00
Appendices y 165
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ICM-2900 Drawing:
2.40"
2.75"
2.40"
ICM-
MOCMDZ
SIGNZ
PWMZ
GND
MOCMDW
SIGNW
PWMW
GND
Holes for
mounting to DMC-
2000 (2 holes)
MOCMDX
SIGNX
PWMX
GND
MOCMDY
SIGNY
PWMY
GND
OUT PWR
ERROR
CMP
AMPENW
AMPENZ
AMPENY
AMPENX
100 pin high
density connector
AMP #2-178238-9
Solderless connections
– use screwdriver to
open contacts for
insertion/removal of
lead wires, part
OUT GND
OUT5
OUT6
OUT7
OUT8
OUT1
OUT2
OUT3
OUT4
replacement: PCD part
# ELFF04240
+5V
HOMEZ
RLSZ
LSCOM
HOMEW
RLSW
FLSZ
FLSW
HOMEX
RLSX
FLSX
GND
HOMEY
RLSY
FLSY
GND
IN5
IN6
IN7
IN8
XLATCH
YLATCH
ZLATCH
WLATCH
12.25"
+5V
+12V
INCOM
ABORT
RESET
GND
-12V
ANA GND
ANALOG5
ANALOG6
ANALOG7
ANALOG8
ANALOG1
ANALOG2
ANALOG3
ANALOG4
+5V
+INX
-INX
GND
+MAX
-MAX
+MBX
-MBX
+5V
+INY
-INY
GND
+MAY
-MAY
+MBY
-MBY
+5V
+INZ
-INZ
GND
+MAZ
-MAZ
+MBZ
-MBZ
+5V
+INW
-INW
GND
+MAW
-MAW
+MBW
-MBW
Front
Side
Back
Figure A-1
166 • Appendices
DMC-2X00
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ICM-2908 Interconnect Module
The ICM-2908 interconnect module provides easy connections between the auxiliary encoder
connections of the DMC-2x00 series controller and other system elements. The ICM-2908 accepts the
36 pin high density cable (CABLE-36) from the controller and provides terminal blocks for easy
access. Each terminal is labeled for quick connection. One ICM-1908 provides access to all of the
auxiliary encoders on a DMC-2x00 (up to 8 axes).
DMC-2X00
Appendices y 167
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ICM-2908 Drawing:
2.40"
2.75"
2.40"
ICM-2908
Holes for
mounting to DMC-
2000 (2 holes)
36 pin high density
connector
AMP #2-178238-5
3M #10236-55-G3VC
Solderless
connections -
insert screwdriver
to open contacts
for insertion/
removal of lead
wires
+AAY
-AAY
+ABY
-ABY
+AAX
-AAX
+ABX
-ABX
+AAW
-AAW
+ABW
-ABW
+AAZ
-AAZ
+ABZ
-ABZ
GND
GND
GND
GND
+5V
+5V
+5V
+5V
12.25"
+AAF
-AAF
+ABF
-ABF
+AAE
-AAE
+ABE
-ABE
+AAH
-AAH
+ABH
-ABH
+AAG
-AAG
+ABG
-ABG
Front
Side
Back
Figure A-2
168 • Appendices
DMC-2X00
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PCB Layout of the ICM-2900:
ANALOG
SWITCH
RP4
U1
AMPLIFIER
ENABLE
BUFFER
12V
5V
U6
* FOR 5 VOLT AMPLIFIER ENABLE -
PLACE PIN 1 OF RP1 ON PIN LABELED
"5V"
* FOR 12 VOLT AMPLIFIER ENABLE -
PLACE PIN 1 OF RP1 ON PIN LABELED
"12V"
RP1
U1
U2
RP2
RP3
OPTIONAL OPTO-ISOLATION
CIRCUIT
100PIN HIGH DENSITY
CONNECTOR
AMP part # 2-178238-9
ICM-2900 BOARD LAYOUT
DMC-2X00
Appendices y 169
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ICM-1900 Interconnect Module
The ICM-1900 interconnect module provides easy connections between the DMC-2x00 series
controllers and other system elements, such as amplifiers, encoders, and external switches. The ICM-
1900 accepts the 100-pin main cable and 25-pin auxiliary cable and breaks them into screw-type
terminals. Each screw terminal is labeled for quick connection of system elements. An ICM-1900 is
required for each set of 4 axes. (Two required for DMC-2x50 thru DMC-2x80).
The ICM-1900 is contained in a metal enclosure. A version of the ICM-1900 is also available with
servo amplifiers (see AMP-19x0).
Features
• Separate DMC-2x00 cables into individual screw-type terminals
• Clearly identifies all terminals
• Provides jumper for connecting limit and input supplies to 5 V supply from PC
• Available with on-board servo drives (see AMP-19X0)
• Can be configured for AEN high or low
NOTE: The part number for the 100-pin connector is #2-178238-9 from AMP
Terminal
Label
+AAX
-AAX
+ABX
-ABX
+AAY
-AAY
+ABY
-ABY
+AAZ
-AAZ
+ABZ
-ABZ
I/O
Description
1
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
X Auxiliary encoder A+
X Auxiliary encoder A-
X Auxiliary encoder B+
X Auxiliary encoder B-
Y Auxiliary encoder A+
Y Auxiliary encoder A-
Y Auxiliary encoder B+
Y Auxiliary encoder B-
Z Auxiliary encoder A+
Z Auxiliary encoder A-
Z Auxiliary encoder B+
Z Auxiliary encoder B-
W Auxiliary encoder A+
W Auxiliary encoder A-
W Auxiliary encoder B+
W Auxiliary encoder B-
Signal Ground
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
+AAW
-AAW
+ABW
-ABW
GND
+VCC
+ 5 volts
ISO OUT
POWER
O
Isolated Output Power(for use with the opto-isolated output
option)
20
21
22
23
ERROR
RESET
CMP
O
I
Error signal
Reset
O
O
Circular Compare output
MOCMDW
W axis motor command to amp input (w / respect to ground)
170 • Appendices
DMC-2X00
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24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
SIGNW
PWMW
MOCMDZ
SIGNZ
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
O
I
W axis sign output for input to stepper motor amp
W axis pulse output for input to stepper motor amp
Z axis motor command to amp input (w / respect to ground)
Z axis sign output for input to stepper motor amp
Z axis pulse output for input to stepper motor amp
Y axis motor command to amp input (w / respect to ground)
Y axis sign output for input to stepper motor amp
Y axis pulse output for input to stepper motor amp
X axis motor command to amp input (w / respect to ground)
X axis sign output for input to stepper motor amp
X axis pulse output for input to stepper motor amp
Isolated Output Ground
PWMZ
MOCMDY
SIGNY
PWMY
MOCMDX
SIGNX
PWMX
ISO OUT GND
+VCC
+ 5 volts
AMPENW
AMPENZ
AMPENY
AMPENX
LSCOM
HOMEW
RLSW
W axis amplifier enable
Z axis amplifier enable
Y axis amplifier enable
X axis amplifier enable
Limit Switch Common
I
W axis home input
I
W axis reverse limit switch input
W axis forward limit switch input
Z axis home input
FLSW
I
HOMEZ
RLSZ
I
I
Z axis reverse limit switch input
Z axis forward limit switch input
Y axis home input
FLSZ
I
HOMEY
RLSY
I
I
Y axis reverse limit switch input
Y axis forward limit switch input
X axis home input
FLSY
I
HOMEX
RLSX
I
I
X axis reverse limit switch input
X axis forward limit switch input
+ 5 volts
FLSX
I
+VCC
GND
Signal Ground
INCOM
XLATCH
YLATCH
ZLATCH
WLATCH
IN5
I
I
I
I
I
I
I
I
I
I
Input common (Common for general inputs and Abort input)
Input 1 (Used for X axis latch input)
Input 2 (Used for Y axis latch input)
Input 3 (Used for Z axis latch input)
Input 4 (Used for W axis latch input)
Input 5
IN6
Input 6
IN7
Input 7
IN8
Input 8
ABORT
Abort Input
DMC-2X00
Appendices y 171
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66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
96
97
98
99
100
101
102
103
104
105
106
107
OUT1
OUT2
OUT3
OUT4
OUT5
OUT6
OUT7
OUT8
GND
O
O
O
O
O
O
O
O
Output 1
Output 2
Output 3
Output 4
Output 5
Output 6
Output 7
Output 8
Signal Ground
AN1
I
I
I
I
I
I
I
I
I
I
I
I
I
I
Analog Input 1
Analog Input 2
Analog Input 3
Analog Input 4
Analog Input 5
Analog Input 6
Analog Input 7
Analog Input 8
X Main encoder A+
X Main encoder A-
X Main encoder B+
X Main encoder B-
X Main encoder Index +
X Main encoder Index -
Analog Ground
+ 5 volts
AN2
AN3
AN4
AN5
AN6
AN7
AN8
+MAX
-MAX
+MBX
-MBX
+INX
-INX
ANA GND
+VCC
+MAY
-MAY
+MBY
-MBY
+INY
-INY
I
I
I
I
I
I
I
I
I
I
I
I
Y Main encoder A+
Y Main encoder A-
Y Main encoder B+
Y Main encoder B-
Y Main encoder Index +
Y Main encoder Index -
Z Main encoder A+
Z Main encoder A-
Z Main encoder B+
Z Main encoder B-
Z Main encoder Index +
Z Main encoder Index -
Signal Ground
+MAZ
-MAZ
+MBZ
-MBZ
+INZ
-INZ
GND
+VCC
+MAW
-MAW
+MBW
+ 5 volts
I
I
I
W Main encoder A+
W Main encoder A-
W Main encoder B+
172 • Appendices
DMC-2X00
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108
109
110
111
112
-MBW
+INW
-INW
+12V
-12V
I
I
I
W Main encoder B-
W Main encoder Index +
W Main encoder Index -
+12 volts
-12 volts
ICM-1900 Drawing:
13.500"
12.560"
11.620"
0.220"
0.440"
Figure A-3
AMP-19x0 Mating Power Amplifiers
The AMP-19x0 series are mating, brush-type servo amplifiers for the DMC-2x00. The AMP-1910
contains 1 amplifier: the AMP-1920, 2 amplifiers; the AMP-1930, 3 amplifiers; and the AMP-1940, 4
amplifiers. Each amplifier is rated for 7 amps continuous, 10 amps peak at up to 80 V. The gain of the
AMP-19x0 is 1 amp/V. The AMP-19x0 requires an external DC supply. The AMP-19x0 connects
directly to the DMC-2x00, and screw type terminals are provided for connection to motors, encoders,
and external switches.
Features
• 7 amps continuous, 10 amps peak; 20 to 80V
• Available with 1, 2, 3, or 4 amplifiers
• Connects directly to DMC-2x00 series controllers
DMC-2X00
Appendices y 173
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• Screw-type terminals for easy connection to motors, encoders, and switches
• Steel mounting plate with ¼” keyholes
Specifications
Minimum motor inductance: 1 mH
PWM frequency: 30 kHz
Ambient operating temperature: 0o to 70o C
Dimensions:
Weight:
Mounting: Keyholes – ¼”∅
Gain: 1 amp/V
Opto-Isolated Outputs for ICM-2900 / ICM-1900 / AMP-
19x0
The ICM/AMP 1900 and ICM-2900 modules from Galil have an option for opto-isolated outputs.
Standard Opto-Isolation and High Current Opto-isolation:
The Opto-isolation option on the ICM-1900 has 2 forms: -opto (standard) and -optohc (high current).
The standard version provides outputs with 4ma drive current / output with approximately 2 usec
response time. The high current version provides 25ma drive current / output with approximately 400
usec response time.
FROM
CONTROLLER
ICM-1900 / ICM-2900
CONNECTIONS
+5V
ISO OUT POWER (ICM-1900,PIN 19)
OUT POWER (ICM-2900)
RP4 on ICM-1900 =10K OHMS
RP2 on ICM-2900
RP3
OUT[x] (66 - 73)
ISO POWER GND (ICM-1900,PIN 35)
OUT GND (ICM-2900)
OUT[x] TTL
Figure A-4
The ISO OUT POWER (OUT POWER ON ICM-2900) and ISO POWER GND (OUT GND ON ICM-
2900) signals should be connected to an isolated power supply. This power supply should be used
only to power the outputs in order to obtain isolation from the controller. The signal "OUT[x]" is one
of the isolated digital outputs where X stands for the digital output terminals.
The default configuration is for active high outputs. If active low outputs are desired, reverse RP3 in
it's socket. This will tie RP3 to GND instead of VCC, inverting the sense of the outputs.
NOTE: If power is applied to the outputs with an isolated power supply but power is not applied to the
controller, the outputs will float high (unable to sink current). This may present a problem when using
174 • Appendices
DMC-2X00
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active high logic and care should be taken. Using active low logic should avoid any problems
associated with the outputs floating high.
Configuring the Amplifier Enable for ICM-2900 / ICM-
1900
The ICM-1900 and ICM-2900 modules can be configured to provide an active low signal to enable
external amplifiers. These modules can also be configured for voltage levels other than TTL.
-LAEN Option:
The standard configuration of the AEN signal is TTL active high. In other words, the AEN signal will
be high when the controller expects the amplifier to be enabled. The polarity can be changed when
using a Galil Interconnect Module. To change the polarity from active high (5 volts = enable, zero
volts = disable) to active low (zero volts = enable, 5 volts = disable), replace the socketed IC, 7407,
with a 7406. These IC’s are labeled U6 on the ICM-1900 and U2 on the ICM-2900 and can be
accessed by removing the cover. This option can be requested when ordering the unit by specifying
the -LAEN option.
-Changing the Amplifier Enable Voltage Level:
To change the voltage level of the AEN signal, note the state of the resistor pack, labeled RP1 on the
ICM-1900 / ICM-2900. When Pin 1 is on the 5V mark, the output voltage is 0-5V. To change to 12
volts, pull the resistor pack and rotate it so that Pin 1 is on the 12 volt side. If you remove the resistor
pack, the output signal is an open collector, allowing the user to connect an external supply with
voltages up to 24V.
DMC-2000
ICM-1900 / ICM-2900
Connection to +5V or +12V made through
Resistor pack RP1. Removing the resistor pack
allows the user to connect their own resistor to
the desired voltage level (Up to24V). Accessed
by removing ICM cover.
+12V
+5V
SERVO MOTOR
AMPLIFIER
AMPENX
GND
100-PIN
HIGH
DENSITY
CABLE
7407 Open Collector
Buffer. The Enable signal
can be inverted by using a
7406. Accessed by
removing ICM-2900 cover.
Figure A-5
DMC-2X00
Appendices y 175
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IOM-1964 Opto-Isolation Module for Extended I/O
Description:
•
•
•
•
•
•
•
Provides 64 optically isolated inputs and outputs, each rated for 2mA at up to 28 VDC
Configurable as inputs or outputs in groups of eight bits
Provides 16 high power outputs capable of up to 500mA each
Connects to controller via 80 pin shielded cable
All I/O points conveniently labeled
Each of the 64 I/O points has status LED
Dimensions 6.8” x 11.4”
High Current
Screw Terminals
Buffer chips (16)
0 1 2 3 4 5 6 7
IOM-1964
REV A
GALIL MOTION CONTROL
MADE IN USA
FOR INPUTS:
UX3
FOR OUTPUTS:
UX1
UX4
UX2
RPX4
RPX2
RPX3
J5
Banks 0 and 1
80 pin high
density connector
Banks 2-7 are
standard banks.
provide high
power output
capability.
Figure A-6
Overview
The IOM-1964 is an input/output module that connects to the motion controller cards from Galil,
providing optically isolated buffers for the extended inputs and outputs of the controller. The IOM-
1964 also provides 16 high power outputs capable of 500mA of current per output point. The IOM-
1964 splits the 64 I/O points into eight banks of eight I/O points each, corresponding to the eight banks
176 • Appendices
DMC-2X00
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of extended I/O on the controller. Each bank is individually configured as an input or output bank by
inserting the appropriate integrated circuits and resistor packs. The hardware configuration of the
IOM-1964 must match the software configuration of the controller card.
All DMC-2x00 series controllers have general purpose I/O connections. On a DMC-2x10, -2x20, -
2x30, and -2x40 the standard uncommitted I/O consists of: eight optically isolated digital inputs, eight
TTL digital outputs, and eight analog inputs.
The DMC-2x00, however, has an additional 64 digital input/output points than the 16 described above
for a total of 80 input/output points. An 80 pin shielded cable connects from the 80 pin connector of
the DMC-2x00 to the 80 pin high density connector on the IOM-1964 (J5). Illustrations for this
connection can be found on pages 10 and 11.
Configuring Hardware Banks
The extended I/O on the DMC-2x00 is configured using the CO command. The banks of buffers on
the IOM-1964 are configured to match by inserting the appropriate IC’s and resistor packs. The layout
of each of the I/O banks is identical.
For example, here is the layout of bank 0:
Resistor Pack for
outputs
RP03 OUT
Resistor Pack for
Input Buffer IC's
inputs
U03
U04
IN
Resistor Pack for
outputs
Output Buffer IC's
Indicator LED's
U01
U02
OUT
Resistor Pack for
LED's
D0
C6
RP01
Bank 0
Figure A-7
All of the banks have the same configuration pattern as diagrammed above. For example, all banks
have Ux1 and Ux2 output optical isolator IC sockets, labeled in bank 0 as U01 and U02, in bank 1 as
U11 and U12, and so on. Each bank is configured as inputs or outputs by inserting optical isolator
IC’s and resistor packs in the appropriate sockets. A group of eight LED’s indicates the status of each
DMC-2X00
Appendices y 177
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I/O point. The numbers above the Bank 0 label indicate the number of the I/O point corresponding to
the LED above it.
Digital Inputs
Configuring a bank for inputs requires that the Ux3 and Ux4 sockets be populated with NEC2505
optical isolation integrated circuits. The IOM-1964 is shipped with a default configuration of banks 2-
7 configured as inputs. The output IC sockets Ux1 and Ux2 must be empty. The input IC’s are labeled
Ux3 and Ux4. For example, in bank 0 the IC’s are U03 and U04, bank 1 input IC’s are labeled U13
and U14, and so on. Also, the resistor pack RPx4 must be inserted into the bank to finish the input
configuration.
Input Circuit
I/OCn
1/8 RPx4
1/4 NEC2505
To DMC-1748* I/O
DMC-1748* GND
x = bank number 0-7
n = input number 17-80
I/On
Figure A-8
Connections to this optically isolated input circuit are done in a sinking or sourcing configuration,
referring to the direction of current. Some example circuits are shown below:
Sinking
Sourcing
I/OCn
I/On
+5V
I/OCn
I/On
GND
+5V
GND
Current
Current
Figure A-9
There is one I/OC connection for each bank of eight inputs. Whether the input is connected as sinking
or souring, when the switch is open no current flows and the digital input function @IN[n] returns 1.
This is because of an internal pull up resistor on the DMC-2x40*. When the switch is closed in either
circuit, current flows. This pulls the input on the DMC-2x40 to ground, and the digital input function
@IN[n] returns 0. Note that the external +5V in the circuits above is for example only. The inputs are
optically isolated and can accept a range of input voltages from 4 to 28 VDC.
Active outputs are connected to the optically isolated inputs in a similar fashion with respect to current.
An NPN output is connected in a sinking configuration, and a PNP output is connected in the sourcing
configuration.
178 • Appendices
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Sinking
Sourcing
I/OCn
I/On
I/OCn
I/On
+5V
GND
PNP
output
NPN
output
Current
Current
Figure A-10
Whether connected in a sinking or sourcing circuit, only two connections are needed in each case.
When the NPN output is 5 volts, then no current flows and the input reads 1. When the NPN output
goes to 0 volts, then it sinks current and the input reads 0. The PNP output works in a similar fashion,
but the voltages are reversed i.e. 5 volts on the PNP output sources current into the digital input and the
input reads 0. As before, the 5 volt is an example, the I/OC can accept between 4-28 volts DC.
Note that the current through the digital input should be kept below 3 mA in order to minimize the
power dissipated in the resistor pack. This will help prevent circuit failures. The resistor pack RPx4 is
standard 1.5k ohm which is suitable for power supply voltages up to 5.5 VDC. However, use of 24
VDC for example would require a higher resistance such as a 10k ohm resistor pack.
*The 1-4 axis models of the DMC-2x00 all work with the IOM-1964, all have identical extended I/O
features.
High Power Digital Outputs
The first two banks on the IOM-1964, banks 0 and 1, have high current output drive capability. The
IOM-1964 is shipped with banks 0 and 1 configured as outputs. Each output can drive up to 500mA of
continuous current. Configuring a bank of I/O as outputs is done by inserting the optical isolator
NEC2505 IC’s into the Ux1 and Ux2 sockets. The digital input IC’s Ux3 and Ux4 are removed. The
resistor packs RPx2 and RPx3 are inserted, and the input resistor pack RPx4 is removed.
Each bank of eight outputs shares one I/OC connection, which is connected to a DC power supply
between 4 and 28 VDC. A 10k ohm resistor pack should be used for RPx3. Here is a circuit diagram:
I/OCn
To DMC-2x40 +5V
1/4 NEC2505
1/8 RPx2
IR6210
VCC
IN
OUT
GND
PWROUTn
DMC-2x40 I/O
1/8 RPx3
I/On
OUTCn
Figure A-11
The load is connected between the power output and output common. The I/O connection is for test
purposes, and would not normally be connected. An external power supply is connected to the I/OC
and OUTC terminals, which isolates the circuitry of the DMC-2x40 controller from the output circuit.
DMC-2X00
Appendices y 179
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I/OCn
VISO
Vpwr
PWROUTn
External
L
Isolated
Power
Supply
o
a
d
GNDISO
OUTCn
Figure A-12
The power outputs must be connected in a driving configuration as shown on the previous page. Here
are the voltage outputs to expect after the Clear Bit and Set Bit commands are given:
Output Command
Result
CBn
SBn
Vpwr = Viso
Vpwr = GNDiso
Standard Digital Outputs
The I/O banks 2-7 can be configured as optically isolated digital outputs; however these banks do not
have the high power capacity as in banks 0-1. In order to configure a bank as outputs, the optical
isolator chips Ux1 and Ux2 are inserted, and the digital input isolator chips Ux3 and Ux4 are removed.
The resistor packs RPx2 and RPx3 are inserted, and the input resistor pack RPx4 is removed.
Each bank of eight outputs shares one I/OC connection, which is connected to a DC power supply
between 4 and 28 VDC. The resistor pack RPx3 is optional, used either as a pull up resistor from the
output transistor’s collector to the external supply connected to I/OC or the RPx3 is removed resulting
in an open collector output. Here is a schematic of the digital output circuit:
Internal Pullup
I/OCn
1/8 RPx3
To DMC-2x40 +5V
1/4 NEC2505
1/8 RPx2
I/On
DMC-2x40 I/O
OUTCn
Figure A-13
180 • Appendices
DMC-2X00
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The resistor pack RPx3 limits the amount of current available to source, as well as affecting the low
level voltage at the I/O output. The maximum sink current is 2mA regardless of RPx3 or I/OC voltage,
determined by the NEC2505 optical isolator IC. The maximum source current is determined by
dividing the external power supply voltage by the resistor value of RPx3.
The high level voltage at the I/O output is equal to the external supply voltage at I/OC. However,
when the output transistor is on and conducting current, the low level output voltage is determined by
three factors. The external supply voltage, the resistor pack RPx3 value, and the current sinking limit
of the NEC2505 all determine the low level voltage. The sink current available from the NEC2505 is
between 0 and 2mA. Therefore, the maximum voltage drop across RPx3 is calculated by multiplying
the 2mA maximum current times the resistor value of RPx3. For example, if a 10k ohm resistor pack
is used for RPx3, then the maximum voltage drop is 20 volts. The digital output will never drop below
the voltage at OUTC, however. Therefore a 10 kΩ resistor pack will result in a low level voltage of
0.7 to 1.0 volts at the I/O output for an external supply voltage between 4 and 21 VDC. If a supply
voltage greater than 21 VDC is used, a higher value resistor pack will be required.
Output Command
Result
CBn
SBn
Vout = GNDiso
Vout = Viso
The resistor pack RPx3 is removed to provide open collector outputs. The same calculation for
maximum source current and low level voltage applies as in the above circuit. The maximum sink
current is determined by the NEC2505, and is approximately 2mA.
Open Collector
To DMC-2x40 +5V
1/4 NEC2505
1/8 RPx2
I/On
DMC-2x40 I/O
OUTCn
Figure A-14
Electrical Specifications
•
I/O points, configurable as inputs or outputs in groups of 8
Digital Inputs
•
•
•
Maximum voltage: 28 VDC
Minimum input voltage: 4 VDC
Maximum input current: 3 mA
DMC-2X00
Appendices y 181
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High Power Digital Outputs
•
•
•
•
Maximum external power supply voltage: 28 VDC
Minimum external power supply voltage: 4 VDC
Maximum source current, per output: 500mA
Maximum sink current: sinking circuit inoperative
Standard Digital Outputs
•
•
•
•
Maximum external power supply voltage: 28 VDC
Minimum external power supply voltage: 4 VDC
Maximum source current: limited by pull up resistor value
Maximum sink current: 2mA
Relevant DMC Commands
CO n
Configures the 64 bits of extended I/O in 8 banks of 8 bits each.
N = n2 + 2*n3 + 4*n4 + 8*n5 + 16*n6 + 32*n7 + 64*n8 + 128*n9
where nx is a 1 or 0, 1 for outputs and 0 for inputs. The x is the bank number
OP
m = 8 standard digital outputs
m,n,o,p,q
n = extended I/O banks 0 & 1, outputs 17-32
o = extended I/O banks 2 & 3, outputs 33-48
p = extended I/O banks 4 & 5, outputs 49-64
q = extended I/O banks 6 & 7, outputs 65-80
SB n
Sets the output bit to a logic 1, n is the number of the output from 1 to 80.
Clears the output bit to a logic 0, n is the number of the output from 1 to 80.
Sets the state of an output as 0 or 1, also able to use logical conditions.
CB n
OB n,m
TI n
Returns the state of 8 digital inputs as binary converted to decimal, n is the bank number +2.
Operand (internal variable) that holds the same value as that returned by TI n.
Function that returns state of individual input bit, n is number of the input from 1 to 80.
_TI n
@IN[n]
Screw Terminal Listing
Rev A+B boards (orange) and Rev C boards (black) have the pinouts listed below
REV A+B
REV C
LABEL
DESCRIPTION
BANK
TERMINAL #
TERMINAL #
1
2
3
4
5
6
7
8
9
GND
5V
Ground
N/A
N/A
N/A
N/A
7
2
1
4
3
6
5
8
7
5V DC out
Ground
GND
5V
5V DC out
I/O bit 80
I/O bit 79
I/O bit 78
I/O bit 77
I/O bit 76
I/O80
I/O79
I/O78
I/O77
I/O76
7
7
7
7
182 • Appendices
DMC-2X00
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REV A+B
REV C
LABEL
DESCRIPTION
BANK
TERMINAL #
TERMINAL #
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
10
9
I/O75
I/O bit 75
7
7
7
7
7
6
6
6
6
6
6
6
6
6
6
5
5
5
5
5
5
5
5
5
5
4
4
4
4
4
4
4
4
4
4
3
3
3
3
3
3
3
3
I/O74
I/O bit 74
12
11
14
13
16
15
18
17
20
19
22
21
24
23
26
25
28
27
30
29
32
31
34
33
36
35
38
37
40
39
42
41
44
43
46
45
48
47
50
49
52
I/O73
I/O bit 73
OUTC73-80
I/OC73-80
I/O72
Out common for I/O 73-80
I/O common for I/O 73-80
I/O bit 72
I/O71
I/O bit 71
I/O70
I/O bit 70
I/O69
I/O bit 69
I/O68
I/O bit 68
I/O67
I/O bit 67
I/O66
I/O bit 66
I/O65
I/O bit 65
OUTC65-72
I/OC65-72
I/O64
Out common for I/O 65-72
I/O common for I/O 65-72
I/O bit 64
I/O63
I/O bit 63
I/O62
I/O bit 62
I/O61
I/O bit 61
I/O60
I/O bit 60
I/O59
I/O bit 59
I/O58
I/O bit 58
I/O57
I/O bit 57
OUTC57-64
I/OC57-64
I/O56
Out common for I/O 57-64
I/O common for I/O 57-64
I/O bit 56
I/O55
I/O bit 55
I/O54
I/O bit 54
I/O53
I/O bit 53
I/O52
I/O bit 52
I/O51
I/O bit 51
I/O50
I/O bit 50
I/O49
I/O bit 49
OUTC49-56
I/OC49-56
I/O48
Out common for I/O 49-56
I/O common for I/O 49-56
I/O bit 48
I/O47
I/O bit 47
I/O46
I/O bit 46
I/O45
I/O bit 45
I/O44
I/O bit 44
I/O43
I/O bit 43
I/O42
I/O bit 42
I/O41
I/O bit 41
DMC-2X00
Appendices y 183
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REV A+B
REV C
LABEL
DESCRIPTION
BANK
TERMINAL #
TERMINAL #
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
95
51
54
53
56
55
58
57
60
59
62
61
64
63
66
65
68
67
70
69
72
71
74
73
76
75
78
77
80
79
82
81
84
83
86
85
88
87
90
89
92
91
94
93
OUTC41-48
I/OC41-48
I/O40
Out common for I/O 41-48
I/O common for I/O 41-48
I/O bit 40
3
3
2
2
2
2
2
2
2
2
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
0
0
0
I/O39
I/O bit 39
I/O38
I/O bit 38
I/O37
I/O bit 37
I/O36
I/O bit 36
I/O35
I/O bit 35
I/O34
I/O bit 34
I/O33
I/O bit 33
OUTC33-40
I/OC33-40
I/O32
Out common for I/O 33-40
I/O common for I/O 33-40
I/O bit 32
I/O31
I/O bit 31
I/O30
I/O bit 30
I/O29
I/O bit 29
I/O28
I/O bit 28
I/O27
I/O bit 27
I/O26
I/O bit 26
I/O25
I/O bit 25
OUTC25-32
I/OC25-32
OUTC25-32
I/OC25-32
PWROUT32
PWROUT31
PWROUT30
PWROUT29
PWROUT28
PWROUT27
PWROUT26
PWROUT25
I/O24
Out common for I/O 25-32
I/O common for I/O 25-32
Out common for I/O 25-32
I/O common for I/O 25-32
Power output 32
Power output 31
Power output 30
Power output 29
Power output 28
Power output 27
Power output 26
Power output 25
I/O bit 24
I/O23
I/O bit 23
I/O22
I/O bit 22
I/O21
I/O bit 21
I/O20
I/O bit 20
I/O19
I/O bit 19
I/O18
I/O bit 18
I/O17
I/O bit 17
OUTC17-24
I/OC17-24
OUTC17-24
Out common for I/O 17-24
I/O common for I/O 17-24
Out common for I/O 17-24
184 • Appendices
DMC-2X00
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REV A+B
REV C
LABEL
DESCRIPTION
BANK
TERMINAL #
TERMINAL #
96
96
I/OC17-24
I/O common for I/O 17-24
Power output 24
Power output 23
Power output 22
Power output 21
Power output 20
Power output 19
Power output 18
Power output 17
Ground
0
0
0
0
0
0
0
0
0
97
95
PWROUT24
PWROUT23
PWROUT22
PWROUT21
PWROUT20
PWROUT19
PWROUT18
PWROUT17
GND
98
98
99
97
100
101
102
103
104
100
99
102
101
104
103
•
Silkscreen on Rev A board is incorrect for these terminals.
NOTE: The part number for the 100-pin connector is #2-178238-9 from AMP.
CB-50-100 Adapter Board
The CB-50-100 adapter board can be used to convert the CABLE-100 to (2) 50 Pin Ribbon Cables.
The 50 Pin Ribbon Cables provide a versatile method of accessing the controller signals without the
use of a Galil Interconnect Module.
Connectors:
JC8 50 PIN IDC
J9 100 PIN HIGH DENSITY CONNECTOR
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
9
9
10
11
12
13
14
15
16
17
18
19
20
10
11
12
13
14
15
16
17
18
19
20
DMC-2X00
Appendices y 185
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21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
186 • Appendices
DMC-2X00
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JC6 50 PIN IDC
J9 100 PIN HIGH DENSITY CONNECTOR
1
51
2
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
84
85
86
87
88
89
90
91
92
93
94
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
DMC-2X00
Appendices y 187
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45
46
47
48
49
50
95
96
97
98
99
100
CB-50-100 Drawing:
15/16"
1/8"
1/8"D, 4 places
1/8"
Mounting bracket
for attaching
inside PC
CB 50-100
REV A
GALIL MOTION
CONTROL
MADE IN USA
J9
JC6, JC8 - 50 pin
shrouded headers w/
center key
JC8
JC6
JC8 - pins 1-50 of J9
JC6 - pins 51-100 of J9
1/51
J9 - 100 pin connector
AMP part # 2-178238-9
4 1/2"
21/71
41/91
1/8"
1/2"
9/16"
1 1/4"
Figure A-15
188 • Appendices
DMC-2X00
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JC8 (IDC 50 Pin)
Pin1 (2.975", 0.6125" )
JC6 (IDC 50 Pin)
Pin1 (2.975", 0.9875" )
1/8"D, 4 places
CB 50-100
REV A
GALIL MOTION
CONTROL
MADE IN USA
J9 - 100 pin connector
AMP part # 2-178238-9
(Pin 1)
J9
DETAIL
1
3
51
2
JC8
JC6
JC6, JC8 - 50 pin
shrouded headers w/
center key
52
53
4
JC8 - pins 1-50 of J9
JC6 - pins 51-100 of J9
Figure A-16
CB-50-80 Adapter Board
The CB-50-80 adapter board can be used to convert the CABLE-80 to (2) 50 Pin Ribbon Cables. The
50 Pin Ribbon Cables provide a versatile method of accessing the extended I/O signals without the use
of the Galil IOM-1964.
The ribbon cables provided by the CB-50-80 are compatible with I/O mounting racks such as Grayhill
70GRCM32-HL and OPTO-22 G4PB24.
When using the OPTO-22 G4PB24 I/O mounting rack, the user will only have access to 48 of the 64
I/O points available on the controller. Block 5 and Block 9 must be configured as inputs and will be
grounded by the I/O rack.
DMC-2X00
Appendices y 189
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Connectors:
JC8 and JC6: 50 Pin Male IDC
J9: 80 Pin High Density Connector, AMP PART #3-178238-0
JC8
J9
JC8
J9
1
1
38
39
40
41
42
43
44
45
46
47
48
49
50
GND
35
2
2
3
3
GND
36
4
4
5
5
GND
37
6
6
7
7
GND
38
8
8
9
9
GND
39
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
10
11
GND
+5V
GND
12
13
14
15
16
17
GND
19
GND
21
GND
23
GND
25
GND
27
GND
29
GND
31
GND
32
GND
33
GND
34
190 • Appendices
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JC6
1
J9 (Continued)
41
2
42
3
43
4
44
5
45
6
46
7
47
8
48
9
49
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
50
51
52
53
54
55
56
57
GND
59
GND
61
GND
63
GND
65
GND
67
GND
69
GND
71
GND
72
GND
73
GND
74
GND
75
GND
76
GND
77
GND
78
GND
79
GND
+5V
GND
DMC-2X00
Appendices y 191
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CB-50-80 Drawing:
CB-50-80 Outline
1/8"
15/16"
1/8"D, 4 places
Mounting bracket
CB 50-80
REV A1
GALIL MOTION
CONTROL
MADE IN USA
for attaching
inside PC
1/8"
J9
JC6, JC8 - 50 pin
shrouded headers w/
center key
JC8
JC6
JC8 - pins 1-50 of J9
JC6 - pins 51-100 of J9
J9 - 80 pin connector
3M part # N10280-52E2VC
AMP part # 3-178238-0
4 1/2"
1/8"
1/2"
9/16"
1 1/4"
Figure A-17
192 • Appendices
DMC-2X00
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CB-50-80 Layout
1/8"D, 4 places
JC6 (IDC 50 Pin)
Pin1 ()
J9 - 80 pin connector
AMP part # 3-178238-0
(Pin 1)
CB 50-80
REV A
GALIL MOTION
CONTROL
MADE IN USA
JC8 (IDC 50 Pin)
Pin1 ( )
J9
DETAIL
1
3
41
2
4
42
JC8
JC6
JC6, JC8 - 50 pin
shrouded headers w/
center key
43
Figure A-18
DMC-2X00
Appendices y 193
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TERM-1500 Operator Terminal
Two types of terminals are offered from Galil; the hand-held unit and the panel mount unit. Both have
the same programming characteristics.
Hand held unit is shown below:
Figure A-19
194 • Appendices
DMC-2X00
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The panel mount terminal is shown below:
Figure A-20
Features
„
For easy data entry to DMC-2x00 motion controller
„
„
„
„
„
„
4 line x 20 character Liquid Crystal Display
Full numeric keypad
Five programmable function keys
Available in Hand-held or Panel Mount
No external power supply required
Connects directly to RS232 port P2 via coiled cable
Description
The TERM-2000 is a compact ASCII terminal for use with the DMC-2x00 motion controller. Its
numeric keypad allows easy data entry from an operator. The TERM-1500 is available with a male
adapter for connection to P2 (Dataset).
NOTE: Since the TERM-1500 requires +5V on pin 9 of RS-232, it can only work with port 2 of the
DMC-2x00.
Specifications - Hand-Held
Keypad
Display
Power
Key Tactile 4 row x 5character
LCD with 5 by 7 character font
5 volts, 30mA (from DMC-2x00)
DMC-2X00
Appendices y 195
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Specifications - Panel Mount
Keypad
Display
Power
30-Key; 5 rows x 6 columns ; 5x7 font
4 row x 20 character LCD
5 volts, 30mA
Keypad Maps - Hand-Held
30 Keys: 5 keys across, 6 down
Single Key Output
6
5
4
3
2
1
F1 (22) F2 (23) F3 (24) F4 (25)
F5 (26)
1
4
7
2
5
8
0
3
6
9
CTRL
SHIFT SPACE BKSPC ENTER
Shift Key Output
6
5
4
3
2
1
A
B
C
H
M
R
D
I
E
J
F
K
G
L
N
S
X
,
O
T
Y
?
P
Q
U
V
W
Z
CTRL
SHIFT
CTRL Key Output
6
5
4
3
2
1
(18)
(19)
*
(16)
(9)
(4)
“
(17)
(2)
!
%
;
+
/
\
$
<
>
-
[
]
^
@
{
}
#
CTRL
SHIFT
ESC
=
NOTE: Values in parentheses are ASCII decimal values. Key locations are represented by [m,n]
where m is element column, n is element row.
Example:
U is <Shift>[1,2]
196 • Appendices
DMC-2X00
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# is <Cntrl>[5,1]
Keypad Map - Panel Mount – 6 columns x 5 rows
Single Key Output
5
4
3
2
1
F1
F2
F3
F4
F5
1
4
7
-
2
5
8
0
3
6
9
.
CTRL
SHIFT SPACE BKSPC ENTER
Shift Key Output
5
4
3
2
1
A
B
C
D
E
F
K
G
L
H
M
R
I
N
S
X
,
J
O
T
Y
?
P
Q
U
V
W
Z
CTRL
SHIFT
CTRL Key Output
5
4
3
2
1
(18)
(16)
(9)
(19)
(2)
!
“
$
[
%
;
*
+
/
\
<
^
>
-
]
(4)
@
{
=
}
#
(17)
CTRL
SHIFT
ESC
NOTE: Values in parentheses are ASCII decimal values. Key locations are represented by [m,n]
where m is element column, n is element row.
Escape Commands
Escape codes can be used to control the TERM-1500 display, cursor style, and position, and sound
settings.
NOTE: The escape character (hex 1B) can be sent through port 2 of the DMC-2x00 with special
syntax {^27}:
Example: MG {P2}{^27},”H”
Sends escape H to the terminal from port 2
Cursor Movement Commands
ESC A
ESC B
ESC C
ESC D
Cursor Up
Cursor Down
Cursor Right
Cursor Left
DMC-2X00
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Erasing Display
ESC E
Clear Display and Home
Clear Display
ESC I
ESC J
ESC K
ESC M
Cursor to End of Display
Cursor to End of Line
Line Containing Cursor
Sounds
ESC T
Short Bell
Long Bell
Click
ESC L
ESC P
ESC Q
Alert
Cursor Style
ESC F
Underscore Cursor On
Underscore Cursor Off
Blinking Cursor On
Blinking Cursor Off
ESC G
ESC R
ESC S
Key Clicks (audible sounds from terminal)
ESC U
Key Click Enable
ESC V
Key Click Disable
Identify (sends “TT!” then terminal firmware version)
ESC Z
Send Terminal ID
Cursor Position
ESC Y
Pr Pc
In the above sequence, Pr is the row number and Pc is the column number of the target cursor location.
These parameters are formed by adding hexadecimal 1F to the row and column numbers. Row and
column numbers are absolute, with row 1, column 1 (Pr = H20, Pc = H20) representing the upper left
corner of the display.
Configuration
<CNTRL><SHIFT>F1 Allows user to configure terminal; Follow prompts on display to change
configuration
198 • Appendices
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Default Configuration:
Baud Rate
Data bits
Parity
9600
7
Ignore PE
enabled
Fast
Display
Repeat
Echo
Disabled
Disabled
Disabled
Handshake
Self Test
Key Click - Disabled <Ctrl>Space <Shift> [2,2]
Key Click - Enabled <Ctrl>Space <Shift> [1,2]
Clear Display and Home <Ctrl>Space <Shift> [5,6]
Function Keys
<CNTRL><SHIFT>F3 Allows function keys to be configured; Follow prompts on display to change
function keys
Default Function Keys
F1
F2
F3
F4
F5
22 decimal
23 decimal
24 decimal
25 decimal
26 decimal
Input/Output of Data – DMC-2x00 Commands
Refer to Chapter 7 in this manual for Data Communication commands.
When using Port 2, use CC command to configure P2.
Example:
CC 9600,0,0,1
Configures P2
MG{P2} “Hello There”, V1{F2.1}
IN{P2} “Enter Value”, NUM
Send message to P2
Prompts operator for value
Example:
#A
CI 0;CC 9600,0,0,1
MG {P2} “press F1 to start X”
MG {P2} “Press F2 to start Y”
#A Interrupt on any key; Configure P2
Print Message to P2
Print Message to P2
DMC-2X00
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#B; JP#B;EN
End Program
#COMINT
Interrupt Routine
JS #XMOVE,P2CH=F1
JS #YMOVE,P2CH=F2
EN1,1
Jump to X move if F1
Jump to Y move if F2
End, Re-enable comm interrupt & restore trip point
Move X routine
#XMOVE;PR1000;BGX;EN
#YMOVE;PR,1000;BGY;EN
Move Y routine
NOTE: F1 through F5 are used as dedicated keywords for testing function keys. Do not use these as
variables.
6-Pin Modular Connector
1
2
3
4
5
6
+5 volts
Handshake in
Handshake out
Data in
Data out
Ground
9-Pin D Adaptor - Male (For P2)
1
2
3
4
5
6
CTS input
Transmit Data - input
Receive Data - output
RTS - output
Ground
CTS - input
RTS - output
CTS - input
5V or no connect or sample clock with jumpers
NOTE: Out and in are referenced to the terminal.
Ordering Information
TERM-1500H-P2
Hand-held terminal with female adapter
TERM-1500P-P2
Panel Mount terminal with female adapter
200 • Appendices
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Coordinated Motion - Mathematical Analysis
The terms of coordinated motion are best explained in terms of the vector motion. The vector velocity,
Vs, which is also known as the feed rate, is the vector sum of the velocities along the X and Y axes, Vx
and Vy.
Vs = Vx 2 +Vy 2
The vector distance is the integral of Vs, or the total distance traveled along the path. To illustrate this
further, suppose that a string was placed along the path in the X-Y plane. The length of that string
represents the distance traveled by the vector motion.
The vector velocity is specified independently of the path to allow continuous motion. The path is
specified as a collection of segments. For the purpose of specifying the path, define a special X-Y
coordinate system whose origin is the starting point of the sequence. Each linear segment is specified
by the X-Y coordinate of the final point expressed in units of resolution, and each circular arc is
defined by the arc radius, the starting angle, and the angular width of the arc. The zero angle
corresponds to the positive direction of the X-axis and the CCW direction of rotation is positive.
Angles are expressed in degrees, and the resolution is 1/256th of a degree. For example, the path
shown in Fig. A-21 is specified by the instructions:
VP
CR
VP
0,10000
10000, 180, -90
20000, 20000
DMC-2X00
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Y
C
D
20000
B
10000
A
X
10000
20000
Figure A-21 - X-Y Motion Path
The first line describes the straight line vector segment between points A and B. The next segment is a
circular arc, which starts at an angle of 180° and traverses -90°. Finally, the third line describes the
linear segment between points C and D. Note that the total length of the motion consists of the
segments:
A-B
Linear
10000 units
R Δθ 2π
360
B-C
C-D
Circular
= 15708
Linear
Total
10000
35708 counts
In general, the length of each linear segment is
Lk = Xk 2 + Yk 2
Where Xk and Yk are the changes in X and Y positions along the linear segment. The length of the
circular arc is
L
k
= Rk ΔΘk 2π 360
The total travel distance is given by
n
D =
L
k
∑
k=1
The velocity profile may be specified independently in terms of the vector velocity and acceleration.
202 • Appendices
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For example, the velocity profile corresponding to the path of Fig. A-21 may be specified in terms of
the vector speed and acceleration.
VS
100000
VA
2000000
The resulting vector velocity is shown in Fig. A-22.
Velocity
10000
time (s)
Ta
0.05
Ts
0.357
Ta
0.407
Figure A-22 - Vector Velocity Profile
The acceleration time, T , is given by
a
VS
100000
T
a
=
=
= 0.05s
VA 2000000
The slew time, Ts, is given by
D
35708
s
=
−
a
=
T
T
0.05 = 0.307s
−
VS
100000
The total motion time, Tt, is given by
D
T
t
=
+ Ta = 0.407s
VS
The velocities along the X and Y axes are such that the direction of motion follows the specified path,
yet the vector velocity fits the vector speed and acceleration requirements.
For example, the velocities along the X and Y axes for the path shown in Fig. A-21 are given in Fig.
A-23.
Fig. A-23a shows the vector velocity. It also indicates the position point along the path starting at A
and ending at D. Between the points A and B, the motion is along the Y axis. Therefore,
Vy = Vs
and
Vx = 0
Between the points B and C, the velocities vary gradually and finally, between the points C and D, the
motion is in the X direction.
Fig. A-23b shows X axis velocity. Fig A-23c shows Y axis velocity.
DMC-2X00
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B
C
(a)
(b)
(c)
A
D
time
Figure A-23 - Vector and Axes Velocities
Example- Communicating with OPTO-22 SNAP-B3000-
ENET
Controller is connected to OPTO-22 via handle F. The OPTO-22’s IP address is 131.29.50.30. The
Rack has the following configuration:
Digital Inputs
Module 1
Module 2
Digital Outputs
Analog Outputs (+/-10V) Module 3
Analog Inputs (+/-10V) Module 4
Instruction
Interpretation
#CONFIG
Label
IHF=131,29,50,30<502>2
WT10
Establish connection
Wait 10 milliseconds
Jump to subroutine
JP #CFGERR,_IHF2=0
JS #CFGDOUT
JS #CFGAOUT
JS #CFGAIN
Configure digital outputs
Configure analog outputs
Configure analog inputs
Save configuration to OPTO-22
MBF = 6,6,1025,1
204 • Appendices
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EN
End
#CFGDOUT
Label
MODULE=2
Set variable
Set variable
Set variable
Jump to subroutine
CFGVALUE=$180
NUMOFIO=4
JP #CFGJOIN
#CFGAOUT
Label
MODULE=3
Set variable
Set variable
Set variable
Jump to subroutine
CFGVALUE=$A7
NUMOFIO=2
JP #CFGJOIN
#CFGAIN
Label
MODULE=5
CFGVALUE=12
NUMOFIO=2
JP#CFGJOIN
Set variable
Set variable
Set variable
Jump to subroutine
#CFGJOIN
Label
DM A[8]
Dimension array
Set variable
I=0
#CFGLOOP
Loop subroutine
Set array element
Increment
A[I]=0
I=I+1
A[I]=CFGVALUE
I=I+1
Set array element
Increment
JP #CFGLOOP,I<(2*NUMOFIO)
Conditional statement
MBF=6,16,632+(MODULE*8),NU Configure I/O using Modbus function code 16 where the starting
MOFIO*2,A[]
EN
register is 632+(MODULE*8), number of registers is
NUMOFIO*2 and A[] contains the data.
end
#CFERR
Label
MG”UNABLE TO ESTABLISH
CONNECTION”
Message
EN
End
Using the equation
I/O number = (Handlenum*1000) + ((Module-1)*4) + (Bitnum-1)
MG @IN[6001] display level of input at handle 6, module 1, bit 2
DMC-2X00
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SB 6006set bit of output at handle 6, module 2, bit 3
or to one
OB 6006,1
AO 608,3.6
set analog output at handle 6, module 53, bit 1 to 3.6 volts
MG @AN[6017] display voltage value of analog input at handle6, module 5, bit 2
206 • Appendices
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DMC-2x00/DMC-1500 Comparison
BENEFIT
DMC-2x00
DMC-1500
Access to parameters – real time data
processing & recording
Data Record - Block Data Transfer
No DMA channel
Easy to install – USB is self configuring Plug and Play
USB not available
Option
Can capture and save array data
Parameters can be stored
Variable storage
Array storage
Option
Firmware can be upgraded in field
without removing controller from PC
Flash memory for firmware
EPROM for firmware which
must be installed on controller
Faster servo operation – good for very
high resolution sensors
12 MHz encoder speed for servos
8 MHz
Faster stepper operation
Higher servo bandwidth
Higher resolution for analog inputs
Improved EMI
3 MHz stepper rate
2 MHz
62 μsec/axis sample time
125 μsec/axis
8 analog inputs with 16-bit ADC option 7 inputs with 16-Bit option
100-pin high density connector
60-pin IDC, 26-pin IDC, 20-pin
IDC (x2)
For precise registration applications
More flexible gearing
Output Position Compare
Available as a special
One master for gearing
Multiple masters allowed in gearing
mode
Binary command mode
Binary and ASCII communication
modes
ASCII only
Gearing
Multiple Gearing Masters Accepted
Single Gearing Master Accepted
Coordinated Motion
2 Sets of Coordinated Motion Accepted Single set of coordinated motion
only
DMC-2X00
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List of Other Publications
"Step by Step Design of Motion Control Systems"
by Dr. Jacob Tal
"Motion Control Applications"
by Dr. Jacob Tal
"Motion Control by Microprocessors"
by Dr. Jacob Tal
Training Seminars
Galil, a leader in motion control with over 500,000 controllers working worldwide, has a proud reputation for
anticipating and setting the trends in motion control. Galil understands your need to keep abreast with these trends
in order to remain resourceful and competitive. Through a series of seminars and workshops held over the past 20
years, Galil has actively shared their market insights in a no-nonsense way for a world of engineers on the move. In
fact, over 10,000 engineers have attended Galil seminars. The tradition continues with three different seminars,
each designed for your particular skill set-from beginner to the most advanced.
MOTION CONTROL MADE EASY
WHO SHOULD ATTEND
Those who need a basic introduction or refresher on how to successfully implement servo motion control systems.
TIME: 4 hours (8:30 am-12:30pm)
ADVANCED MOTION CONTROL
WHO SHOULD ATTEND
Those who consider themselves a “servo specialist” and require an in-depth knowledge of motion control systems to
ensure outstanding controller performance. Also, prior completion of “Motion Control Made Easy” or equivalent is
required. Analysis and design tools as well as several design examples will be provided.
TIME: 8 hours (8-5pm)
PRODUCT WORKSHOP
WHO SHOULD ATTEND
Current users of Galil motion controllers. Conducted at Galil’s headquarters in Rocklin, CA, students will gain
detailed understanding about connecting systems elements, system tuning and motion programming. This is a
“hands-on” seminar and students can test their application on actual hardware and review it with Galil
specialists.
Attendees must have a current application and recently purchased a Galil controller to attend this course.
TIME: Two days (8:30-4:30pm)
208 • Appendices
DMC-2X00
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Contacting Us
Galil Motion Control
270 Technology Way
Rocklin, CA 95765
Phone: 916-626-0101
Fax: 916-626-0102
E-Mail Address: [email protected]
URL: www.galilmc.com
FTP: www.galilmc.com/ftp
WARRANTY
All controllers manufactured by Galil Motion Control are warranted against defects in materials and workmanship
for a period of 18 months after shipment. Motors, and Power supplies are warranted for 1 year. Extended warranties
are available.
In the event of any defects in materials or workmanship, Galil Motion Control will, at its sole option, repair or
replace the defective product covered by this warranty without charge. To obtain warranty service, the defective
product must be returned within 30 days of the expiration of the applicable warranty period to Galil Motion Control,
properly packaged and with transportation and insurance prepaid. We will reship at our expense only to destinations
in the United States and for products within warranty.
Call Galil to receive a Return Materials Authorization (RMA) number prior to returning product to Galil.
Any defect in materials or workmanship determined by Galil Motion Control to be attributable to customer
alteration, modification, negligence or misuse is not covered by this warranty.
EXCEPT AS SET FORTH ABOVE, GALIL MOTION CONTROL WILL MAKE NO WARRANTIES EITHER
EXPRESSED OR IMPLIED, WITH RESPECT TO SUCH PRODUCTS, AND SHALL NOT BE LIABLE OR
RESPONSIBLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES.
COPYRIGHT (3-97)
The software code contained in this Galil product is protected by copyright and must not be reproduced or
disassembled in any form without prior written consent of Galil Motion Control, Inc.
DMC-2X00
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Index
Abort.....1, 40, 41, 81, 87, 127, 171, 172, 173, 191, 202,
203
Coordinated Motion
Linear Interpolation36, 37, 69, 70, 81, 82, 83, 85, 86,
91
Data Record ..................................57, 59, 101, 102, 252
Echo49, 58, 60, 244
Edit Mode....................................................34, 122, 137
Editor ....................................................34, 35, 121, 122
EEPROM ................................1, 5, 15, 16, 17, 163, 204
Electronic Cam............................69, 70, 95, 98, 99, 105
Electronic Gearing ..........................1, 69, 70, 91, 94, 95
Ellipse Scale................................................................89
Enable
Off-On-Error................................. 40, 171, 172, 173
Stop Motion .................................................... 81, 87
Absolute Position.............................. 33, 70, 71, 72, 129
Absolute Value ................................... 96, 107, 144, 172
Acceleration.......................... 3, 30, 71, 79, 83, 158, 247
Accessories............................................................... 206
AMP-19x0........................................ 206, 215, 218, 219
Amplifier Enable ...................... 7, 22, 43, 171, 206, 220
Amplifier Gain.................................... 4, 6, 24, 186, 188
Analog Input...1, 6, 39, 43, 80, 144, 146, 147, 149, 161,
168, 191, 206, 209, 249, 252
Amplifier Enable................. 7, 22, 43, 171, 206, 220
Encoder
Analysis
WSDK .................................14, 19, 24, 99, 193, 206
Arm Latch................................................................. 120
Array..........1, 15, 70, 102, 103, 104, 127, 142, 146, 147
Automatic Subroutine
Auxiliary Encoder1, 6, 13, 23, 30, 39, 44, 45, 93, 107,
112, 113, 114, 160, 191, 192, 196, 203, 212
Differential.... 7, 23, 25, 45, 160, 176, 191, 192, 203
Dual Encoder.........................................66, 113, 149
Index Pulse..............................................23, 40, 117
Quadrature... 5, 7, 112, 158, 164, 183, 191, 192, 202
Error Code.......................................53, 65, 66, 127, 128
Error Handling ..............................................ii, 123, 171
Error Limit .......... 22, 24, 31, 44, 46, 137, 171, 172, 202
Off-On-Error ..................... 22, 40, 44, 171, 172, 173
Example
Binary....................................................................64
Change Speed along Vector Path........................131
Command Error...................................................139
Command Error w/Multitasking .........................140
Communication Interrupt............................140, 152
Continuous Dual Loop ........................................113
Contour................................................................101
Cut-to-Length......................................................150
Daisy Chain...........................................................50
Define Output Waveform Using AT...................132
Design Example ....................................................31
Electronic CAM ....................................................99
Ethernet Communication Error ...........................141
Example Applications.........................................164
Gearing..................................................................94
Generating an Array............................................102
CMDERR ....................................124, 137, 139, 140
ININT ..................................124, 135, 137, 160, 161
LIMSWI.........39, 124, 136, 137, 138, 172, 174, 203
MCTIME .....................................124, 129, 137, 139
POSERR......................................124, 136, 172, 173
Position Error...................................................... 137
TCPERR............................................. 124, 137, 141
Auxiliary Encoder....................................................... 93
Backlash ..............................70, 112, 113, 114, 168, 169
Dual Loop..................................... 70, 112, 113, 114
Baud Rate ................................... 17, 18, 19, 48, 49, 176
Begin Motion...................................... 25, 29, 50, 82, 89
Binary ............................1, 53, 61, 63, 64, 162, 227, 252
Bit-Wise.................................................... 133, 142, 153
Burn 28, 47
EEPROM............................................ 1, 5, 163, 204
Capture Data
Record............................70, 104, 147, 148, 149, 252
Circle ........................................................ 124, 165, 166
Circular Interpolation ........................................... 37, 86
Clear Bit...................................... 45, 158, 159, 202, 225
Clear Sequence ......................................... 81, 83, 87, 89
CMDERR ......................................... 124, 137, 139, 140
210 • Index
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Independent Axis.................................................. 72
Input Interrupt............................................. 138, 161
Inputting Numeric Data ...................................... 150
Jog80
Amplifier Enable........... 7, 22, 23, 43, 171, 206, 220
Digital Input1, 41, 144, 159, 222, 223, 224, 226, 227
Digital Output 1, 144, 158, 206, 219, 222, 224, 225,
227
Latch................................................................... 120
Limit Switch ............................................... 137, 174
Linear Interpolation .............................................. 83
Motion Complete................................................ 138
Motion Smoothing.............................................. 115
Multiple Move Sequence.................................... 130
Multiple Move with Wait ................................... 132
Opto 22 ............................................................... 249
Output Bit ........................................................... 159
Output Port ......................................................... 159
Position Follower................................................ 161
Printing a Variable.............................................. 155
Record and Playback .......................................... 104
Recording into An Array .................................... 149
Repetitive Position Trigger................................. 130
Set Bit and Clear Bit........................................... 159
Set Output when At Speed.................................. 131
Sinusoidal Commutation................................. 21, 27
Sinusoidal Motion............................................... 105
Start Motion on Input.......................................... 130
Start Motion on Switch....................................... 160
Tangent Axis......................................................... 89
Turn on output after move .................................. 159
Using Inputs........................................................ 160
Using Variables for Joystick............................... 146
Wire Cutter ......................................................... 164
Feedrate ........................................................ 82, 88, 166
FIFO ............................................................. 59, 60, 126
Filter Parameter
Home Input ................................... 40, 117, 119, 191
Limit Switch. 39, 123, 127, 136, 137, 138, 146, 172,
174, 176, 203
ICM-1900............................ 43, 206, 215, 218, 219, 220
ICM-290013, 18, 22, 23, 43, 44, 45, 171, 206, 207, 211,
214, 219, 220
Index Pulse....................................................23, 40, 117
ININT........................................124, 135, 137, 160, 161
Input Interrupt...........................124, 135, 137, 160, 161
Integrator...............................................30, 31, 180, 186
Interconnect Module
AMP-19x0................................... 206, 215, 218, 219
ICM-1900...................... 43, 206, 215, 218, 219, 220
ICM-2900. 13, 18, 22, 23, 43, 44, 45, 171, 206, 207,
211, 214, 219, 220
Internal Variable .................................36, 145, 146, 227
Interrogation 31, 32, 34, 66, 83, 126, 127, 155, 156, 193
Invert...........................................25, 112, 176, 202, 219
Jog 1, 69, 79, 80, 91, 152
Jumper..... 14, 15, 16, 19, 30, 43, 50, 106, 202, 204, 215
Label ...............................................................16, 22, 30
Program Label.....................................127, 128, 132
Special Label...............................................123, 136
Latch .......................................................6, 66, 119, 203
Arm Latch ...........................................................120
Position Capture..................................................119
Limit Switch........ 39, 124, 136, 137, 138, 172, 174, 203
Linear Interpolation.... 36, 37, 69, 70, 81, 82, 83, 85, 86,
91
Damping ....................................... 30, 176, 180, 185
Gain ...........................................30, 31, 34, 176, 180
Integrator ........................................ 30, 31, 180, 186
PID.........................................3, 25, 30, 31, 180, 184
Proportional .................................... 30, 31, 114, 180
Stability................................113, 114, 175, 176, 180
Find Edge...................................... 40, 58, 117, 119, 203
Formatting ........................................................ 154, 157
Frequency 7, 30, 105, 116, 185, 187, 188, 191, 202, 219
Function
Arithmetic............................121, 133, 142, 145, 158
Gain 4, 6, 24, 30, 31, 34, 176, 180
Gear Ratio............................................................. 91, 94
Gearing ............................1, 69, 70, 91, 94, 95, 193, 252
Halt 82, 125, 126, 128, 129, 131, 132
Logical Operator ...............................................133, 152
Masking
Bit-Wise ..............................................133, 142, 153
Memory.. 1, 3, 5, 27, 28, 34, 52, 61, 121, 123, 127, 133,
136, 137, 148, 163, 252
Message ...... 17, 18, 48, 54, 60, 127, 137, 143, 154, 155
Modelling..................................................................180
Motion Complete
MCTIME..................................... 124, 129, 137, 139
Motion Smoothing .......... 70, 71, 79, 106, 114, 115, 116
Motor Command................. 3, 21, 25, 27, 185, 193, 202
Multitasking..............................................125, 139, 140
Off-On-Error..................... 22, 40, 44, 58, 171, 172, 173
Operand
Internal Variable............................ 36, 145, 146, 227
Operator
hardware
Extended I/O....................................................... 222
Hardware .................................................................... 39
I/O158
Hardware Handshake................................ 16, 17, 48, 60
Home Input......................................... 40, 117, 119, 191
Homing............................................... 40, 117, 119, 203
I/O
Bit-Wise ......................................................133, 142
Output
Amplifier Enable................. 7, 22, 43, 171, 206, 220
Digital Output 1, 144, 158, 206, 219, 222, 224, 225,
227
Error Output..................................................46, 171
Motor Command........... 3, 21, 25, 27, 185, 193, 202
2 • Index
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Output Compare.................................................... 45
Step and Direction .............................................. 3, 4
Position Error
POSERR..............................124, 136, 137, 172, 173
Position Limit ........................................................... 173
Program Flow ........................................... 123, 128, 160
Interrupt ..1, 123, 124, 131, 135, 136, 138, 140, 141,
152, 153, 160, 161, 203, 245
Stack ............................................136, 139, 141, 161
Programming .......................... 40, 61, 69, 146, 176, 177
Proportional Gain ....................................................... 30
Protection
Error Limit.....22, 24, 31, 44, 46, 137, 171, 172, 202
Torque Limit................................................... 24, 34
PWM ............................................................ 6, 202, 219
Quadrature.........5, 7, 112, 158, 164, 183, 191, 192, 202
Quit
Synchronization ............................................1, 7, 47, 95
Syntax .............................................................61, 62, 63
Tangent .............................................70, 86, 88, 89, 144
Teach...........................................................70, 104, 148
Data Capture ...............................................148, 149
Latch ................................. 6, 66, 119, 120, 149, 203
Play-Back............................................................104
Record........................... 70, 104, 147, 148, 149, 252
Tell Error Code .............................................65, 66, 128
Tell Position............................32, 60, 66, 108, 146, 156
Tell Torque............................................................25, 66
Terminal... 15, 18, 19, 21, 22, 24, 34, 35, 39, 43, 48, 49,
51, 61, 121, 122, 125, 146, 193, 206
Theory.......................................................................177
Damping........................................ 30, 176, 180, 185
Digital Filter.................................. 61, 184, 186, 188
Modeling.............................................177, 181, 185
PID........................................ 3, 25, 30, 31, 180, 184
Stability....................... 113, 114, 169, 175, 176, 180
TIME.........................................................................147
Timeout.......................................................................19
MCTIME..................................... 124, 129, 137, 139
Torque Limit .........................................................24, 34
Trigger ...................... 121, 128, 129, 130, 132, 202, 203
Trippoint .... 35, 71, 83, 88, 89, 101, 106, 107, 128, 129,
130, 193
Abort1, 40, 41, 81, 87, 127, 171, 172, 173, 191, 202,
203
Stop Motion .................................................... 81, 87
Record .................................70, 104, 147, 148, 149, 252
Latch..........................................6, 66, 119, 120, 203
Teach ............................................................ 70, 104
Register........................................................... 19, 20, 21
Reset ...4, 15, 16, 17, 23, 28, 29, 39, 41, 46, 53, 60, 171,
173, 176, 202, 203, 204
Scale
Troubleshoot .............................................................175
TTL 6, 7, 22, 39, 44, 45, 171, 191, 202, 220, 222
Tuning.................................................1, 14, 25, 31, 113
Stability....................... 113, 114, 169, 175, 176, 180
WSDK................................. 14, 19, 24, 99, 193, 206
Upload.........................................................35, 148, 193
User Unit...................................................................158
Variable...... 5, 15, 36, 67, 113, 121, 126, 127, 133, 142,
144, 145, 146, 153, 154, 155, 158, 167, 193
Internal Variable............................ 36, 145, 146, 227
Vector Acceleration ........................................37, 83, 89
Vector Deceleration ..................................37, 83, 84, 89
Vector Mode .........................................................81, 86
Circular Interpolation..............................37, 86, 166
Clear Sequence....................................81, 83, 87, 89
Ellipse Scale....................................................82, 89
Feedrate.........................................................88, 166
Linear Interpolation36, 37, 69, 70, 81, 82, 83, 86, 91
Tangent........................................ 70, 86, 88, 89, 144
Vector Speed........... 37, 81, 82, 83, 84, 87, 88, 131, 248
Wire Cutter................................................................164
WSDK.......................................14, 19, 24, 99, 193, 206
Zero Stack.........................................................139, 161
Ellipse Scale ......................................................... 89
Serial Port.....16, 17, 18, 19, 20, 49, 124, 140, 141, 152,
154, 155, 199, 200, 201, 204
Set Bit......................................... 45, 158, 159, 202, 225
Sine 70, 98, 144
Single-Ended ............................................ 7, 23, 25, 191
Slew 30, 32, 70, 71, 117, 129, 164, 203
Smoothing.....1, 30, 70, 71, 79, 82, 83, 87, 89, 106, 107,
114, 115, 116
Software
Terminal15, 18, 19, 21, 22, 24, 34, 35, 39, 43, 48, 49,
51, 61, 121, 122, 125, 146, 193, 206
WSDK ...........................14, 19, 20, 24, 99, 193, 206
Special Label ............................................ 123, 136, 174
Stability .............................113, 114, 169, 175, 176, 180
Stack ................................................. 136, 139, 141, 161
Zero Stack................................................... 139, 161
Step Motor.........................3, 4, 6, 14, 30, 116, 202, 203
KS, Smoothing.30, 70, 106, 107, 108, 114, 115, 116
Stepper Position Maintenance .................................. 108
Stop Code ................................... 66, 119, 127, 149, 176
Stop Motion.......................................................... 81, 87
Subroutine...39, 105, 121, 123, 124, 125, 132, 133, 134,
136, 137, 138, 139, 140, 152, 160, 172, 174, 203
DMC-2X00
Index y 3
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