USER MANUAL
DMC-3425
Manual Rev. 1.1b
By Galil Motion Control, Inc.
Galil Motion Control, Inc.
3750 Atherton Road
Rocklin, California 95765
Phone: (916) 626-0101
Fax: (916) 626-0102
Internet Address: [email protected]
URL: www.galilmc.com
Rev 6/06
Contents
Contents
i
Chapter 1 Overview
1
Introduction ...............................................................................................................................1
Overview of Motor Types..........................................................................................................2
Standard Servo Motors with +/- 10 Volt Command Signal.........................................2
Stepper Motor with Step and Direction Signals ..........................................................2
Brushless Servo Motor with Sinusoidal Commutation................................................2
DMC-3425 Functional Elements...............................................................................................4
Microcomputer Section ...............................................................................................4
Motor Interface............................................................................................................4
Communication ...........................................................................................................4
General I/O..................................................................................................................5
System Elements .........................................................................................................5
Motor...........................................................................................................................5
Amplifier (Driver) .......................................................................................................5
Encoder........................................................................................................................6
Watch Dog Timer........................................................................................................6
Chapter 2 Getting Started
7
The DMC-3425 Motion Controller............................................................................................7
Elements You Need...................................................................................................................8
Installing the DMC-3425 Controller..........................................................................................8
Step 1. Determine Overall Motor Configuration........................................................9
Step 2. Configuring Jumpers on the DMC-3425.........................................................9
Step 3. Connecting AC or DC power and the Serial Cable to the DMC-3425..........11
Step 4. Installing the Communications Software.......................................................12
Step 5. Establishing Communication between the DMC-3425 and the host PC .......12
Step 6. Set-up axis for sinusoidal commutation (optional).......................................17
Step 7. Make connections to amplifier and encoder..................................................17
Step 8a. Connect Standard Servo Motor...................................................................19
Step 8b. Connect brushless motor for sinusoidal commutation................................23
Step 8c. Connect Step Motors ...................................................................................26
Step 9. Tune the Servo System..................................................................................27
Step 10. Configure the Distributed Control System ..................................................28
Design Examples .....................................................................................................................32
Example 1 - System Set-up .......................................................................................32
Example 2 - Profiled Move .......................................................................................32
Example 3 - Position Interrogation............................................................................32
Example 4 - Absolute Position..................................................................................32
DMC-3425
Contents • i
Example 5 - Velocity Control (Jogging) ...................................................................33
Example 6 - Operation Under Torque Limit .............................................................33
Example 7 - Interrogation..........................................................................................33
Example 8 - Operation in the Buffer Mode...............................................................33
Example 9 - Motion Programs...................................................................................34
Example 10 - Motion Programs with Loops..............................................................34
Example 11- Motion Programs with Trippoints........................................................34
Example 12 - Control Variables ................................................................................35
Example 13 - Control Variables and Offset ..............................................................35
Chapter 3 Connecting Hardware
37
Overview .................................................................................................................................37
Using Inputs.............................................................................................................................37
Limit Switch Input.....................................................................................................37
Home Switch Input....................................................................................................38
Abort Input ................................................................................................................38
Uncommitted Digital Inputs......................................................................................39
Amplifier Interface ..................................................................................................................39
TTL Inputs...............................................................................................................................40
Analog Inputs ..........................................................................................................................40
TTL Outputs ............................................................................................................................41
Chapter 4 Communication
43
Introduction .............................................................................................................................43
RS232 Port...............................................................................................................................43
RS232 - Port 1 DATATERM ................................................................................43
RS-232 Configuration ...............................................................................................43
Ethernet Configuration ............................................................................................................44
Communication Protocols .........................................................................................44
Addressing.................................................................................................................44
Ethernet Handles .......................................................................................................45
Global vs. Local Operation........................................................................................45
Operation of Distributed Control...............................................................................47
Accessing the I/O of the Slaves.................................................................................47
Handling Communication Errors...............................................................................48
Multicasting...............................................................................................................48
Unsolicited Message Handling..................................................................................49
IOC-7007 Support .....................................................................................................49
Modbus Support ........................................................................................................50
Other Communication Options..................................................................................51
Data Record .............................................................................................................................52
Data Record Map.......................................................................................................52
Explanation of Status Information and Axis Switch Information..............................55
Notes Regarding Velocity and Torque Information ..................................................56
QZ Command............................................................................................................56
Using Third Party Software.......................................................................................57
Chapter 5 Command Basics
59
Introduction .............................................................................................................................59
Command Syntax - ASCII.......................................................................................................59
Coordinated Motion with more than 1 axis...............................................................60
Command Syntax - Binary ......................................................................................................60
Binary Command Format..........................................................................................61
Binary command table...............................................................................................62
ii • Contents
DMC-3425
Controller Response to DATA ................................................................................................63
Interrogating the Controller .....................................................................................................64
Interrogation Commands...........................................................................................64
Summary of Interrogation Commands ......................................................................64
Interrogating Current Commanded Values................................................................64
Operands....................................................................................................................64
Command Summary..................................................................................................65
Chapter 6 Programming Motion
67
Overview .................................................................................................................................67
Global vs. Local Operation........................................................................................67
Independent Axis Positioning..................................................................................................69
Command Summary - Independent Axis ..................................................................70
Operand Summary - Independent Axis .....................................................................70
Examples ...................................................................................................................70
Independent Jogging................................................................................................................72
Command Summary - Jogging..................................................................................72
Operand Summary - Independent Axis .....................................................................72
Examples ...................................................................................................................72
Linear Interpolation Mode (Local Mode)................................................................................73
Specifying Linear Segments......................................................................................73
Additional Commands...............................................................................................74
Command Summary - Linear Interpolation...............................................................75
Operand Summary - Linear Interpolation..................................................................75
Example.....................................................................................................................76
Example - Linear Move.............................................................................................76
Example - Multiple Moves........................................................................................77
Vector Mode: Linear and Circular Interpolation (Local Mode) ..............................................78
Specifying Vector Segments .....................................................................................78
Additional commands................................................................................................79
Command Summary - Coordinated Motion Sequence..............................................80
Operand Summary - Coordinated Motion Sequence.................................................80
Electronic Gearing (Local Mode)............................................................................................82
Command Summary - Electronic Gearing ................................................................82
Electronic Cam (Local Mode) .................................................................................................83
Contour Mode (Local Mode)...................................................................................................89
Specifying Contour Segments ...................................................................................89
Additional Commands...............................................................................................91
Command Summary - Contour Mode .......................................................................91
Operand Summary - Contour Mode ..........................................................................91
Virtual Axis (Local Mode) ......................................................................................................94
Ecam Master Example...............................................................................................95
Sinusoidal Motion Example ......................................................................................95
Stepper Motor Operation .........................................................................................................95
Specifying Stepper Motor Operation.........................................................................95
Stepper Motor Smoothing .........................................................................................96
Monitoring Generated Pulses vs. Commanded Pulses ..............................................96
Motion Complete Trippoint.......................................................................................97
Using an Encoder with Stepper Motors.....................................................................97
Command Summary - Stepper Motor Operation.......................................................97
Operand Summary - Stepper Motor Operation..........................................................97
Dual Loop (Auxiliary Encoder)...............................................................................................98
Using the CE Command............................................................................................98
Additional Commands for the Auxiliary Encoder.....................................................98
Backlash Compensation ............................................................................................98
DMC-3425
Contents• iii
Example.....................................................................................................................99
Motion Smoothing.................................................................................................................100
Using the IT and VT Commands:............................................................................100
Example...................................................................................................................100
Homing..................................................................................................................................101
Example...................................................................................................................102
Command Summary - Homing Operation...............................................................104
Operand Summary - Homing Operation..................................................................104
High Speed Position Capture (Latch) ....................................................................................104
Example...................................................................................................................105
Chapter 7 Application Programming
107
Overview ...............................................................................................................................107
Global vs. Local Programming................................................................................107
Entering Programs .................................................................................................................108
Edit Mode Commands.............................................................................................108
Example:..................................................................................................................109
Program Format.....................................................................................................................109
Using Labels in Programs .......................................................................................109
Special Labels..........................................................................................................110
Commenting Programs............................................................................................110
Executing Programs - Multitasking .......................................................................................111
Debugging Programs .............................................................................................................112
Trace Command ......................................................................................................113
Error Code Command..............................................................................................113
Stop Code Command...............................................................................................113
RAM Memory Interrogation Commands ................................................................113
Operands..................................................................................................................114
Breakpoints and single stepping..............................................................................114
EEPROM Memory Interrogation Operands ............................................................114
Program Flow Commands .....................................................................................................115
Event Triggers & Trippoints....................................................................................115
Conditional Jumps...................................................................................................119
If, Else, and Endif....................................................................................................121
Subroutines..............................................................................................................123
Stack Manipulation..................................................................................................123
Auto-Start and Auto Error Routine .........................................................................123
Automatic Subroutines for Monitoring Conditions.................................................124
Mathematical and Functional Expressions ............................................................................127
Mathematical Operators ..........................................................................................127
Bit-Wise Operators..................................................................................................128
Functions .................................................................................................................129
Variables................................................................................................................................129
Programmable Variables .........................................................................................130
Operands................................................................................................................................131
Special Operands.....................................................................................................131
Examples .................................................................................................................132
Arrays ....................................................................................................................................132
Defining Arrays.......................................................................................................132
Assignment of Array Entries...................................................................................132
Uploading and Downloading Arrays to On Board Memory....................................133
Automatic Data Capture into Arrays.......................................................................133
Deallocating Array Space........................................................................................135
Outputting Numbers and Strings ...........................................................................................135
Sending Messages ...................................................................................................135
iv • Contents
DMC-3425
Displaying Variables and Arrays.............................................................................137
Interrogation Commands.........................................................................................137
Formatting Variables and Array Elements ..............................................................139
Converting to User Units.........................................................................................140
Hardware I/O .........................................................................................................................140
Digital Outputs ........................................................................................................140
Digital Inputs...........................................................................................................141
Input Interrupt Function ..........................................................................................142
Analog Inputs ..........................................................................................................142
Extended I/O of the DMC-3425 Controller...........................................................................143
Configuring the I/O of the DMC-3425....................................................................143
Saving the State of the Outputs in Non-Volatile Memory.......................................144
Accessing Extended I/O ..........................................................................................144
Interfacing to Grayhill or OPTO-22 G4PB24 .........................................................145
Example Applications............................................................................................................145
Wire Cutter..............................................................................................................145
A-B (X-Y) Table Controller....................................................................................146
Speed Control by Joystick.......................................................................................148
Position Control by Joystick....................................................................................149
Chapter 8 Hardware & Software Protection
151
Introduction ...........................................................................................................................151
Hardware Protection ..............................................................................................................151
Output Protection Lines...........................................................................................151
Input Protection Lines .............................................................................................152
Software Protection ...............................................................................................................152
Example:..................................................................................................................152
Programmable Position Limits................................................................................152
Example:..................................................................................................................153
Off-On-Error ...........................................................................................................153
Examples:................................................................................................................153
Automatic Error Routine.........................................................................................153
Example:..................................................................................................................153
Limit Switch Routine ..............................................................................................154
Chapter 9 Troubleshooting
155
Overview ...............................................................................................................................155
Installation .............................................................................................................................155
Communication......................................................................................................................156
Stability..................................................................................................................................156
Operation ...............................................................................................................................156
Chapter 10 Theory of Operation
157
Overview ...............................................................................................................................157
Operation of Closed-Loop Systems.......................................................................................159
System Modeling...................................................................................................................160
Motor-Amplifier......................................................................................................161
Encoder....................................................................................................................163
DAC ........................................................................................................................164
Digital Filter ............................................................................................................164
ZOH.........................................................................................................................165
System Analysis.....................................................................................................................165
System Design and Compensation.........................................................................................167
The Analytical Method............................................................................................167
DMC-3425
Contents• v
Appendices
171
Electrical Specifications ........................................................................................................171
Servo Control ..........................................................................................................171
Input/Output ............................................................................................................171
Power Requirements................................................................................................171
Performance Specifications ...................................................................................................171
Connectors for DMC-3425....................................................................................................172
J3 DMC-3425 General I/O; 37- PIN D-type ...........................................................172
J3 DMC-3425-Stepper General I/O; 37- PIN D-type..............................................173
J5 POWER; 6 PIN MOLEX....................................................................................173
J1 RS232 Main port: DB-9 Pin Male: .....................................................................174
Pin-Out Description...............................................................................................................174
ICM-1460 Interconnect Module ............................................................................................175
Opto-Isolation Option for ICM-1460.....................................................................................177
Opto-isolated inputs: ...............................................................................................177
Opto-isolated outputs: .............................................................................................178
64 Extended I/O of the DMC-3425 Controller ......................................................................179
Configuring the I/O of the DMC-3425 with DB-14064..........................................179
Connector Description:............................................................................................181
IOM-1964 Opto-Isolation Module for Extended I/O Controllers..........................................183
Description: .............................................................................................................183
Overview .................................................................................................................184
Configuring Hardware Banks..................................................................................185
Digital Inputs...........................................................................................................185
High Power Digital Outputs ....................................................................................187
Standard Digital Outputs.........................................................................................188
Electrical Specifications..........................................................................................189
Relevant DMC Commands......................................................................................190
Screw Terminal Listing...........................................................................................190
Coordinated Motion - Mathematical Analysis.......................................................................193
List of Other Publications......................................................................................................196
Training Seminars..................................................................................................................196
Contacting Us ........................................................................................................................197
WARRANTY ........................................................................................................................198
Index
199
vi • Contents
DMC-3425
Chapter 1 Overview
Introduction
The DMC-3425 provides a highly versatile, powerful form of distributed control where multiple DMC-
3425 controllers can be linked together on the Ethernet. One DMC-3425 is designated as a “master”
that receives all commands from the host computer and passes them to the other “slave” DMC-3425
controllers. Efficient, quick communications are realized as this approach eliminates the usual,
multiple communication links between the host computer and each controller.
Each DMC-3425 precisely controls two servo motors, providing ECAM, gearing and both linear and
circular interpolation for coordinated motion along the two local axis. A single axis DMC-3415 is also
available. When acting as the “master,” a DMC-3425 can receive PR, PA and JG commands for up to
eight axes and distribute them to the appropriate controller. Coordinated motion is commanded locally
by each DMC-3425 “slave” controller. Performance capability of these controllers includes: 12 MHz
encoder input frequency, 16-bit motor command output DAC, +/-2 billion counts total travel per move,
250 μsec minimum sample rate and non-volatile memory for program and parameter storage.
Designed for maximum flexibility, the DMC-3425 can be interfaced to a variety of motors and drives
including step motors, brush and brushless servo motors and hydraulics. The DMC-3425 can also be
configured to provide sinusoidal commutation for brushless motors.
The controller accepts feedback from a quadrature linear or rotary encoder with input frequencies up to
12 million quadrature counts per second. Modes of motion include jogging, point-to-point positioning,
electronic cam, electronic gearing and contouring. Several motion parameters can be specified
including acceleration and deceleration rates and slew speed. The DMC-3425 also provides motion
smoothing to eliminate jerk.
For synchronization with outside events, the DMC-3425 provides uncommitted I/O. The DMC-3425
provides up to 3 digital inputs, 3 digital outputs and 2 analog inputs. The DMC-3415 provides 7
digital inputs, 3 digital outputs and 2 analog inputs. Committed digital inputs are provided for forward
and reverse limits, abort, home, and definable input interrupts. An additional 64 configurable I/O
points may be added with the optional DB-14064 daughter card. The DMC-3425 distributed system
may also be linked with multiple IOC-7007 Ethernet I/O modules for complete machine I/O control.
Event triggers can automatically check for elapsed time, distance and motion complete.
The DMC-3425 is easy to program. Instructions are represented by two letter commands such as BG
for Begin and SP for Speed. Conditional instructions, Jump statements and arithmetic functions are
included for writing self-contained applications programs. An internal editor allows programs to be
quickly entered and edited, and support software such as the WSDK allows quick system set-up and
tuning. Commands may also be sent in Binary to decrease processing time.
To prevent system damage during machine operation, the DMC-3425 provides many error-handling
features. These include software and hardware limits, automatic shut-off on excessive error, abort
input and user-definable error and limit routines.
DMC-3425
Chapter 1 Overview• 1
The DMC-3425 is designed for stand-alone applications and provides non-volatile storage for
programs, variables and array elements.
This manual uses ‘DMC-3425’ to refer to the distributed control E-series from Galil. However, most
functions described in this manual are available using either the DMC-3425 or the DMC-3415. If a
function is specific to only one of the controllers, this will be explicitly stated.
Overview of Motor Types
The DMC-3425 can provide the following types of motor control:
1. Standard servo motors with +/- 10 volt command signals
2. Step motors with step and direction signals
3. Brushless servo motors with sinusoidal commutation
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 Motors with +/- 10 Volt Command Signal
The DMC-3425 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 notch 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 (+/- 10Volt) to connect to a servo amplifier. This connection
is described in Chapter 2.
Stepper Motor with Step and Direction Signals
The DMC-3425 can control 2 stepper motors. In this mode, the controller provides two signals to
connect to each 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. Chapter 2 describes the proper
connection and procedure for using stepper motors.
NOTE: In order to use two stepper motors on the DMC-3425, the controller must be ordered as a
DMC-3425-Stepper. In this mode, the Amp Enable and Error outputs are converted to the Step and
Direction signals for the Y-axis. Contact Galil for other stepper options.
Brushless Servo Motor with Sinusoidal Commutation
The DMC-3415 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. Please note, for a 2 axis DMC-3425, converting to a brushless
motor uses up the second axis.
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*. For faster
motors, please contact the factory.
The controller provides a one-time, automatic set-up procedure. The parameters determined by this
procedure can then be saved in non-volatile memory to be used whenever the system is powered on.
2 • Chapter 1 Overview
DMC-3425
The DMC-3415 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 controller will estimate the commutation
phase upon reset. This allows the motor to function immediately upon power up. The Hall effect
sensors also provide a method for setting the precise commutation phase. Chapter 2 describes the
proper connection and procedure for using sinusoidal commutation of brushless motors.
* 6 Milliseconds per magnetic cycle assumes a servo update of 1 msec (default rate).
DMC-3425
Chapter 1 Overview• 3
DMC-3425 Functional Elements
The DMC-3425 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
ETHERNET
AUXILIARY ENCODERS
+/- 10 VOLT OUTPUT FOR
SERVO MOTORS
1 Meg RAM
RS-232
4 Meg FLASH EEPROM
PULSE/DIRECTION OUTPUT
FOR STEP MOTORS
HIGH SPEED ENCODER
COMPARE OUTPUT
I/O INTERFACE
2 UNCOMMITTED
ANALOG INPUTS
3 PROGRAMMABLE
OUTPUTS
3 PROGRAMMABLE,
INPUTS
HIGH-SPEED LATCH FOR EACH AXIS
Figure 1.1 - DMC-3425 Functional Elements
Microcomputer Section
The main processing unit of the DMC-3425 is a specialized 32-bit Motorola 68331 Series
Microcomputer with 1 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-3425 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 +/-10Volt
analog signals. For stepper motor operation, the controller generates a step and direction signal.
Communication
The communication interface with the DMC-3425 consists of one RS-232 port (19.2 kbaud) and one
10base-T Ethernet port.
4 • Chapter 1 Overview
DMC-3425
General I/O
The DMC-3415 provides interface circuitry for 7 TTL inputs and 3 TTL outputs. In addition, the
controller provides two 12-bit analog inputs. The general inputs can also be used for triggering a high-
speed positional latch for each axis.
NOTE: In order to accommodate 2 axes on the DMC-3425, many of the general I/O features become
dedicated I/O for the second axis. The standard DMC-3425 will have 3 TTL inputs, 3 TTL outputs and
2 analog inputs. If extra I/O is needed, the DB-14064 I/O daughter card increases general purpose I/O
by 64 points.
System Elements
As shown in Fig. 1.2, the DMC-3425 is part of a motion control system, which includes amplifiers,
motors and encoders. These elements are described below.
Power Supply
Amplifier (Driver)
Computer
DMC-3425 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 for more information.
The motor may be a step or servo motor and can be brush-type or brushless, rotary or linear. For step
motors, the controller is capable of controlling 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 peak motor 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.
DMC-3425
Chapter 1 Overview• 5
For step motors, the amplifiers should accept step and direction signals.
Encoder
An encoder translates motion into electrical pulses that are fed back into the controller. The DMC-3425
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-,
CHB,CHB-). The DMC-3425 decodes either type into quadrature states or four times the number of
cycles. Encoders may also have a third channel (or index) for synchronization. The DMC-3425 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-3425. Single-
ended 12 Volt signals require a bias voltage input to the complementary inputs.)
The DMC-3425 can accept analog feedback instead of an encoder for any axis. For more information
see description of analog feedback in the Command Reference under the AF command.
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 to talk to one of our applications
engineers about your particular system requirements.
Watch Dog Timer
The DMC-3425 provides an internal watch dog timer which checks for proper microprocessor
operation. The timer toggles the Amplifier Enable Output (AEN), which can be used to switch the
amplifiers off in the event of a serious DMC-3425 failure. The AEN output is normally high. During
power-up and if the microprocessor ceases to function properly, the AEN output will go low. The
error light for each axis will also turn on at this stage. A reset is required to restore the DMC-3425 to
normal operation. Consult the factory for a Return Materials Authorization (RMA) number if your
DMC-3425 is damaged.
6 • Chapter 1 Overview
DMC-3425
Chapter 2 Getting Started
The DMC-3425 Motion Controller
Daughter card connector for
DB-14064 Extended I/O card
Stepper motor/Motor off
configuration jumpers
+12V/-12V Test
Points
RAM
+5V/Gnd Test
Points
JP2
9-Pin DSub
RS232 serial port
J6
DMC-1415
REV D
U4
GALIL MOTION CONTROL
MADE IN USA
Ethernet
network IC
U1
Motorola
68331
6 Pin Molex
Power Connector
Master reset/baud
rate jumpers
J4
J1
A8
GL-1800
U10
U2
A4
A2
A1
J5
JP1
Reset switch
Distributed Control Axis
configuration jumpers
SW1
J2
JP3
J3
D2
D4
SD MC
Step/Direction or
Motor Command
configuration jumpers
RJ-45 10BaseT
Ethernet connector
Status/Communications
LED's
Main 37-pin DSub
connector
Figure 2.1 – Outline of the DMC-3425
DMC-3425
Chapter 2 Getting Started• 7
Elements You Need
Before you start, you must get all the necessary system elements. These include:
1. (1) DMC-3425 or DMC-3415, (1) 37-pin cable (order Cable -37).
2. Servo motor(s) with encoders or stepper motors.
3. Appropriate motor drive - servo amp (Power Amplifier or AMP-1460) or stepper drive.
4. Power Supply for Amplifier
5. +5V, ±12V supply for DMC-3425
6. Communication CD from Galil
7. WSDK Servo Design Software (not necessary, but strongly recommended)
8. Interface Module ICM-1460 with screw-type terminals or integrated Interface
Module/Amplifier, AMP-1460. (Note: An interconnect module is not necessary, but strongly
recommended.) Also, the AMP-1460 only provides for 1 axis power amplification.
The motors may be servo (brush or brushless type) or steppers. The driver (amplifier) should be
suitable for the motor and may be linear or pulse-width-modulated and it may have current feedback or
voltage feedback.
For servo motors, the drivers should accept an analog signal in the +/-10 Volt range as a command.
The amplifier gain should be set so 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. For velocity mode
amplifiers, a command signal of 10 Volts should run the motor at the maximum required speed.
For step motors, the driver should accept step and direction signals. For start-up of a step motor
system refer to Step 8c “Connecting Step Motors”.
The WSDK software is highly recommended for first time users of the DMC-3425. It provides step-
by-step instructions for system connection, tuning and analysis.
Installing the DMC-3425 Controller
Installation of a complete, operational DMC-3425 system consists of 9 steps.
Step 1.
Step 2.
Step 3.
Step 4.
Step 5.
Step 6.
Step 7.
Step 8a.
Step 8b.
Step 8c.
Step 9.
Step 10.
Determine overall motor configuration.
Configuring jumpers on the DMC-3425.
Connect the DC power supply and serial cable to the DMC-3425.
Install the communications software.
Establish communications between the DMC-3425 and the host PC.
Set-up axis for sinusoidal commutation.
Make connections to amplifier and encoder.
Connect standard servo motor.
Connect brushless motor for sinusoidal commutation.
Connect step motor.
Tune servo system.
Configure distributed control system.
8 • Chapter 2 Getting Started
DMC-3425
Step 1. Determine Overall Motor Configuration
Before setting up the motion control system, the user must determine the desired motor configuration.
The DMC-3425 can control standard brush or brushless servo motors, sinusoidally commutated
brushless motors or stepper motors. For control of other types of actuators, such as hydraulics, please
contact Galil. The following configuration information is necessary to determine the proper motor
configuration:
Standard Servo Motor Operation:
The DMC-3425 has been setup by the factory for standard servo motor operation providing an analog
command signal of +/- 10 volt. The position of the jumpers at JP2/JP3 determines the type of output
the controllers will provide, analog motor command or PWM output. The installation of these jumpers
is discussed in the section “Configuring Jumpers on the DMC-3425”. Figure 2.2 shows how the
jumpers are configured for the standard output mode.
The DMC-3425 controller will output the analog command signal to either brush or brushless servo
amplifiers. Please note that if the brushless amplifier provides the sinusoidal commutation, the
standard servo motor operation from the controller will be used. If the commutation is to be performed
by the controller, please see below.
Sinusoidal Commutation:
Please consult the factory before operating with sinusoidal commutation.
Sinusoidal commutation is configured through a single software command, BA. This setting causes
the controller to reconfigure the control axis to output two commutated phases. The DMC-3425
requires two DAC outputs for a single axis of commutation. Issuing the BA command will enable the
second DAC for commutation.
If a DMC-3425 is used for sinusoidal commutation, the second axis will be used for the second DAC
phase. Please note that if the DMC-3425 is used for sinusoidal commutation, it will still be
represented by two axes within the distributed system, even though only one axis is truly active. The
DMC-3415 in brushless mode will take only a single axis within the distributed system.
Further instruction for sinusoidal commutation connections are discussed in Step 6.
Stepper Motor Operation:
The DMC-3415 can be configured to operate in stepper mode by installing a hardware jumper and
issuing a software command. The DMC-3425 can be configured to operate with two stepper motors by
ordering the DMC-3425-Stepper option from the factory. To configure the DMC-3425 for stepper
motor operation, the controller requires a jumper for the stepper motors and the command, MT, must
be given. The installation of the stepper motor jumper is discussed in the following section entitled
"Configuring Jumpers on the DMC-3425". Further instructions for stepper motor connections are
discussed in Step 8b.
Step 2. Configuring Jumpers on the DMC-3425
Master Reset and Upgrade Jumper
JP1 contains two jumpers, MRST and UPGD. 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. Whenever the controller has a master reset, all programs, arrays, variables, and
motion control parameters stored in EEPROM will be ERASED.
The UPGD 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
DMC-3425
Chapter 2 Getting Started• 9
there is a power fault during a firmware update. If EEPROM corruption occurs, your controller may
not operate properly. In this case, install the UPGD Jumper and use the update firmware function on
the Galil Smart Terminal or WSDK to re-load the system firmware.
Setting the Baud Rate on the DMC-3425
The jumpers labeled “9600” and “1200” at JP1 allow the user to select the serial communication baud
rate. The baud rate can be set using the following table:
JUMPER SETTINGS
BAUD RATE
9600
OFF
ON
1200
OFF
OFF
ON
--
19200
9600
1200
OFF
The default baud rate for the controller is 19.2k.
Selecting MO as default on the DMC-3425
The default condition for the motor on the DMC-3425 is the servo on (SH) state. This will enable the
amplifiers upon power up of the controller. This state can be changed to the motor off (MO) default by
placing a jumper at JP2 across the MO terminals. This will power up the controller with the amplifiers
disabled and the motor command off. The SH command must then be given in order for the servos or
steppers to operate.
Stepper Motor Jumpers
The DMC-3415 is user configurable to control either a servo motor or a stepper motor. The DMC-
3425 is factory default to servo control, but may also control two steppers if ordered from the factory
as a DMC-3425-Stepper.
To configure the DMC-3415 for stepper output, two jumpers must be placed on the controller. First,
the SMX jumper at location JP2 must be installed. This configures the board for step/direction output.
Second, the jumpers at location JP3 must be moved from the MC position to the SD position as shown
in Figure 2.2. This configures the output pins on the controller to output step and direction instead of
the analog motor command.
The configuration for two stepper motors on the DMC-3425-Stepper is handled at the factory. The
same procedure is used, placing jumpers on SMX and SMY at location JP2, and moving the SD/MC
jumpers at location JP3. A board modification is also required, which should only be handled by Galil
technicians.
JP3
JP3
SD
MC
SD MC
Setting for step/direction output
Setting for analog motor command
Figure 2.2 - Jumper settings for motor command output
10 • Chapter 2 Getting Started
DMC-3425
Axis Configuration Jumpers
When using the HC automatic configuration, jumpers must be set to indicate which controller is the
master and which controllers are slaves. Depending on the configuration of the jumpers, a controller
will be set up as either the A (B) master or any of the axes slaves.
The 8-pin jumper, found at location J4 next to the Molex power connector, is used to select axes
configurations. Jumpers at this location are labeled A1, A2, A4 and A8, which represent the binary
value for each of the 8 axes within a system. The following chart shows proper jumper selection for
each of the DMC-3415 or DMC-3425’s in a system.
Master A (B) axis
Slave Axis B
Slave Axes C
Slave Axis D
Slave Axes E
Slave Axis F
Slave Axes G
Slave Axis H
No Jumpers
A1 On A2 Off A4 Off A8 Off
A1 Off A2 On A4 Off A8 Off
A1 On A2 On A4 Off A8 Off
A1 Off A2 Off A4 On A8 Off
A1 On A2 Off A4 On A8 Off
A1 Off A2 On A4 On A8 Off
A1 On A2 On A4 On A8 Off
Jumpers on a card are used to denote the first axis it represents in a system. Therefore, a DMC-3415
takes up a single jumper setting. A DMC-3425 is selected with a single jumper setting but represents
two axes.
For example, the jumper settings for a system with a DMC-3415 master A axis, a DMC-3425 slave BC
axis and a DMC-3415 slave D axis, the following jumper settings would be used.
Master A – No Jumpers
Slave Axis BC – A1 On A2 Off A4 Off A8 Off
Slave Axis D – A1 On
A2 On A4 Off A8 Off
A1 A2
A4
A8
Fig. 2.3 – Example jumper settings for DMC-3425 E, F axis configuration.
Step 3. Connecting AC or DC power and the Serial Cable to the
DMC-3425
1. Insert 37-pin cable to J3. Connect the other end of the cable to the ICM-1460.
2. If using serial communications, use the 9-pin RS232 ribbon cable to connect the SERIAL port
of the DMC-3425 to your computer or terminal communications port. The DMC-3425 serial
DMC-3425
Chapter 2 Getting Started• 11
port is configured as DATASET. Your computer or terminal must be configured as a
DATATERM for full duplex, no parity, 8 bits data, one start bit and one stop bit.
Your computer needs to be configured as a "dumb" terminal that sends ASCII characters as
they are typed to the DMC-3425.
Connections to the controller for Ethernet communication are covered in Step 5.
3. If using the card level version, apply ±12V and +5V power to the J5 connector. If using the
box level version, connect the AC cord to a power outlet. AC power requirements for the
controller are single phase, 50 or 60 Hz at 90 to 260 VAC.
4. Applying power will turn on the green LED power indicator.
Step 4. Installing the Communications Software
After applying power to the computer, you should install the Galil software that enables
communication between the controller and PC.
Using DOS:
Using the Galil Software CD-ROM, go to the directory, DMCDOS. Type "INSTALL" at the DOS
prompt and follow the directions.
Using Windows 3.x (16 bit versions):
Using the Galil Software CD ROM, go to the directory, DMCWIN16. Run DMCWIN16.exe at the
Command prompt and follow the directions.
Using Windows 95, NT or 98 (32 bit versions):
The Galil Software CD-ROM will automatically begin the installation procedure when the CD-ROM is
installed. After installing the Galil CD-ROM software on your computer, you can easily install other
software components as desired. To install the basic communications software, run the Galil Software
CD-ROM and choose “DMC Smart Terminal”. This will install the Galil Terminal that can be used
for communication.
Step 5. Establishing Communication between the DMC-3425 and the
host PC
Note: This section will show how to communicate with a single DMC-3425 or DMC-3415 controller.
If the controllers will be configured in a multi-axis, distributed control system, only the master axis
needs an IP address actively configured.
Communicating through the RS-232 Serial Communications Port
Connect the DMC-3425 serial port to your computer via the Galil CABLE-9PIN-D (RS-232 Cable).
Using Galil Software for DOS
To communicate with the DMC-3425, 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 port.
12 • Chapter 2 Getting Started
DMC-3425
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, such as WSDK or DMCSmartTerm.
The registry window is equipped with a button 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. Use the Properties button to
change the properties of a current controller. For a new registration, you will need to supply the Galil
Controller type. The controller model number must be entered. If you are changing an existing
controller, this field will already have an entry. Pressing the down arrow to the right of this field will
reveal a menu of valid controller types. Once the DMC-3425 has been selected, there is a choice for
either Serial or Ethernet communication, as shown below. Select Serial communication.
DMC-3425
Chapter 2 Getting Started• 13
After selecting Next, the registry information will show a default Comm Port of 1 and a default Comm
Speed of 19200 appears. This information should be changed as necessary to reflect the computers
Comm Port and the baud rate set by the controller's baud rate jumpers.
Once you have set the appropriate Registry information for your controller, Select Finish and close the
registry window. You will now be able to communicate with the DMC-3425. Within WSDK, select
File and Connect to Controller. Within DMCSmartTerm, select Tools and Select Controller. Once
14 • Chapter 2 Getting Started
DMC-3425
the entry has been selected, click on the OK button. If the software has successfully established
communications with the controller, the registry entry will be displayed at the top of the screen.
If you are not properly communicating with the controller, the program will pause for 3-15 seconds.
The top of the screen will display the message “Status: not connected with Galil motion controller” and
the following error will appear: “STOP - Unable to establish communication with the Galil controller.
A time-out occurred while waiting for a response from the Galil controller.” If this message appears,
you must click OK. In this case, 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 straight-through serial cable is being used (no Null modem). See appendix for the
correct pin-outs for the serial cable.
Once you establish communications, click on the menu for terminal and you will receive a colon
prompt. Communicating with the controller is described in later sections.
Using Non-Galil Communication Software
The DMC-3425 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 that sends ASCII characters as they are
typed to the DMC-3425. Use the EO command to specify if the characters should be echoed back
from the controller.
Sending Test Commands to the Terminal:
After you connect your terminal, press <carriage return> or the <enter> key on your keyboard. In
response to carriage return (CR), the controller responds with a colon, :
Now type
TPA (CR)
This command directs the controller to return the current position of the A axis. The controller should
respond with a number such as
0000000
Communicating through the Ethernet
For Ethernet communication, connect the DMC-3425 to your computer or to a hub. If connecting
through a switch or a hub, a standard RJ45 Ethernet cable is used. If connecting directly to the PC, a
cross-over RJ45 Ethernet cable must be used.
Using Galil Software for Windows
The controller must be registered in the Galil Windows registry for the host computer to communicate
with it. The registry may be accessed via Galil software, such as WSDK or DMCSmartTerm.
From WSDK, the registry is accessed under the FILE menu. From DMCSmartTerm it is accessed
under the Tools and Controller Registration menu. In the Galil Registry, the DMC-3425 can either
be added manually with the New Controller button or the software can automatically try to find the
controller with the Find Ethernet Controller button.
The first registry option is to use the New Controller button. The DMC-3425 should be selected from
the models listed, with Ethernet selected as the mode of communication.
DMC-3425
Chapter 2 Getting Started• 15
After Next is pressed, the next screen will allow the IP address to be selected and assigned.
Enter the IP address obtained from your system administrator into the box IP Address. Select the
button corresponding to the protocol in which you wish to communicate with the controller, UDP or
TCP. If the IP address has not been already assigned to the controller, click on ASSIGN IP
ADDRESS.
16 • Chapter 2 Getting Started
DMC-3425
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
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. Once the correct
controller has been selected, click on Finish.
If an IP address has already been assigned to the controller through the serial port and the IA
command, add this address to the IP Address box and then select Finish.
The second method for registering the controller is by using the option within the registry labeled Find
Ethernet Controllers. This utility uses the DMCNet software program to search for any controllers
on the network, both with and without IP addresses. If the DMC-3425 does not have an IP address, the
utility will listen for the BOOTP packet and then ask for an IP address to be assigned. Once the IP
address is added, click on Register and the controller will be added to the Galil Registry. If an IP
address has already been assigned to the controller, the utility will list that controller with its current IP
address. At this point, click on Register and the controller will be added to the Galil Registry.
Once you have set the appropriate Registry information for your controller, Select Close to close the
registry window. You will now be able to communicate with the DMC-3425. Within WSDK, select
File and Connect to Controller. Within DMCSmartTerm, select Tools and Select Controller. Once
the appropriate entry has been selected, click on the OK button. If the software has successfully
established communications with the controller, the registry entry will be displayed at the top of the
screen.
See Chapter 4 Communication for additional information on the Ethernet configuration and
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 6. Set-up axis for sinusoidal commutation (optional)
* This step is only required when the controller will be used to control a brushless motor with
sinusoidal commutation. Please consult the factory before operating with sinusoidal commutation.
The command BA is used to specify sinusoidal commutation mode for the DMC-3415 or DMC-3425.
In this mode the controller will output two sinusoidal phases for the DACs. Once specified, follow the
procedure outlined in Step 8b.
Step 7. Make connections to amplifier and encoder
Once you have established communications between the software and the DMC-3425, you are ready to
connect the rest of the motion control system. The motion control system generally consists of an
ICM-1460 Interface Module, a servo amplifier, and a motor to transform the current from the servo
amplifier into torque for motion. Galil also offers the AMP-1460 Interface Module which is an ICM-
1460 equipped with a servo amplifier for a DC motor.
DMC-3425
Chapter 2 Getting Started• 17
A signal breakout board of some type is strongly recommended. If you are using a breakout board
from a third party, consult the documentation for that board to insure proper system connection.
If you are using the ICM-1460 or AMP-1460 with the DMC-3425, connect the 37-pin cable between
the controller and interconnect module.
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.
Note: If you are using a DMC-3425-Stepper, the amplifier enable signal is used for
the second stepper output.
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, proceed to connect the two ground
signals directly.
The amplifier enable signal is used by the controller to disable the motor. This
signal is labeled AMPEN on the ICM-1460 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. As shown in Figure 3.1, AEN
can be used to disable the amplifier for these conditions.
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 and the amplitude can be changed if you are using the ICM-1460
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 AEN signal, note the state of the JP1 jumper on
the ICM-1460. When the jumper is placed across 5V and AEN, the output voltage is
0-5V. To change to 12 volts, pull the jumper and rotate it so that +12V is connected
to AEN. If you remove the jumper, 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
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.
18 • Chapter 2 Getting Started
DMC-3425
The DMC-3425 accepts single-ended or differential encoder feedback with or
without an index pulse. If you are not using the AMP-1460 or the ICM-1460, you
will need to consult the appendix for the encoder pinouts for connection to the
motion controller. The AMP-1460 and the ICM-1460 can accept encoder feedback
from a 10-pin ribbon cable or individual signal leads. For a 10-pin ribbon cable
encoder, connect the cable to the protected header connector labeled JP2. For
individual wires, 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, CHB, and INDEX. These labels represent channel A, channel B, and the
INDEX pulse, respectively. 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.
Once the encoder is connected as described above, turn the motor shaft and
interrogate the position with the instruction TP <return>. The controller response
will vary as the motor is turned.
At this point, if TP 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 (sinusoidal commutation only)
Please consult factory before operating with sinusoidal commutation. Hall sensors
are only used with sinusoidal commutation on the DMC-3415 or DMC-3425 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-purpose inputs (bits 1 - 7). If you are using the
DMC-3425, only the first 3 inputs are available for general purpose.
Each set of inputs must use inputs that are in consecutive order. The input lines are
specified with the command, BI. For example, if the Hall sensors are connected to
inputs 1, 2 and 3, use the instruction:
BI1 <CR>
Step 8a. Connect Standard Servo Motor
The following discussion applies to connecting the DMC-3425 controller to standard servo motor
amplifiers:
DMC-3425
Chapter 2 Getting Started• 19
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.
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 D). Before connecting the motor amplifiers to the controller, read the following
discussion on setting Error Limits and Torque Limits.
Step A. 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 DMCSmartTerm, the following parameters can be given to avoid
system damage:
Input the commands:
ER 2000,2000 <CR>
OE 1,1 <CR>
Sets error limit to be 2000 counts
Disables amplifier when excess 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 AEN signal to be connected from the controller to
the amplifier.
Step B. Setting Torque Limit as a Safety Precaution
To limit the maximum voltage signal to your amplifier, the DMC-3425 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:
TL 1 <CR>
Sets torque limit to 1 Volt on A axis
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.
Step C. Disable motor
Issue the motor off command to disable the motor.
MO <CR>
Turns motor off
Step D. Connecting the Motor
20 • Chapter 2 Getting Started
DMC-3425
Once the parameters have been set, connect the analog motor command signal
(ACMD) to the amplifier input.
Issue the servo here command to turn the motors on. To test the polarity of the
feedback, command a move with the instruction:
SH <CR>
Servo Here to turn motors on
Position relative 1000 counts
Begin motion
PR 1000 <CR>
BG <CR>
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. In
this case, 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:
TT <CR>
Tell torque
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-3425
Chapter 2 Getting Started• 21
J2
ICM-1460
Encoder lines
VAMP+
Motor 1
Power Supply
AMPGND
Motor
Motor 2
Figure 2.3 - System Connections with the AMP-1460 Amplifier
22 • Chapter 2 Getting Started
DMC-3425
ICM-1460
Description
Connection
Channel A+
Channel B+
Channel A-
Channel B-
Index -
MA+
MB+
MA-
MB-
I-
Index +
I+
Gnd
+5V
GND
5V
Red Connector
Red Wire
Black Wire
Black Connector
11 INHIBIT
4 +REF IN
2 SIGNALGND
Figure 2.4 - System Connections with a separate amplifier (MSA 12-80). This diagram shows the
connections for a standard DC Servo Motor and encoder.
Step 8b. Connect brushless motor for sinusoidal commutation
Please consult the factory before operating with sinusoidal commutation. Any controller within
the distributed system may be configured for sinusoidal commutation. If a DMC-3415 is used, the
second DAC is simply initiated with the BA command. If a DMC-3425 is used, it will control only a
single brushless motor, but will take up two axes in configuration. When using sinusoidal
commutation, the parameters for the commutation must be determined and saved in the controller’s
non-volatile memory. The servo can then be tuned as described in Step 9.
Step A. Disable the motor amplifier
Use the command, MO, to disable the motor amplifiers.
Step B. Connect the motor amplifier to the controller.
The sinusoidal commutation amplifier requires 2 signals, usually denoted as Phase A
and Phase B. These inputs should be connected to the two sinusoidal signals
DMC-3425
Chapter 2 Getting Started• 23
generated by the controller. The first signal is the main controller motor output,
ACMD. The second signal utilizes the second DAC on the controller and is brought
out on the ICM-1460 at pin 38 (ACMD2).
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).
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 you are using 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 <CR>
On the other hand, if you are using a rotary motor with 4000 counts per revolution
and 3 magnetic cycles per revolution (three pole pairs) the command is:
BM 1333.333 <CR>
Step D. Test the Polarity of the DACs and Hall Sensor Configuration.
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.
The user must specify the value for V and T. For example, the command:
BS 2,700 <CR>
will test the brushless axis with a voltage of 2 volts, applying it for 700 milliseconds
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.
If Hall Sensors are Available:
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 occurs 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.
24 • Chapter 2 Getting Started
DMC-3425
If Hall Sensors are Not Available:
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. 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.
If Hall Sensors are Not Available:
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 argument is a real number that represents the voltage to be applied
to the amplifier during the initialization. When the voltage is specified by a positive
number, the initialization process will end up in the motor off (MO) state. A
negative number causes the process to end in the Servo Here (SH) state.
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 <CR>
will drive the axis to zero, using a 2V signal. The controller will then leave the
motor enabled. For systems that have external forces working against the motor,
such as gravity, the BZ argument must provide a torque 10x the external force. If the
torque is not sufficient, the commutation zero may not be accurate.
If Hall Sensors are Available:
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 _BZx.
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:
SH <CR>
Enable A axis motor
DMC-3425
Chapter 2 Getting Started• 25
PRA=-1*(_BZA) <CR> Move A motor close to zero commutation phase
BGA <CR>
AMA<CR>
BZA=-1 <CR>
Begin motion on A axis
Wait for motion to complete on A axis
Drive motor to commutation phase zero and leave motor
on
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 motor upon power or reset, the following
commands may be given:
SH <CR>
Enable motor
BC <CR>
Enable the brushless calibration command
Command a relative position movement
PR 50000 <CR>
BG <CR>
Begin motion. When the hall sensors detect a phase
transition, the commutation phase is re-set.
Step 8c. 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 DE. The encoder position can be interrogated
with TP. Only the DMC-3415 allows the use of the main encoder input with a stepper motor. The
DMC-3425 does not have this option.
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-3425 profiler commands the step motor amplifier. All DMC-3425 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-3425 you must follow this procedure:
Step A. Install SM jumper
Install the jumper SMX at location JP2 to enable stepper motor operation on the
DMC-3415. For the DMC-3425-Stepper, the jumpers should be loaded on SMX and
SMY. For a discussion of SM jumpers, see section “Step 2. Configuring Jumpers on
the DMC-3425”.
Step B. Connect step and direction signals from the controller to respective signals on your
step motor amplifier.
The DMC-3415 outputs STEPX (step) signals on the ICM-1460 terminal labeled
ACMD, and outputs DIRX (direction) signals on the ICM-1460 terminal labeled
ACMD2.
26 • Chapter 2 Getting Started
DMC-3425
The DMC-3425 outputs STEPY signals on the ICM-1460 terminal labeled ERROR,
and outputs DIRX on the ICM-1460 terminal labeled AMPEN. X-axis connections
are identical to the DMC-3415.
Consult the documentation for your step motor amplifier for proper connections.
Step C. Configure DMC-3425 for motor type using MT command. You can configure the
DMC-3425 for active high or active low pulses. Use the command MT 2 for active
high step motor pulses and MT -2 for active low step motor pulses. See description
of the MT command in the Command Reference.
Note: The DMC-3425 must be ordered as a DMC-3425-Stepper to drive two axes of stepper motors.
Step 9. Tune the Servo System
The system compensation provides fast and accurate response by adjusting the filter parameters. 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 Windows Servo Design Kit
(WSDK software).
If the torque limit was set as a safety precaution in the previous step, you may want to increase this
value. See Step B of the above section “Setting Torque Limit as a Safety Precaution”
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 <CR>
Integrator gain
and set the proportional gain to a low value, such as
KP 1 <CR>
Proportional gain
Derivative gain
KD 100 <CR>
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 <CR>
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 <CR>
TE <CR>
Proportion gain
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.
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 <CR>
becomes zero. As KI is increased, its effect is amplified and it may lead to vibrations. If this occurs,
simply reduce KI.
For a more detailed description of the operation of the PID filter and/or servo system theory, see
Chapter 10 Theory of Operation.
DMC-3425
Chapter 2 Getting Started• 27
Step 10. Configure the Distributed Control System
The final step in Getting Started with the DMC-3425 distributed control system is to configure the
individual controllers as their respective axes in the system. For more information on the operation of
distributed control, please refer to Chapter 4.
Configuring Operation for Distributed Control
There are two methods for configuring a distributed control system; an automatic mode or a manual
mode. The automatic mode uses a single command (HC) to configure all the slaves in a particular
system. This command uses the BOOTP packets from the slaves, along with configuration jumpers, to
automatically select IP addresses and set up the system. In the manual mode, slave controllers are
assigned IP addresses and then configured into axes through various software commands. Both
methods are outlined below.
Automatic Configuration of Distributed Control
The automatic method of assigning a distributed control network uses the HC command to indicate
number of axes, type of communication and update rate of a system. This command also configures
the number of IOC extended I/O modules in the system, if any.
The data update rate specifies the rate at which each slave sends a data packet to the master containing
current status information. The data records are used by the master controller to make decisions based
on the status of the slave controllers or IOC-7007 modules. This data record rate may be selected
manually with the QW command, but will be set automatically by the second field of the HC
command.
The data contained in the record is as follows:
reference position
encoder position
position error
velocity
torque
limit and home switches
axis status (in motion, motor off, at speed, stopcode)
uncommitted inputs
uncommitted outputs
user defined variables (4)
In order for the HC command to be initiated, an IP address must already be assigned to the master. See
Step 5 “Establishing Communication between the DMC-3425 and the host PC” for information on
addressing the master controller. The slaves, in this method, will typically remain without IP
addresses. If the slaves are to be addressed manually while still using the HC mode, skip to the next
section Manual Slave IP configuration with HC command.
Once initiated, the master controller will ARP for slaves with IP address already assigned, and then
‘listen’ for BOOTP packets from the slave controllers without IP addresses. As it receives these
packets, the master will configure the slave axes according to jumpers set on each slave controller.
Once this connection has been established, the master will initiate QW, or data records, to begin from
each slave for status updates.
The full procedure for this method is as follows:
28 • Chapter 2 Getting Started
DMC-3425
Step 1. Assign IP address to master controller either through IA command or through
BOOTP utility in the Galil Software Registry. You may then burn this IP address
into the master with the BN in order to keep this address during resets.
Step 2. Place jumpers on each slave controller indicating which slave corresponds to which
axes in the system. See section “Step 2. Configuring Jumpers on the DMC-3425”.
Step 3. Determine total number of axes, data update rate, and number of IOC-7007
controllers in the distributed system.
Step 4. Issue the command HCn,m,o,p where n is the total number of axes, m is the data
update rate in milliseconds, o is a 1 for UDP communication or 2 for TCP/IP
communication and p is the total number of IOC-7007’s in the system. When using
UDP communication, the HC command will assign one handle for both commands
and QW records. When using TCP/IP communication, the HC command will assign
one handle for commands and one handle for QW records. If o is a 3, then TCP/IP is
used for commands, and UDP is used for QW records.
Step 5. Poll the operand _HC for success of connection. A response of 1 indicates the
command is currently executing, a 2 for a successful configuration and a 0 for a
failed configuration or no HC issued.
NOTE: The HC command may take up to 20 seconds to complete due to the time involved in waiting
for the BOOTP packets.
Manual Slave IP configuration with HC command
It may be desired to manually assign an IP address to the slaves, while still using the HC command to
connect to these slaves. This is possible, but you will need to take into account the addressing scheme
the HC command is using, and you must install axis configuration jumpers according to “Step 2.
Configuring jumpers on the DMC-3425”.
When the HC command is initiated, the master will ARP addresses where it expects slave controllers
to reside. If no controllers respond to the ARPs, the master will then ‘listen’ for the BOOTP packets
from un-assigned slave controllers.
For addressing the slaves manually, the IP address MUST be assigned as follows. This will insure that
the HC command will properly configure these controllers based on the master IP address.
Assume Master IP address = m.n.o.p where m, n, o and p is a valid Ethernet IP address.
First Slave IP address (Axis B or C) = m.n.o.p+2
Next slave is assigned +2 if previous slave was a single axis (DMC-3415).
Next slave is assigned +4 if previous slave was a dual axis (DMC-3425).
Slave axes are always assigned addresses based on their first axis.
IOC-7007 controllers are addressed as follows:
IOC 1 = m.n.o.p+16
IOC 2 = m.n.o.p+20
For example, in a 5 axis/1 IOC-7007 system with a DMC-3415 A axis Master, a DMC-3415
B axis, a DMC-3425 CD axis and a DMC-3415 E axis the following IP addresses would
be set:
Assume Master IP address – 10.10.50.10
B Axis DMC-3415 – 10.10.50.12
CD Axis DMC-3425 – 10.10.50.14
E Axis DMC-3415 – 10.10.50.18
DMC-3425
Chapter 2 Getting Started• 29
IOC-7007 (1) – 10.10.50.26
Automatic Configuration Example
The example below shows a typical setup file for the DMC-3425 distributed control system using the
automatic configuration. This example is for a UDP system, with one handle used per slave. The IP
addresses of the slaves are unassigned, as this is the simplest way for the slave controllers to be
configured. The IP address of the master needs to have been assigned as described in Step 5
“Establishing Communication between the DMC-3425 and the host PC”. The HC command will
automatically assign those IP addresses based on the axis jumper settings described in Chapter 2.
Instruction
#SETUP
Interpretation
Begin Program
HC=6,20,1,0
Automatic configuration for a 6 axis UDP system with 20 msec
update rate. The final 0 indicates no IOC-7007 Ethernet I/O
modules in the system.
#LOOP; JP#LOOP,_HC=1
Wait while automatic configuration operates. This could take
up to 10+ seconds.
IF (_HC=0)
Test for HC success. 0 = failed while 2 = success.
MG”CONFIGURATION FAILED”
ELSE
MG”CONFIG SUCCESS”
ENDIF
EN
Manual Configuration of Distributed Control
For the manual configuration of distributed control, each 3425 must be assigned an IP address. This
can be done with the BOOTP procedure in the Galil software or the IA command can be used to assign
the IP address through the serial port. Once the IP address has been assigned, a BN command should
be issued to save this value in the controller’s non-volatile memory. Since all configuration is done
manually in this method, there is no limit for the IP address of each slave in the system.
Upon power-up or reset, the master 3425 must establish each slave connection. The following steps
must be taken while connected to the master 3425:
1. Using the IH command, open handles for each slave. For a TCP/IP connection, each
slave controller must have 2 open handles, one for commands from the master, the other
for data returned from the slave (QW). The second internet handle for each slave
controller must contain a specific port value. The value must be an even number greater
than 502. For a UDP connection, a slave controller can use a single handle for both
commands from the master as well as data returned from the slave. The command for
opening the communication handle is:
IHh=ip0,ip1,ip2,ip3<p>n h is the handle. ip is the slave IP address. <p specifies
port number. >n specifies connection type, 1 for UDP or 2 for TCP/IP.
2. Set the total number of axes in the system with the NA command. For example, assume
there are 2 DMC-3425 slave cards, therefore there will be 6 axes (2 in the master and 4 in
the slaves) and the command would be NA6.
3. Connect each slave handle to the master. This is accomplished with the CH command.
The format of this command is:
CHa=h1,h2
where a is the first axis designator of the slave controller, h1 is the
handle for commands and h2 is the handle for slave status. h1 may equal h2 in a
UDP setup.
30 • Chapter 2 Getting Started
DMC-3425
Note that only one of the 2 axes (per DMC-3425) needs to be assigned with the CH command.
4. In order for the Master controller to be able to make decisions based on the status of the
slave/server controllers, it is necessary for the slaves to generate data records giving their
current status. The record is sent at a rate set by the QW command. The QW command
must be executed by the master before the slave can issue a record under any method.
The format of the command is
QWh=n where h is the handle. n is a number between 4 and 16000.
n sets the number of samples (msec with default TM1000).
n equal to 0 disables the mode.
The data contained in the record is as follows:
reference position
encoder position
position error
velocity
torque
limit and home switches
axis status (in motion, motor off, at speed, stopcode)
uncommitted inputs
uncommitted outputs
user defined variables (4)
Manual Configuration Example
The example below shows a typical setup file for the DMC-3425 distributed control system in manual
mode. This example is for a TCP/IP system, with two handles used per slave. The IP address of the
first slave (Axes C and D) is 160.50.10.1, while the address of the second slave (Axes E and F) is
160.50.10.2. Note that in the two axis setup, different port numbers are used for the second handle to
the same IP address.
Instruction
#SETUP
Interpretation
Begin Program
IHD=160,50,10,1>2
IHE=160,50,10,1<510>2
IHF=160,50,10,2>2
IHG=160,50,10,2<512>2
NA6
Set handle D (for commands) to slave 1's IP
Open handle E for slave 1's data record
Set handle F (for commands) to slave 2’s IP
Open handle G for slave 2's data record
6 axis total
CHC=D,E
Axis C & D assigned to slave 1 (Handle D,E)
Axis E & F assigned to slave 2 (Handle F,G)
Handle E sends data record every 20 msec
Handle G sends data record every 20 msec
CHE=F,G
QWE=20
QWG=20
EN
Note: This program is the minimum necessary for manually setting up the controller. An actual
application program should make use of error and status checking. An example would be testing the
operand _IHh2 for successful handle connections. See Command Reference for more details.
DMC-3425
Chapter 2 Getting Started• 31
Design Examples
Here are a few examples for tuning and using your controller. These examples are shown for a single axis system
only, but can be modified to test up to 8 axes within a distributed control network. See Chapter 6
Programming Motion for more examples of multi-axis programming.
Example 1 - System Set-up
This example assigns the system filter parameters, error limits and enables the automatic error shut-off.
Instruction
KP 10
Interpretation
Set proportional gain
Set damping
KD 100
KI 1
Set integral
OE 1
Set error off
ER 1000
Set error limit
Example 2 - Profiled Move
Objective: Rotate 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.
Instruction
PR 10000
SP 20000
DC 100000
AC 100000
BGA
Interpretation
Distance
Speed
Deceleration
Acceleration
Start Motion
In response, the motor turns and stops.
Example 3 - Position Interrogation
The position of the A axis may be interrogated with the instruction
TPA
Tell position
which returns the position of the main encoder.
The position error, which is the difference between the commanded position and the actual position
can be interrogated by the instructions
TEA
Tell error
Example 4 - Absolute Position
Objective: Command motion by specifying the absolute position.
Instruction
DP 0
Interpretation
Define the current position as 0
Sets the desired absolute position
Start motion on A axis
PA 7000
BGA
32 • Chapter 2 Getting Started
DMC-3425
Example 5 - Velocity Control (Jogging)
Objective: Drive the motor at specified speeds.
Instruction
JG 10000
AC 100000
DC 50000
BGA
Interpretation
Set Jog Speed
Set acceleration
Set deceleration
Start motion on A axis
after a few seconds, command:
JG –40000
New speed and Direction
TVA
Returns speed
This causes velocity changes including direction reversal. The motion can be stopped with the
instruction
STA
Stop
Example 6 - Operation Under Torque Limit
The magnitude of the motor command may be limited independently by the instruction TL. The
following program illustrates that effect.
Instruction
TL 0.2
Interpretation
Set output limit to 0.2 volts
Set speed
JG 10000
BGA
Start motion on A axis
The motor will probably not move as the output signal is not 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
TL 1.0
Increase torque limit to 1 volt.
TL 9.98
Increase torque limit to maximum, 9.98 Volts.
The maximum level of 10 volts provides the full output torque.
Example 7 - Interrogation
The values of the parameters may be interrogated using a ?. For example, the instruction
KP ?
Return gain
The same procedure applies to other parameters such as KI, KD, FA, etc.
Example 8 - Operation in the Buffer Mode
The instructions may be buffered before execution as shown below.
Instruction
PR 600000
SP 10000
WT 10000
BGA
Interpretation
Distance
Speed
Wait 10000 milliseconds before reading the next instruction
Start the motion
DMC-3425
Chapter 2 Getting Started• 33
Example 9 - Motion Programs
Motion programs may be edited and stored in the memory. They may be executed at a later time.
The instruction
ED
Edit mode
moves the operation to the editor mode where the program may be written and edited. For example, in
response to the first ED command, the Galil Windows software will open a simple editor window.
From this window, the user can type in the following program:
#A
Define label
PR 700
SP 2000
BGA
EN
Distance
Speed
Start motion
End program
This program can be downloaded to the controller by selecting the File menu option download. Once
this is done, close the editor.
Now the program may be executed with the command
XQ #A
Start the program running
Example 10 - 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 motor V1 counts
Start motion
BGA
AMA
After motion is complete
Wait 500 ms
WT 500
TPA
Tell position
V1=V1+1000
JP #Loop,V1<10001
EN
Increase the value of V1
Repeat if V1<10001
End
After the above program is entered, download the program from the File menu and exit the Editor. To
start the motion, command:
XQ #A
Execute Program #A
Example 11- Motion Programs with Trippoints
The motion programs may include trippoints as shown below.
Instruction
#B
Interpretation
Label
DP0
Define initial position
Set target
PR 30000
34 • Chapter 2 Getting Started
DMC-3425
SP 5000
BGA
Set speed
Start motion
AD 4000
TPA
Wait until A moved 4000
Tell position
EN
End program
To start the program, command:
XQ #B
Execute Program #B
Example 12 - 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
AMA
Wait until move is complete
Wait 500 ms
WT 500
#B
V1 = _TP
PR –V1/2
BGA
Determine distance to zero
Command move 1/2 the distance
Start motion
AMA
After motion
WT 500
V1=
Wait 500 ms
Report the value of V1
Exit if position=0
Repeat otherwise
End
JP #C, V1=0
JP #B
#C;EN
To start the program, command
XQ #A
Execute Program #A
This program moves the motor to an initial position of 4000 and returns it to zero on increments of half
the distance. Note, _TP is an internal variable that returns the value of the position. Internal variables
may be created by preceding a DMC-3425 instruction with an underscore, _.
Example 13 - Control Variables and Offset
Objective: Illustrate the use of variables in iterative loops and use of multiple instructions on one line.
Instruction
#A
Interpretation
Set initial values
KI0
DP0
V1=8; V2=0
#B
Initializing variables to be used by program
Program label #B
OF V1
WT 200
Set offset value
Wait 200 msec
DMC-3425
Chapter 2 Getting Started• 35
V2=_TP
Set variable V2 to the current position
Exit if error small
JP#C,@ABS[V2]<2
MG V2
Report value of V2
Decrease Offset
V1=V1-1
JP #B
Return to top of program
End
#C;EN
This program starts with a large offset and gradually decreases its value, resulting in decreasing error.
36 • Chapter 2 Getting Started
DMC-3425
Chapter 3 Connecting Hardware
Overview
The DMC-3425 provides digital inputs for A and B forward limit, A and B reverse limit, A and B
home input and abort input. The controller also has 3 uncommitted, TTL inputs, 3 TTL outputs
and 2 analog inputs (12-bit).
The DMC-3415 provides a forward and reverse limit, home input and abort input. The controller also
has 7 uncommitted, TTL inputs, 3 TTL outputs and 2 analog inputs (12-bit).
This chapter describes the inputs and outputs and their proper connection.
Using 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. To
set the activation state of the limit switches refer to the command CN, configure, in the Command
Reference.
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 that the user can include in any motion control program and is useful for executing
specific instructions upon activation of a limit switch.
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, return the state of the forward and reverse limit switches, respectively
(x represents the axis, A or B). The value of the operand is either a ‘0’ or ‘1’ corresponding to the
logic state of the limit switch, active or inactive, respectively. If the limit switches are configured for
active low, no connection or a 5V input will be read as a ‘0’, while grounding the switch will return a
‘1’. If the limit switches are configured for active high, the reading will be inverted and no connection
or a 5V input will be read as a ‘1’, while grounding the switch will return a ‘0’.
Using a terminal program, the state of a limit switch can be printed to the screen with the command,
MG _LFx or MG _LRx. This prints the value of the limit switch operands for the 'x' axis. The logic
DMC-3425
Chapter 3 Connecting Hardware• 37
state of the limit switches can also be interrogated with the TS command. For more details on TS,
_LFx, _LRx, or MG see the Command Reference.
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 changes between logic states 0 and
1, corresponding to either 0V or 5V depending on the configuration set by the user (CN command).
The CN command can be used to customize the homing routine to the user’s application.
There are three homing routines supported by the DMC-3425: Find Edge (FE), Find Index (FI), and
Standard Home (HM).
The Find Edge routine is initiated by the command sequence: FEx <return>, BGx <return> (where x
could be any axis on the controller, A through H). 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. Refer to the CN
command to set the correspondence between the Home Input voltage and motion direction. The motor
will decelerate to a stop when a transition is seen on the input. 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: FIx <return>, BGx <return> (where x
could be any axis on the controller, A through H). Find Index will cause the motor to accelerate to
the user-defined slew speed (SP) 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 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 HMx <return>, BGx <return>
(where x could be any axis on the controller, A through H). 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 (dependent on the CN command). 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.
38 • Chapter 3 Connecting Hardware
DMC-3425
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
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.
Uncommitted Digital Inputs
The general use inputs are TTL and are accessible through the ICM-1460 or AMP-1460 as IN1 – IN3
for the DMC-3425 and IN1 – IN7 for the DMC-3415. The inputs can be accessed directly from the 37
Pin-D cable or connector on the controller, also. For a description of the pinouts, consult the appendix.
These inputs can be interrogated with the use of the command TI (Tell Inputs), the operand _TI, the
function @IN[n] and the distributed I/O command TZ. All of these commands may be used locally to
address individual controllers, or globally through the distributed control network. See Chapter 4 for a
discussion of Global vs. Local communication as it pertains to I/O of the control system.
NOTE: For systems using the ICM-1460 or AMP-1460 interconnect module, there is an option to
provide opto-isolation on the inputs. In this case, the user provides an isolated power supply (+5V to
+24V and ground). For more information, see the section “Opto-Isolation Option for ICM-1460” in
the Appendix of this manual, or consult Galil.
Amplifier Interface
The DMC-3425 analog command voltage, ACMD, ranges between +/-10V. This signal, along with
GND, provides the input to the power amplifiers. The power amplifiers must be sized to drive the
motors and load. For best performance, the amplifiers should be configured for a 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. If the controller is operating in stepper mode, the pulse and direction
signals will be input into a stepper drive.
The DMC-3425 also provides an amplifier enable signal, AEN. This signal is activated under the
following conditions: the watchdog timer activates, the motor-off command, MO, is given, or the
OE1command (Enable Off-On-Error) is given and the position error exceeds the error limit. As
shown in Figure 3.1, AEN can be used to disable the amplifier for these conditions.
Note: For a controller ordered as a DMC-3425-Stepper, the amplifier enable signal is used for the
second stepper output.
The standard configuration of the AEN signal is TTL active high. In this configuration the AEN 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-1460 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 AEN signal, note the state of the jumper on the ICM/AMP-1460.
When JP1 has a jumper from “AEN” to “5V” (default setting), the output voltage is 0-5V. To change
to 12 volts, pull the jumper out and rotate it so that it connects the pins marked “AEN” and “+12V”. If
the jumper is removed entirely, the output is an open collector, allowing the user to connect an external
supply with voltages up to 24V.
To connect an external 24V supply, remove the jumper JP1 from the interconnect board. Connect a
2.2kΩ resistor in series between the +24V of the supply and the amplifier enable terminal on the
interconnect (AMPEN). Then wire the AMPEN to the enable pin on the amplifier. Connect the -24V
DMC-3425
Chapter 3 Connecting Hardware• 39
to the ground, GND, of the interconnect and connect the GND of the interconnect to the GND of the
amplifier.
DMC-3425
ICM-1460
Connection to +5V or +12V made through
jumper location JP1. Removing the jumper
allows the user to connect their own supply to
the desired voltage level (Up to24V).
+12V
+5V
SERVO
MOTOR
AMPEN
AMPLIFIER
GND
37 - 40
Pin Cable
ACMD
7407 Open Collector
Buffer. The Enable signal
can be inverted by using
a 7406.
Analog Switch
Figure 3.1 - Connecting AEN to the motor amplifier
TTL Inputs
As previously mentioned, the DMC-3425 has 3 uncommitted TTL level inputs while the DMC-3415
has 7 uncommitted TTL level inputs. The command @IN, TI and TZ will read the state of the inputs.
For more information on these commands refer to the Command Reference.
The reset input is also a TTL level, non-isolated signal and is used to locally reset the DMC-3425
without resetting the PC.
Analog Inputs
The DMC-3425 has 2 analog inputs configured for the range between –10V and +10V. The inputs are
decoded by a 12-bit ADC giving a voltage resolution of approximately .005V. The impedance of these
inputs is 10Kohms. The analog inputs may be read using the @AN[n] function, where n is the number
of the analog input to be read.
40 • Chapter 3 Connecting Hardware
DMC-3425
TTL Outputs
The DMC-3425 provides three general use outputs, an output compare and 4 status LED’s.
The general use outputs are TTL and are accessible through the ICM-1460 as OUT1 thru OUT3.
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 Reference.
The value of the outputs can be checked with the operand _OP, the function @OUT[] and the
distributed control command TZ. Chapter 4 contains more information with regards to I/O in the
distributed control network.
The output compare signal is TTL and is available on the ICM-1460 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.
Note: For a controller ordered as a DMC-3425-Stepper, the Error output is taken for the second
stepper motor output.
There are four status LEDs on the controller, which indicate operating and error conditions on the
controller. Below is a list of those LEDs and their functions.
Green Power LED - The green status LED indicates that the +5V power has been applied properly to
the controller.
Red Status/Error LED - The red error LED will flash on initially at power up, and stay lit for
approximately 1 – 8 seconds. After this initial power up condition, the LED will illuminate
for the following reasons:
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.
Green Link LED – The second green LED is lit when there is an Ethernet connection to the
controller. This LED tests only for the physical connection, not for an active or enabled link.
Yellow Activity LED – The yellow LED indicates traffic across the Ethernet connection. This LED
will show both transmit and receive activity across the connection. If there is no Ethernet
connection or IP address assigned, the LED will flash at regular intervals to show that the
BOOTP packets are being broadcast.
Note: For systems using the ICM-1460 or AMP-1460 interconnect module, there is an option to
provide opto-isolation for the outputs. In this case, the user provides an isolated power supply
(+5V to +24V and ground). For more information, see the section “Opto-Isolation Option for
ICM-1460” in the Appendix of this manual, or contact Galil.
DMC-3425
Chapter 3 Connecting Hardware• 41
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42 • Chapter 3 Connecting Hardware
DMC-3425
Chapter 4 Communication
Introduction
The DMC-3425 has one RS232 port and one Ethernet port. The RS-232 port is the data set. The
Ethernet port is a 10Base-T link. The RS-232 is a standard serial link with communication baud rates
up to 19.2kbaud.
For initial setup, Galil recommends starting with the RS-232 interface. The RS-232 provides a
simplified interface that minimizes the potential problems for first time setup. Once the configuration
parameters have been properly set and saved on the controller, the Ethernet communication should be
established.
RS232 Port
The DMC-3425 has a single RS232 connection for sending and receiving commands from a PC or
other terminal. The pin-outs for the RS232 connection are as follows.
RS232 - Port 1 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
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 selecting the proper jumper configuration on the
DMC-3425 according to the table below.
Baud Rate Selection
JUMPER SETTINGS
BAUD RATE
96
OFF
ON
12
--
OFF
OFF
19200
9600
DMC-3425
Chapter 4 Communication• 43
OFF
ON
1200
Handshaking Modes
The RS232 port is configured for hardware handshaking. In this mode, the RTS and CTS lines are
used. The CTS line will go high whenever the DMC-3425 is not ready to receive additional
characters. The RTS line will inhibit the DMC-3425 from sending additional characters. Note: The
RTS line goes high for inhibit. This handshake procedure ensures proper communication especially at
higher baud rates.
Ethernet Configuration
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-3425 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 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.
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.
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-3425 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-3425 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. Next, select the DMC-
3425 controller communicating via Ethernet from the software registry. Once the controller has been
selected, the next screen shows options for the actual connection. 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. A full description of addressing the card may be found in Chapter 2
Getting Started.
44 • Chapter 4 Communication
DMC-3425
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.
The second method for setting an IP address is to send the IA command through the DMC-3425 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.
Ethernet Handles
An Ethernet handle is a communication resource within a device. The DMC-3425 can have a
maximum of 8 Ethernet handles open at any time. When using TCP/IP, each connection to a device,
such as the host computer, requires an individual Ethernet handle. In UDP/IP, one handle may be used
for all the masters, but each slave uses one. (Pings and ARP's do not occupy handles.) If all 8 handles
are in use and a 9th master tries to connect, it will be sent a "reset packet" that generates the appropriate
error in its windows application.
The TH command may be used to indicate which handles are currently connected to and which are
currently free.
Global vs. Local Operation
Each DMC-3425 controls two axes of motion, referred to as A and B. The host computer can
communicate directly with any DMC-3425 using an Ethernet or RS-232 connection. When the host
computer is directly communicating with any DMC-3425, all commands refer to the first two axes as
A and B. Direct communication with the DMC-3425 is known as LOCAL OPERATION.
The concept of Local and Global Operation also applies to application programming. See Chapter 7:
Global vs. Local Programming.
DMC-3425
Chapter 4 Communication• 45
LOCAL OPERATION
Host Computer
RS-232
or
Ethernet
DMC-3425
A and B
Axes
DMC-3425
A and B
Axes
DMC-3425
A and B
Axes
DMC-3425
A and B
Axes
The DMC-3425 supports Galil’s Distributed Control System. This allows up to 4 DMC-3425s to be
connected together as a single virtual 8-axis controller. In this system, one of the controllers is
designated as the master. The master can receive commands from the host computer that apply to all
of the axes in the system.
A simple way to view Local and Global Operation: When the host communicates with a slave
controller, it considers the slave as a 2-axis controller. When the host communicates with a master, it
considers the master as a multi-axis controller. Similarly, an application program residing in a slave
controller deals only with 2 motors as A & B. An application program in a master deals with all
motors referenced as A through H.
GLOBAL OPERATION
Host Computer
RS-232
or
Ethernet
DMC-3425
A and B
Axes
Ethernet
DMC-3425
C and D
Axes
DMC-3425
E and F
Axes
DMC-3425
G and H
Axes
The controllers may operate under both Local and/or Global Mode. In general, operating in Global
Mode simplifies controlling the entire system. However, Local Mode operation is necessary in some
46 • Chapter 4 Communication
DMC-3425
situations; using Local Mode for setup and testing is useful since this isolates the controller. Specific
modes of motion require operation in Local Mode. Also, each controller can have a program,
including the slave controllers. When a slave controller has a program, this program would always
operate in Local Mode.
Operation of Distributed Control
For most commands it is not necessary to be conscious of whether an axis is local or remote. For
instance to set the KP value for the A and C axes, the command to the master would be
KP 10,,20
Similarly, the interrogation commands can also be issued. For example, the position error for all axes
would be TE. The position operand for the F axis would be_TPF.
Some commands inherently are sent to all controllers. These include commands such as AB (abort),
CN and TM. In addition, the * may be used to send commands to all controllers. For example
SP*=1000
will send a speed of 1000 cts/sec to all axes. This syntax may be used with any configuration or
parameter commands.
Certain commands need to be launched specifically. For this purpose there is the SA command. In its
simplest form the SA command is
SAh= "command string"
Here "command string" will be sent to handle h. For example, the SA command is the means for
sending an XQ command to a slave/server. A more flexible form of the command is
SAh= field1,field2,field3,field4 ... field8
where each field can be a string in quotes or a variable.
For example, to send the command KI,,5,10; Assume var1=5 and var2=10 and send the command:
SAF= "KI",var1,var2
When the Master/client sends an SA command to a Slave/server, it is possible for the master to
determine the status of the command. The response _IHh4 will return the number 1 to 4. One means
waiting for the acknowledgement from the slave. Two means a colon (command accepted) has been
received. Three means a question mark (command rejected) has been received. Four means the
command timed out.
If a command generates responses (such as the TE command), the values will be stored in _SAh0 thru
_SAh7. If a field is unused its _SA value will be -2^31.
Accessing the I/O of the Slaves
The I/O of the server/slaves is settable and readable from the master. The bit numbers are adjusted by
the handle number of the slave controller. Each handle adds 100 to the bit number. Handle A is 100
and handle H is 800. In a TCP/IP control setup with two handles per slave, Galil recommends using
the value of the first handle for simplicity. In a UDP system, the single handle per slave is used to
address the I/O.
The command TZ can be used to display all of the digital I/O contained in a distributed control system.
Any IOC-7007’s configured using the HC command will also be displayed with the TZ command. See
the Command Reference for more information on the TZ command.
DMC-3425
Chapter 4 Communication• 47
Digital Outputs
For outputs, the SB and CB commands are used to command individual output ports, while the OP
command is used for setting bytes of data. The SB and CB commands may be set globally through the
master, while the OP command must be sent to the slave using the SA command.
Outputs may be set globally according to the following numbering scheme: Bitnum = (Slave Handle *
100) + Output Bit. For example:
Set Bit 2 on a UDP distributed slave using the E handle for communication. The E handle would have
a numerical value of 500, plus the bit number of 2. The command would therefore become SB502.
Specific outputs in a distributed system may be read by using the @OUT[n] function, where n is the
corresponding bit number as defined above.
Output bits on an IOC-7007 may also be set through the master controller in a distributed network.
Please refer to the IOC-7007 Manual for information on setting and reading these I/O points.
Digital Inputs
Digital inputs may be addressed individually using the @IN[n] function, or in blocks using the TI
command. Both of these commands may be sent globally to the controller. The ‘n’ in the @IN[n]
function operates identically to the SB/CB syntax. This means that a specific input bit is referenced as
the slave handle number * 100 plus the input bit. For example:
Read input bit 4 on a TCP/IP distributed slave using the C handle for communication. The C handle in
this case would give a value of 300. Therefore, to read bit 4, the command would be MG@IN[304].
The MG in this case simply displays this data to the terminal.
The TI command may be used to read all inputs on a slave in blocks of 8. This is helpful if the slave
controller in question has a DB-14064 expanded I/O daughter card. The TI command uses the slave
handle number * 100 plus the block number to be read. The block number is only used if the
controller has the DB-14064 expansion option.
Inputs on an IOC-7007 may also be read through the master controller in a distributed network. Please
refer to the IOC-7007 Manual for information on setting and reading these points.
Analog Inputs
Each DMC-3425 controller has two 12-bit analog inputs. These inputs are read with the command
@AN[n], where n is the input to be read. The master controller has n = 1 and 2, the first slave
controller uses n = 3 and 4, etc.
Handling Communication Errors
A new automatic subroutine which is identified by the label #TCPERR, has been added. If a controller
has an application program running and the TCP or UDP communication is lost, the #TCPERR routine
will automatically execute. The #TCPERR routine should be ended with a RE command. In the UDP
configuration, the QW commands must be active in order for the #TCPERR routine on the master to
operate properly.
Multicasting
A multicast may only be used in UDP 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.
48 • Chapter 4 Communication
DMC-3425
The Galil Registry has an option to disable the opening of the multicast handle on the DMC-3425. By
default this multicast handle will be opened.
Unsolicited Message Handling
Anytime a controller generates an internal response from a program, generates an internal error or
sends a message from a program using the MG command, this is termed an unsolicited message.
There are two software commands that will configure how the controller handles these messages; the
CW and the CF command.
The DMC-3425 has 8 Ethernet handles as well as 1 serial port where unsolicited messages may be
sent. The CF command is used to configure the controller to send these messages to specific ports. In
addition, the Galil Registry has various options for sending this CF command. For more information,
see the CF command in the DMC-3425 Command Reference. The MG can also send the message to a
specific handle using the MG{Eh} syntax, where h is the handle. See the MG command in the
Command Reference for more information.
The CW command has two data fields that affect unsolicited messages. The first field configures the
most significant bit (MSB) of the message. A value of 1 will set the MSB of unsolicited messages,
while a value of 2 suppresses the MSB. The majority of software programs use a setting of CW2,
although the Galil Smart Terminal and WSDK will set this to CW1 for internal usage. If you have
difficulty receiving characters from the controller, or receive garbage characters instead of messages,
check the status of the CW command for a setting of CW2.
IOC-7007 Support
The IOC-7007 is an Intelligent Ethernet I/O controller that can be programmed in standard Galil
language. This module allows various configurations of TTL inputs, opto-isolated inputs, high power
outputs and relay switches to be used in the Galil distributed motion system. Each IOC-7007 may be
populated by up to seven IOM I/O modules.
The IOC-7007 Ethernet I/O controller may be used in a distributed system and commanded by the
master controller. The HC command is used to specify total number of IOC-7007 controllers within
that distributed system. Once configured, the I/O of that IOC-7007 becomes incorporated in the
distributed system, much the same as board level I/O of the DMC-3425 slaves.
Inputs of the IOC-7007 are read using the standard @IN[n] and TI commands as follows:
@IN[n] where n is the IOC-7007 input bit to be read. n is calculated with the equation n =
(HandleNum * 1000) + BitNum. HandleNum is the numeric value of the IOC-7007 handle (1 – 8)
while BitNum is the specific bit number on the IOC to be read.
TIn where n is the IOC-7007 input slot to be read. n is calculated with the equation n =
(HandleNum * 1000) + SlotNum. Again, HandleNum is the numeric value of the IOC-7007 handle (1
– 8). SlotNum corresponds to the location of the IOM input module in the 7 slots of the IOC-7007 (0 –
6). This will return either an 8 bit or 16 bit decimal value depending on which IOM input module is
being used.
Outputs of the IOC-7007 are set and cleared using the standard SB and CB commands, as well as with
the OQ and OB commands. Outputs can be read with the @OUT[n] command. These commands
operate as follows:
SBn or CBn where n is the IOC-7007 output to be set or cleared. n is calculated identically to
the @IN[n] configuration, with n = (HandleNum * 1000) + BitNum.
@OUT[n] where n is the IOC-7007 output to be read. This uses the same n configuration as
SB and CB.
OQn,m where n is the IOC-7007 output location and m is the data to be written. Specifically,
n = (HandleNum * 1000) + SlotNum where HandleNum is the numeric value of the IOC-7007 handle
DMC-3425
Chapter 4 Communication• 49
(1 – 8) and SlotNum is the slot number of the IOM output module to be written to (0 – 6). m is the
decimal representation of the data written to the 4 (0 – 15) or 8 (0 – 255) output points of the IOM
module.
Please refer to the IOC-7007 manual for complete information on how to configure, read and write
information to the IOC-7007 Ethernet I/O module.
Modbus Support
The Modbus protocol supports communication between 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.
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, and should
be set to 502, which is the Modbus defined port number. 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<502>2 - This will open handle #2 and connect to the IP address 151.25.255.9, port
502, 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-3425 can use a specific slave address or default to the
handle number.
The Modbus protocol has a set of commands called function codes. The DMC-3425 supports the 10
major function codes:
Function Code
01
Definition
Read Coil Status (Read Bits)
02
03
04
05
06
07
15
16
17
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
50 • Chapter 4 Communication
DMC-3425
The DMC-3425 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
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 8 (H). 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.
Other Communication Options
User Defined Ethernet Variables
It may be necessary within a distributed system to share information that is not contained as position,
torque, velocity or other control data. The DMC-3425 provides 2 user defined variables that are
passed as part of the QW record shared among the distributed system. In this way, it is not necessary
for a single controller to write variable data directly to all the other controllers in the system.
ZA and ZB are two user defined variables which are passed with the QW record at each update. Data
that is written to these variables is then seen by the master DMC-3425 in the system.
Handle Switching
By default, when initiating a communication session with a DMC-3425 controller, the first available
handle is used. If no handles have been assigned to the controller, the A handle is chosen. The
command HS allows the user to switch this connection to another handle, freeing up the initial handle
or trading with another currently used handle. Or, once handles have been defined, the HS command
may be used to switch handles to prioritize slave locations and I/O locations.
Handle Restore on Communication Failure
There are instances within an Ethernet system, whether UDP or TCP/IP, when a handle may become
disconnected without closing properly. An example of this would be a simple cable failure, where the
Ethernet cable of a certain slave becomes detached.
The command HR is used to enable a mode in which the master controller, upon seeing a failure on a
handle, will attempt to restore that handle. This is helpful when a distributed system is already fully
configured and a slave is lost. The #TCPERR routine can be used to flag the error, while the handle
restore will attempt to reconnect to the slave until the problem is fixed. This makes it unnecessary to
re-run the setup for the entire distributed system.
DMC-3425
Chapter 4 Communication• 51
Note: This function is only available if the system has been configured using the automatic handle
configuration command, HC.
Waiting on Handle Responses
The operation of the distributed network has commands being sent to the master controller, which then
distributes these commands to the slave axes in the system. For example, the command
PR10,10,10,10,10,10,10,10 sent to the master becomes packets of PR10,10 sent by the master to each
of the slaves in the system. When the slave receives this command from the master, a colon or
question mark is generated and sent back to the master to acknowledge the command.
The HW command allows the user to select whether or not the master will wait on this colon response
from the slave. If the HW is set to 0, the master will not wait for these responses. This results in faster
command execution but could cause problems if any slave errors are generated. The setting HW1, on
the other hand, insures that the master knows of any slave errors but does result in a slightly increased
command execution time as it waits for these responses.
Data Record
The DMC-3425 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 ABCDEFGHS
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.
NOTE: A, B, C, & D can be interchanged with X, Y, Z, & W respectively.
Data Record Map
DATA TYPE
ITEM
1st byte of header
2nd byte of header
3rd 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
UB
UB
UB
UB
UW
UB
UB
UB
UB
UB
UB
UB
UB
UB
UB
UB
UB
4rth byte of header
sample number
general input bank 0 (Inputs 1-7)
general input bank 1 (Always 0)
general input bank 2 (DB-14064)
general input bank 3 (DB-14064)
general input bank 4 (DB-14064)
general input bank 5 (DB-14064)
general input bank 6 (DB-14064)
general input bank 7 (DB-14064)
general input bank 8 (DB-14064)
general input bank 9 (DB-14064)
general output bank 0 (Outputs 1 – 3)
general output bank 1 (Always 0)
52 • Chapter 4 Communication
DMC-3425
UB
UB
UB
UB
UB
UB
UB
UB
UB
UB
UW
UW
SL
general output bank 2 (DB-14064)
general output bank 3 (DB-14064)
general output bank 4 (DB-14064)
general output bank 5 (DB-14064)
general output bank 6 (DB-14064)
general output bank 7 (DB-14064)
general output bank 8 (DB-14064)
general output bank 9 (DB-14064)
error code
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
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
general status
segment count of coordinated move for S plane
coordinated move status for S plane
distance traveled in coordinated move for S plane
0
UW
UW
SL
0
0
UW
UB
UB
SL
A axis status
A axis switches
A axis stopcode
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
Analog Input 1
B axis status
B axis switches
B axis stopcode
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
Analog Input 2
C axis status
C axis switches
C axis stopcode
C axis reference position
C axis motor position
C axis position error
C axis auxiliary position
C axis velocity
SL
SL
SL
SL
SW
C axis torque
DMC-3425
Chapter 4 Communication• 53
SW
UW
UB
UB
SL
C axis analog input
D axis status
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
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
D axis switches
D axis stopcode
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 input
E axis status
E axis switches
E axis stopcode
E axis reference position
E axis motor position
E axis position error
E axis auxiliary position
E axis velocity
SL
SL
SL
SL
SW
SW
UW
UB
UB
SL
E axis torque
E axis analog input
F axis status
F axis switches
F axis stopcode
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 input
G axis status
G axis switches
G axis stopcode
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 input
H axis status
H axis switches
H axis stopcode
H axis reference position
54 • Chapter 4 Communication
DMC-3425
SL
SL
SL
SL
SW
SW
H axis motor position
H axis position error
H axis auxiliary position
H axis velocity
H block
H block
H block
H block
H block
H block
H axis torque
H axis analog input
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
in Data
Record
T Block
Present
in Data
Record
S Block
Present
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 that 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
DMC-3425
Chapter 4 Communication• 55
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
Switch
Motion is
making
final
Negative Mode of Motion
Latch is
armed
Off-On-
Error
occurred
Motor
Off
Direction Motion
is
Move
slewing
Contour
decel.
Coordinated Motion Status Information for 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
1
2
3
Number of axes present
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
56 • Chapter 4 Communication
DMC-3425
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-3425 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. In the absence of the Galil Windows Terminal software, the Telnet terminal may be used for
communication with the DMC-3425 Ethernet controller. The Windows Hyperterminal may also be
used for communication.
DMC-3425
Chapter 4 Communication• 57
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58 • Chapter 4 Communication
DMC-3425
Chapter 5 Command Basics
Introduction
The DMC-3425 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-3425 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-3425, or an
entire group of commands can be downloaded into the DMC-3425 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-3425 instruction set and syntax. A summary of commands as well as
a complete listing of all DMC-3425 instructions is included in the Command Reference chapter.
Command Syntax - ASCII
DMC-3425 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-3425 command interpreter.
NOTE: If you are using a Galil terminal program, commands will not be processed until a <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-3425 commands are sent in upper case.
For example, the command
PR 4000 <return>
Position relative
DMC-3425
Chapter 5 Command Basics• 59
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.
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-3425 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 N 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.
BG ABCDEFGH
Begin all axes
BG D
Begin D only
Coordinated Motion with more than 1 axis
When requesting action for coordinated motion, the letter S is used to specify a coordinated motion
plane. For example:
BG S
Begin coordinated sequence, S
BG SW
Begin coordinated sequence, S, and W axis
Command Syntax - Binary
60 • Chapter 5 Command Basics
DMC-3425
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 are 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
Bit 1 = B axis or 2nd data field
Bit 0 = A axis or 1st data field
DMC-3425
Chapter 5 Command Basics• 61
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 A (bit 0), B (bit 1) and C (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
No.
d6
d7
d8
d9
da
db
dc
dd
de
df
Reserved
KP
KI
reserved
reserved
RP
ad
ae
KD
DV
AF
KF
PL
TP
af
TE
b0
b1
b2
a3
b4
b5
b6
b7
b8
b9
ba
bb
bc
bd
TD
LI
TV
VP
RL
ER
IL
CR
TT
TN
TS
TL
LE, VE
VT
TI
e0
e1
e2
e3
e4
e5
e6
e7
e8
MT
CE
OE
FL
SC
VA
reserved
reserved
reserved
TM
VD
VS
BL
AC
DC
SP
VR
90
91
92
reserved
reserved
CM
CN
LZ
OP
62 • Chapter 5 Command Basics
DMC-3425
IT
93
94
95
96
97
98
99
9a
9b
9c
9d
9e
9f
CD
be
bf
OB
e9
ea
eb
ec
ed
ee
ef
f0
f1
f2
f3
f4
f5
f6
f7
f8
f9
fa
fb
fc
fd
fe
ff
FA
DT
SB
FV
ET
c0
c1
c2
c3
c4
c5
c6
c7
c8
c9
ca
cb
cc
cd
ce
cf
CB
GR
EM
EP
I I
DP
EI
DE
EG
AL
OF
EB
reserved
reserved
reserved
reserved
reserved
reserved
reserved
reserved
reserved
reserved
reserved
reserved
reserved
reserved
reserved
reserved
reserved
GM
EQ
Reserved
Reserved
Reserved
Reserved
Reserved
BG
EC
reserved
AM
MC
TW
MF
MR
AD
AP
a0
a1
a2
a3
a4
a5
a6
a7
a8
a9
aa
ST
AB
HM
FE
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-3425 returns a : for valid commands and a ? for invalid commands.
For example, if the command BG is sent in lower case, the DMC-3425 will return a ?.
:bg <return>
invalid command, lower case
?
DMC-3425 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>
Tell Code command
1 Unrecognized
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.
DMC-3425
Chapter 5 Command Basics• 63
Interrogating the Controller
Interrogation Commands
The DMC-3425 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
RL
∧R ∧V
SC
TB
TC
TD
TE
TI
Report Command Position
Report Latch
Firmware Revision Information
Stop Code
Tell Status
Tell Error Code
Tell Dual Encoder
Tell Error
Tell Input
TP
Tell Position
TR
TS
Trace
Tell Switches
Tell Torque
TT
TV
Tell Velocity
For example, the following example illustrates how to display the current position of the A 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 ?,?,?,?
Request A,B,C,D values
PR ,?
Request B value only
The controller can also be interrogated with operands.
Operands
Most DMC-3425 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
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
64 • Chapter 5 Command Basics
DMC-3425
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.
DMC-3425
Chapter 5 Command Basics• 65
THIS PAGE LEFT BLANK INTENTIONALLY
66 • Chapter 5 Command Basics
DMC-3425
Chapter 6 Programming Motion
Overview
The DMC-3425 provides many 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.
Global vs. Local Operation
Each DMC-3425 controls two axes of motion, referred to as A and B. The host computer can
communicate directly with any DMC-3425 using an Ethernet or RS-232 connection. When the host
computer is directly communicating with any DMC-3425, all commands refer to the first two axes as
A and B. Direct communication with the DMC-3425 is known as LOCAL OPERATION.
LOCAL OPERATION
Host Computer
RS-232
or
Ethernet
DMC-3425
A and B
Axes
DMC-3425
A and B
Axes
DMC-3425
A and B
Axes
DMC-3425
A and B
Axes
The DMC-3425 supports Galil’s Distributed Control System. This allows up to eight axes of DMC-
3425 and DMC-3415 controllers to be connected together as a single virtual axis controller. In this
system, one of the controllers is designated as the master. The master can receive commands from the
host computer that apply to all of the axes in the system.
DMC-3425
Chapter 6 Programming Motion• 67
GLOBAL OPERATION
Host Computer
RS-232
or
Ethernet
DMC-3425
A and B
Axes
Ethernet
DMC-3425
C and D
Axes
DMC-3425
E and F
Axes
DMC-3425
G and H
Axes
The controllers may operate under both Local and/or Global mode. In general, operating in Global
mode simplifies controlling the entire system. However, Local Mode operation is necessary in some
situations; Using local mode for setup and testing is useful since this isolates the controller. Specific
modes of motion require operation in Local Mode. Also, each controller can have a program,
including the slave controllers. When a slave controller has a program, this program would always
operate in Local mode.
The following table describes the modes of motion and whether this mode will work in Global or
Local Mode:
Mode of Motion
Basic description
Commands
Global
LOCAL
Relative Independent
Axis Positioning
Each axis operates independently and motion is
specified with a relative distance, velocity,
acceleration and deceleration. The axis follows the
prescribed velocity profile.
PR, AC, DC, SP YES
YES
Absolute Independent
Axis Positioning
Each axis operates independently and motion is
specified with an absolute position, velocity,
acceleration and deceleration. The axis follows the
prescribed velocity profile.
PA, AC, DC, SP YES
YES
YES
Independent Jogging
Linear Interpolation
Each axis operates independently and the axis
follows a prescribed velocity profile with no final
endpoint. The motion is specified with velocity,
acceleration and deceleration. Motion stops on Stop
command.
JG
YES
NO
AC, DC
ST
2 thru 8 axes of coordinated motion. The path is
described by linear incremental segments and vector
velocity, vector acceleration and vector
deceleration. The vector motion follows the
prescribed velocity profile.
LM
YES
LI, LE
VS, VA, VD
68 • Chapter 6 Programming Motion
DMC-3425
Vector Motion
2-D motion path consisting of arc segments and
linear segments, such as engraving or quilting.
Vector velocity, vector acceleration and vector
deceleration are specified. The vector motion
follows the prescribed velocity profile.
VM
NO
YES
VP, CR
VS, VA, VD
Electronic Gearing
Contour Mode
Motion in which one axis must follow another axis
such as conveyer speed. Once setup, the slave axis
will follow the master position.
GA
GR
NO
NO
YES
YES
1 – 8 axes of motion along arbitrary profiles or
mathematically prescribed profiles such as sine or
cosine trajectories. The path is described by linear
incremental segments and the time between
segments
CM
CD
DT
Electronic Cam
Following a trajectory based on a master encoder
position.
EA
EM
EP
NO
YES
ET
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),
acceleration ramp (AC), and deceleration ramp (DC), for each axis. On begin (BG), the DMC-3425
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-3425 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.
DMC-3425
Chapter 6 Programming Motion• 69
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
ST ABCD
IP a,b,c,d
DESCRIPTION
Specifies relative distance
Specifies absolute position
Specifies slew speed
Specifies acceleration rate
Specifies deceleration rate
Starts motion
Stops motion before end of move
Changes position target
IT a,b,c,d
Time constant for independent motion smoothing
Trippoint for profiler complete
Trippoint for "in position"
AM ABCD
MC ABCD
The lower case specifiers (a,b,c,d) represent position values for each axis.
The DMC-3425 also allows use of single axis specifiers such as PRA=2000
Operand Summary - Independent Axis
OPERAND
DESCRIPTION
_ACn
Return acceleration rate for the axis specified by ‘n
Return deceleration rate for the axis specified by ‘n’
Returns the speed for the axis specified by ‘n’
_DCn
_SPn
_PAn
Returns current destination if ‘n’ axis is moving, otherwise returns the current commanded
position if not in a move.
_PRn
Returns current incremental distance specified for the ‘n’ axis
Examples
Absolute Position Movement
Instruction
Interpretation
PA 10000,20000
Specify absolute A,B position
Acceleration for A,B
Deceleration for A,B
Speeds for A,B
AC 1000000,1000000
DC 1000000,1000000
SP 50000,30000
BG AB
Begin motion
Multiple Move Sequence
Required Motion Profiles:
A-Axis
1000 counts
Position
15000 count/sec
Speed
2
Acceleration/Deceleration
500000 counts/sec
500 counts
B-Axis
Position
70 • Chapter 6 Programming Motion
DMC-3425
10000 count/sec
Speed
2
Acceleration/Deceleration
500000 counts/sec
100 counts
C-Axis
Position
5000 counts/sec
500000 counts/sec
Speed
Acceleration/Deceleration
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 1000,500,100
Specify relative position movement of 1000, 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
VELOCITY
(COUNTS/SEC)
A axis velocity profile
B axis velocity profile
20000
15000
10000
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.
DMC-3425
Chapter 6 Programming Motion• 71
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 a 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-
3425 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
AC a,b,c,d
BG ABCD
DC a,b,c,d
IP a,b,c,d
DESCRIPTION
Specifies acceleration rate
Begins motion
Specifies deceleration rate
Increments position instantly
Time constant for independent motion smoothing
Specifies jog speed and direction
Stops motion
IT a,b,c,d
JG +/- a,b,c,d
ST ABCD
Parameters can be set with individual axes specifiers such as JGB=2000 (set jog speed for B axis to
2000) or ACBH=400000 (set acceleration for B and H axes to 400000).
Operand Summary - Independent Axis
OPERAND
DESCRIPTION
_ACn
Return acceleration rate for the axis specified by ‘n’
Return deceleration rate for the axis specified by ‘n’
Returns the jog speed for the axis specified by ‘n’
Returns the actual velocity of the axis specified by ‘n’ (averaged over .25 sec)
_DCn
_SPn
_TVn
Examples
Jog in A and C axes
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.
72 • Chapter 6 Programming Motion
DMC-3425
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
V1 =@AN[1]
VEL=V1*50000/10
JG VEL
JP #B
Linear Interpolation Mode (Local Mode)
The DMC-3425 provides a linear interpolation mode for 2 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. Since the
DMC3425 is a 2-axis controller, the LM command would specify LM AB.
When using the linear interpolation mode, the LM command only needs to be specified once unless the
axes for linear interpolation change.
Specifying Linear Segments
The command LI x,y or LI a,b 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.
DMC-3425
Chapter 6 Programming Motion• 73
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-3425 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.
Additional Commands
The commands VS n, VA n, and VD n are used to specify the vector speed, acceleration and
deceleration. The vector speed is computed using the equation:
2
2
2
VS =AS +BS , where AS, and BS are the speed of the A, and B 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’ trippoint, 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 x,y < 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
74 • Chapter 6 Programming Motion
DMC-3425
LE
End linear segments
Begin motion sequence
Program end
BGS
EN
Changing Feedrate:
The command VR n allows the feedrate, VS, to be scaled between 0 and 10 with a resolution of .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 feedrate override. VR does not
ratio the accelerations. For example, VR .5 results in the specification VS 2000 to be divided in half.
Command Summary - Linear Interpolation
COMMAND
DESCRIPTION
LM nn
Specify axes for linear interpolation
LM ?
Returns number of available spaces for linear segments in DMC-3425 sequence buffer.
Zero means buffer full. 512 means buffer empty.
LI x,y < n
LI a,b < n
Specify incremental distances relative to current position, and assign vector speed n.
VS n
VA n
VD n
VR n
BGS
CS
Specify vector speed
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)
Trippoint for After Sequence complete
Trippoint 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-3425 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)
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 Y=2000. The value of
_AV at this point is 7000, _CS equals 1, _VPA=5000 and _VPB=0.
DMC-3425
Chapter 6 Programming Motion• 75
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 trippoint, which slows the speed to 1000 count/s. Once the motors
reach the corner, the speed is increased back to 4000 cts / s.
Instruction
#LMOVE
DP 0,0
Interpretation
Label
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
LMAB
LI 5000,0
LI 0,5000
LE
VS 4000
BGS
Specify vector speed
Begin motion sequence
AV 4000
VS 1000
AV 5000
VS 4000
EN
Set trippoint to wait until vector distance of 4000 is reached
Change vector speed
Set trippoint to wait until vector distance of 5000 is reached
Change vector speed
Program end
Example - Linear Move
Make a coordinated linear move in the AB plane. Move to coordinates 40000,30000 counts at a vector
2
speed of 100000 counts/sec and vector acceleration of 1000000 counts/sec .
Instruction
LM AB
Interpretation
Specify axes for linear interpolation
Specify AB distances
Specify end move
LI40000,30000
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 VA and VB
the axis speeds are determined by the DMC-3425 from:
2
VA2 VB
=
+
VS
The resulting profile is shown in Figure 6.2.
76 • Chapter 6 Programming Motion
DMC-3425
30000
27000
POSITION B
3000
0
0
4000
36000
40000
POSITION A
FEEDRATE
0
0.1
0.5
0.6
TIME (sec)
VELOCITY
A-AXIS
TIME (sec)
VELOCITY
B-AXIS
TIME (sec)
Figure 6.2 - Linear Interpolation
Example - 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
Interpretation
Load Program
Define Array
#LOAD
DM VA [750],VB [750]
DMC-3425
Chapter 6 Programming Motion• 77
COUNT=0
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
COUNT=COUNT+1
JP #LOOP,COUNT<750
#A
Loop if array not full
Label
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 (Local Mode)
The DMC-3425 allows a long 2-D path consisting of linear and arc segments to be prescribed. Motion
along the path is continuous at the chosen vector speed even at transitions between linear and circular
segments. The DMC-3425 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. Note that only one pair of
axes can be specified for coordinated motion at any given time.
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 a,b specifies the coordinates of the end points of the vector movement with respect
to the starting point. The command, CR r,θ,δ define a circular arc with a radius r, starting angle of θ,
and a traversed angle δ. The notation for θ is that zero corresponds to the positive horizontal direction,
and for both θ and δ, the counter-clockwise (CCW) rotation is positive.
78 • Chapter 6 Programming Motion
DMC-3425
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 that 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 tells the controller to decelerate to a stop following the last motion in the sequence. If a VE
command is not given, an Abort (AB1) must be used to abort the coordinated motion sequence.
The user must keep enough motion segments in the DMC-3425 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 the PCI bus
speed.
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 motion smoothing constant used for 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 x,y < n >m
CR r,θ,δ < n >m
The first parameter, <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 parameter, > 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 Feedrate:
The command VR n allows the feedrate, VS, to be scaled from 0 and 10 times 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 feedrate override. VR does
not ratio the accelerations. For example, VR .5 results in the specification VS 2000 act as VS 1000.
DMC-3425
Chapter 6 Programming Motion• 79
Compensating for Differences in Encoder Resolution:
By default, the DMC-3425 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 that represent the ratio of the encoder resolutions. For more
information refer to ES in the Command Reference.
Trippoints:
The AV n command is the After Vector trippoint, which waits for the vector relative distance of n to
occur before executing the next command in a program.
Command Summary - Coordinated Motion Sequence
COMMAND
VM m,n
DESCRIPTION
Specifies the axes for the planar motion where m and n represent the planar axes.
Return coordinate of last point, where m=A,B,C or D.
VP m,n
CR r,θ,δ
Specifies arc segment where r is the radius, θ is the starting angle and δ is the travel
angle. Positive direction is CCW.
VS n
VA n
VD n
VR n
BGS
CS
Specify vector speed or feedrate of sequence.
Specify vector acceleration along the sequence.
Specify vector deceleration along the sequence.
Specify vector speed ratio
Begin motion sequence
Clear sequence.
AV n
AMS
ES m,n
VT
Trippoint for After Relative Vector distance, n.
Holds execution of next command until Motion Sequence is complete.
Ellipse scale factor.
S curve smoothing constant for coordinated moves
LM?
Return number of available spaces for linear and circular segments in DMC-3425
sequence buffer. Zero means buffer is full. 512 means buffer is empty.
Operand Summary - Coordinated Motion Sequence
COMMAND
DESCRIPTION
_VPM
The absolute coordinate of the axes at the last intersection along the sequence.
Distance traveled.
_AV
_LM
Number of available spaces for linear and circular segments in DMC-3425 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.
80 • Chapter 6 Programming Motion
DMC-3425
Example:
Traverse the path shown in Fig. 6.3. Feedrate 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
C (-4000,3000)
D (0,3000)
R = 1500
B (-4000,0)
A (0,0)
Figure 6.3 - The Required Path
DMC-3425
Chapter 6 Programming Motion• 81
Electronic Gearing (Local Mode)
This mode allows one axis to be electronically geared to the other axis. The master 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 specifies the master axis. GR n,n 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 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 n,n selects 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, GACD indicates that
the gearing is the commanded position of D.
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, JG, VP, or LI commands.
Command Summary - Electronic Gearing
COMMAND
DESCRIPTION
GA n
Specifies master axes for gearing where:
n = A,B for main encoder as master
n = CA, CB for commanded position.
GR n,n
GM n,n
MF n,n
MR n,n
GA?
Sets gear ratio for slave axes. 0 disables electronic gearing for specified axis.
1 sets gantry mode, 0 disables gantry mode
Trippoint for forward motion past specified value. Only one field may be used.
Trippoint for reverse motion past specified value. Only one field may be used.
Retuns the GA command setting
Example – Electronic Gearing
Objective: Gear an A-axis slave motor at a speed of 2.5 times the speed of the B-axis master.
GAB
Specify B-axis as the master for A
GR2.5
Specify gear ratio for A to be 2.5 times the B axis master.
Example - Gantry Mode
In applications where both the master and the follower are controlled by the DMC-3425 controller, it
may be desired to synchronize the follower with the commanded position of the master, rather than the
actual position. This eliminates the possibility of an oscillation on the master passing the oscillation on
to the slave.
82 • Chapter 6 Programming Motion
DMC-3425
For example, assume that a gantry is driven by two axes, A and B, one on each side. 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:
GA, CA
Specify the commanded position of A as master for B.
Set gear ratio for B as 1:1
Set gantry mode
GR,1
GM,1
PR 3000
BG A
Command A motion
Start motion on A axis
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 the B axis.
Under these conditions, this IP command is equivalent to:
PR,10
Specify position relative movement of 10 on the B axis
BGB
Begin motion on the B axis
Often the correction is quite large. Such requirements are common when synchronizing cutting knives
or conveyor belts.
Example - 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 (Local Mode)
The electronic cam is a motion control mode that enables the periodic synchronization of several axes
of motion. Similar to the gearing mode, the DMC-3425 uses only A and B main axes as the master or
slave.
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.
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
p is the selected master axis
For the given example, since the master is a, we specify EAA
Step 2. Specify the master cycle and the change in the slave axis (es).
DMC-3425
Chapter 6 Programming Motion• 83
In the electronic cam mode, the position of the master is always expressed within one cycle. In this
example, the position of a 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
where a,b specify the cycle of the master and the total change of the slaves over one cycle.
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]=x,y
where n indicates the order of the point.
The value, n, starts at zero and may go up to 256. The parameters x,y indicate the corresponding slave
position. For this example, the table may be specified by
84 • Chapter 6 Programming Motion
DMC-3425
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
where a,b 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
where a,b are the master positions at which the corresponding slave axes are disengaged.
DMC-3425
Chapter 6 Programming Motion• 85
3000
2250
1500
0
2000
4000
6000
Master X
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.
To illustrate the complete process, consider the cam relationship described by
the equation:
Y = 0.5 X + 100 sin (0.18 X)
*
*
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 0.18X 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.
86 • Chapter 6 Programming Motion
DMC-3425
Instruction
#SETUP
EAA
Interpretation
Label
Select A as master
Cam cycles
EM 2000,1000
EP 20,0
Master position increments
Index
N = 0
#LOOP
Loop to construct table from equation
Note 3.6 = 0.18∗20
Define sine position
P = N∗3.6
S = @SIN [P] 100
*
Y = N 10+S
*
Define slave position
Define table
ET [N] =, B
N = N+1
JP #LOOP, N<=100
EN
Repeat the process
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
#RUN
EB1
Interpretation
Label
Enable cam
PA,500
SP,5000
BGB
B 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
The following example illustrates a cam program with a master axis, A, and a single slave B.
Instruction
#A;V1=0
Interpretation
Label; Initialize variable
PA 0,0;BGAB;AMAB
EA A
Go to position 0,0 on A and B axes
A axis as the Master for ECAM
Change for A is 4000, zero for B
ECAM interval is 400 counts with zero start
When master is at 0 position; 1st point.
2nd point in the ECAM table
EM 4000,0
EP400,0
ET[0]=,0
ET[1]=,20
DMC-3425
Chapter 6 Programming Motion• 87
ET[2]=,60
ET[3]=,120
ET[4]=,140
ET[5]=,140
ET[6]=,140
ET[7]=,120
ET[8]=,60
ET[9]=,20
ET[10]=,0
EB 1
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
JGA=4000
EG ,0
Set A to jog at 4000
Engage both A and B when Master = 0
Begin jog on A axis
BGA
#LOOP;JP#LOOP,V1=0
EQ,2000
MF2000
Loop until the variable is set
Disengage B when Master = 2000
Wait until the Master goes to 2000
Stop the A axis motion
ST A
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. The next page 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 master, and the
second graph shows the cycle on the B axis.
88 • Chapter 6 Programming Motion
DMC-3425
Contour Mode (Local Mode)
The DMC-3425 also provides a contouring mode. This mode allows any arbitrary position curve to be
prescribed for any motion 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, CMAB specifies contouring on
the A and B 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 over a
n
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. 6.5. The position A may be described by the
points:
DMC-3425
Chapter 6 Programming Motion• 89
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
Increment 1
Increment 2
Increment 3
DA=48
DA=240
DA=48
Time Increment =4
Time Increment =8
Time Increment =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
Description
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 6.5 - The Required Trajectory
90 • Chapter 6 Programming Motion
DMC-3425
Additional Commands
The command, WC, is used as a trippoint "When Complete" or “Wait for Contour Data”. This allows
the DMC-3425 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 ?.
Command Summary - Contour Mode
Command
Description
CM AB
Specifies which axes for contouring mode. Any non-contouring axes may be operated in
other modes.
CD a,b
DT n
Specifies position increment over time interval. Range is +/-32,000. Zero ends contour
mode.
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.
Operand Summary - Contour Mode
Operand
Description
_CS
Return segment number
General Velocity Profiles
The Contour Mode is ideal for generating an arbitrary velocity profile. 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.
Generating an Array - An Example
Consider the velocity and position profiles shown in Fig. 6.6. 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:
ω = (A/B) [1 - cos (2πΤ/B)]
X = (AT/B) - (A/2π)sin (2πΤ/B)
Note: ω is the angular velocity; X 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:
X = 50T - (6000/2π) sin (2π T/120)
Note that the velocity, ω, in count/ms, is
DMC-3425
Chapter 6 Programming Motion• 91
ω = 50 [1 - cos 2π T/120]
Figure 6.6 - Velocity Profile with Sinusoidal Acceleration
The DMC-3425 can compute trigonometric functions. However, the argument must be expressed in
degrees. Using our example, the equation for X is written as:
X = 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 DIF. Finally the motors are run
in the contour mode.
Contour Mode Example
Instruction
#POINTS
DM POS[16]
DM DIF[15]
C=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
92 • Chapter 6 Programming Motion
DMC-3425
C=0
#C
D=C+1
DIF[C]=POS[D]-POS[C]
Compute the difference and store
C=C+1
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-3425 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]
RA C[]
Dimension array
Specify array for automatic record
Specify data for capturing (such as _TPA or _TPB)
RD _TPA
RC n,m
Specify capture time interval where n is 2n msec, m is number of records to be
captured
RC? or _RC
Returns a 1 if recording
Record and Playback Example:
Instruction
#RECORD
DM APOS[501]
RA APOS[]
RD _TPA
Interpretation
Begin Program
Dimension array with 501 elements
Specify automatic record
Specify A position to be captured
Turn A motor off
MOA
RC2
Begin recording; 4 msec interval
Continue until done recording
Compute DX
#A;JP#A,_RC=1
#COMPUTE
DM DX[500]
C=0
Dimension Array for DX
Initialize counter
DMC-3425
Chapter 6 Programming Motion• 93
#L
Label
D=C+1
DELTA=XPOS[D]-XPOS[C] Compute the difference
DX[C]=DELTA
C=C+1
Store difference in array
Increment index
JP #L,C<500
#PLAYBCK
CMA
Repeat until done
Begin Playback
Specify contour mode
Specify time increment
Initialize array counter
Loop counter
DT2
I=0
#B
CD XPOS[I];WC
Specify contour data I=I+1 Increment array counter JP #B,I<500 Loop until
done
DT 0;CD0
EN
End contour mode
End program
For additional information about automatic array capture, see Chapter 7, Arrays.
Virtual Axis (Local Mode)
The DMC-3425 controller has an internal motion profiler, also referred to as a virtual axis. This axis is
designated as the N axis and has no encoder input and no DAC output. With the N axis, a commanded
position profile can be generated using the following modes of motion:
Mode of Motion
Virtual Axis usage
Commands
Relative Independent
Axis Positioning
N axis profile is specified with a relative distance, velocity,
acceleration and deceleration. The N axis profile follows the
prescribed velocity profile.
PRN=<value>
ACN=<value>
DCN=<value>
SPN=<value>
Absolute Independent
Axis Positioning
N axis profile is specified with an absolute distance, velocity, PAN=<value>
acceleration and deceleration. The N axis profile follows the
prescribed velocity profile.
ACN=<value>
DCN=<value>
SPN=<value>
Independent Jogging
Vector Motion
N axis profile is specified with a prescribed velocity with no
final endpoint. The motion is specified with velocity,
acceleration and deceleration. Motion stops on Stop
command.
JGN=<value>
ACN=<value>
DCN=<value>
STN=<value>
N axis profile replaces one of the 2 axes specified for 2-D
motion. Vector velocity, vector acceleration and vector
deceleration are specified. The vector motion follows the
prescribed velocity profile.
VMxN
VMNx
x represents the 2nd
axis used for
vector motion
Electronic Gearing
Electronic Cam
N axis can be used as a master axis for gearing
GAx=N
GA N,N
N axis can be used as a master axis for electronic CAM
EA N
EMN=<value>
94 • Chapter 6 Programming Motion
DMC-3425
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 A 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, or amplitude and F is the frequency in Hz.
Set VA and VD to maximum values for the fastest acceleration.
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.
NOTE: If two steppers are to be used with the DMC-3425, the controller must be ordered from the
factory as a DMC-3425-Stepper.
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.
DMC-3425
Chapter 6 Programming Motion• 95
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 trippoint 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:
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 that 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 2, which corresponds to a time constant of 6 sample
periods.
Fourth, the output of the stepper smoothing filter is buffered and is available for input to the stepper
motor driver. The pulses that 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.
96 • Chapter 6 Programming Motion
DMC-3425
Stepper Smoothing Filter
(Adds a Delay)
Output
(To Stepper Driver)
Motion Profiler
Output Buffer
Reference Position (RP)
Step Count Register (TD)
Motion Complete Trippoint
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 trippoint (Motion Complete) is generally more useful than AM
trippoint (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.
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
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
_ITa
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
_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
DMC-3425
Chapter 6 Programming Motion• 97
Dual Loop (Auxiliary Encoder)
The DMC-3415 provides an interface for a second encoder except when configured for stepper motor
operation or circular compare. Please note, the DMC-3425 has only a single encoder per axis. 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 CEa, where the
parameter a equals 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 when the DMC-3415 is configured for a stepper motor.
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, DEa can be used to define the position of the auxiliary encoder. For example,
DE 500
sets the initial value.
The position of the auxiliary encoder may be interrogated with the command, DE?.
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 encoder:
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.
98 • Chapter 6 Programming Motion
DMC-3425
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 that require position accuracy only at the endpoint.
Example
Continuous Dual Loop
Connect the load encoder to the main encoder port and connect the motor encoder to the dual encoder
port. The dual loop 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
DV1
activates the dual loop and
DV0
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 that 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
DE0
PR 40000
Main move
BGA
Start motion
#CORRECT
AMA
Correction loop
Wait for motion completion
Find linear encoder error
Compensate for motor error
Exit if error is small
v1=10000-_DEA
v2=-_TEA/4+v1
JP#END,@ABS[v2]<2
DMC-3425
Chapter 6 Programming Motion• 99
PR v2*4
BGA
Correction move
Start correction
Repeat
JP#CORRECT
#END
EN
Motion Smoothing
The DMC-3425 controller allows the smoothing of the velocity profile to reduce the mechanical
vibration of the system.
Trapezoidal velocity profiles have acceleration rates that 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
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 parameter a 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. 6.7 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
100 • Chapter 6 Programming Motion
DMC-3425
ACCELERATION
TIME
TIME
TIME
TIME
VELOCITY
ACCELERATION WITH
SMOOTHING
VELOCITY WITH
SMOOTHING
Figure 6.7 - Trapezoidal velocity and smooth velocity profiles
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. 6.7.
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
DMC-3425
Chapter 6 Programming Motion• 101
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-3425 defines the home position (0) as the position at which the index was
detected.
Example
Instruction
Interpretation
Label
#HOME
AC 1000000
DC 1000000
SP 5000
HM A
Acceleration Rate
Deceleration Rate
Speed for Home Search
Home A
BG A
Begin Motion
After Complete
Send Message
End
AM A
MG "AT HOME"
EN
#EDGE
Label
AC 2000000
DC 2000000
SP 8000
FE B
Acceleration rate
Deceleration rate
Speed
Find edge command
Begin motion
After complete
Send message
Define position as 0
End
BG B
AM B
MG "FOUND HOME"
DP,0
EN
102 • Chapter 6 Programming Motion
DMC-3425
_HMA=1
_HMA=0
POSITION
HOME SWITCH
VELOCITY
MOTION BEGINS
TOWARD HOME
DIRECTION
POSITION
POSITION
VELOCITY
MOTION REVERSE
TOWARD HOME
DIRECTION
VELOCITY
MOTION TOWARD
INDEX
DIRECTION
POSITION
INDEX PULSES
POSITION
Figure 6.8 - Motion intervals in the Home sequence
DMC-3425
Chapter 6 Programming Motion• 103
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
_HMn
Contains the value of the state of the Home Input
Contains stop code
_SCn
_TSn
Contains status of switches and inputs
High Speed Position Capture (Latch)
Often it is desirable to capture the position precisely for registration applications. The DMC-3425
provides a position latch feature. This feature allows the position of the encoders of A or B axis 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. The inputs on these controllers are TTL. Latch time
latency on a high or low going signal is less than 1μsec. Each axis has one general input associated to
the axis for position capture:
Input
IN1
Function
A Axis Latch
B Axis Latch
IN2
The DMC-3425 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 AB command to arm the latch.
2. Test to see if the latch has occurred (Input goes low) by testing the operand, _ALA or
_ALB. 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 command RL AB or RL
AB command or monitor the value of the operands _RLA and _RLB.
NOTE: The latch must be re-armed after each latching event.
104 • Chapter 6 Programming Motion
DMC-3425
Example
Instruction
Interpretation
#Latch
Latch program
JG,5000
BG B
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=
EN
Jump to #Wait label if latch has not occurred
Set ‘Result’ equal to the reported position of B axis
Print result
End
DMC-3425
Chapter 6 Programming Motion• 105
THIS PAGE LEFT BLANK INTENTIONALLY
106 • Chapter 6 Programming Motion
DMC-3425
Chapter 7 Application Programming
Overview
The DMC-3425 provides a powerful programming language that allows users to customize the
controller for their particular application. Programs can be downloaded into the DMC-3425 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-3425 provides commands that allow the DMC-
3425 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-3425 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 that the operator can change as necessary.
Global vs. Local Programming
As mentioned previously, multiple DMC-3425 controllers can be connected through an Ethernet hub.
The DMC-3425 controllers can be setup to operate in 2 modes; LOCAL OPERATION and
GLOBAL OPERATION.
In Local Operation, the host computer can download a program to any DMC-3425 and all program
commands refer to the two axes on the controller as A and B. Each controller operates independently.
This type of program is referred to as a LOCAL PROGRAM.
In Global Operation, up to eight axes of DMC-3425 and DMC-3415 controllers act as a “virtual multi-
axis controller”. One DMC-3425 is designated as the master controller and the other controllers are
designated as slave controllers. The host computer can download a program to the master DMC-3425.
The master controller program contains commands that address all axes in the system. This GLOBAL
PROGAM will operate as if it was a program on a traditional multi-axis controller. In addition, each
slave controller can also be programmed with a LOCAL PROGRAM that applies only to the 2 axes
of the controller.
The type of program, global program or local program, will affect the command syntax. In a global
program, all axes have a unique axis designator (A-H). In a local program, each program addresses
only the 2 axes of the controller. These two axes are always referred to as A and B.
The following sections in this chapter discuss each aspect of creating an applications program. Where
applicable, subjects are identified as applicable only to LOCAL PROGRAMS with the word LOCAL
next to each header.
DMC-3425
Chapter 7 Application Programming• 107
The program memory size for each DMC-3425 is 80 characters per line and 500 lines long.
Entering Programs
The DMC-3425 has an internal editor that may be used to create and edit programs in the controller's
memory. The internal editor is a rudimentary editor and is only recommended when operating with
Galil’s DOS utilities or through a simple RS-232 communication interface such as the Windows Utility
Hyperterminal.
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.
Instruction
:ED
Interpretation
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-3425 will return a colon.
108 • Chapter 7 Application Programming
DMC-3425
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
Interpretation
:LS
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
Program Format
A DMC program consists of 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-3425 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-3425 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 that may be defined is 254.
Valid labels
#BEGIN
#SQUARE
#X1
#BEGIN1
Invalid labels
#1Square
#123
Example
Instruction
Interpretation
#START
Beginning of the Program
Specify relative distances on A and B axes
Begin Motion
PR 10000,20000
BG AB
DMC-3425
Chapter 7 Application Programming• 109
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-3425 has some special labels, which are used to define input interrupt subroutines, limit
switch subroutines, error handling subroutines, command error subroutines and auto start and recovery
routines.
#AUTO
Label for automatic execution of program upon power up. This program
must be saved in the non-volatile memory with the BP command.
#AUTOERR
Label for detecting errors in the #AUTO routine. If a Checksum error
were to occur, the #AUTO would fail to start at power up. This
#AUTOERR routine would be called instead.
#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
Ethernet communication error
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 and the Apostrophe (‘)
Programs on the DMC-3425 can be commented using the command, NO, or the apostrophe. These
commands allow the user to include up to 78 characters on a single line. This can be used to include
comments from the programmer as in the following example:
Instruction
Interpretation
#PATH
Label
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
Comment - No Operation
Circle Motion
Comment - No Operation
110 • Chapter 7 Application Programming
DMC-3425
VP 0,3000
Vector Position
‘ TOP LINE
Comment - No Operation
Circle
CR 1500,90,-180
‘ HALF CIRCLE MOTION
Comment - No Operation
Vector End
VE
‘ END VECTOR SEQUENCE
Comment - No Operation
Begin Sequence
BGS
‘ BEGIN SEQUENCE MOTION
EN
Comment - No Operation
End of Program
‘ END OF PROGRAM
Comment - No Operation
NOTE: NO and the apostrophe are controller commands. Therefore, inclusion of these commands
will require a small process time by the controller.
REM Command
If you are using Galil software to communicate with the DMC-3425 controller, you may also include
REM statements. ‘REM’ statements begin with the word ‘REM’ and may be followed by any
comments that 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-3425 can run 2 independent programs simultaneously. These programs are called threads
and are numbered 0 and 1, where 0 is the main thread. Multitasking is useful for executing independent
operations such as PLC functions that occur independently of motion.
DMC-3425
Chapter 7 Application Programming• 111
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.
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
CB1
Wait 40 msec from reference, then initialize reference
Clear Output 1
JP #LOOP1
#TASK0
XQ #TASK1,1
#LOOP2
PR 1000
BGA
Repeat Loop1
Task2 label
Execute Task1
Loop2 label
Define relative distance
Begin motion
AMA
After motion done
Wait 10 msec
WT 10
JP #LOOP2,@IN[2]=1
HX
Repeat motion unless Input 2 is low
Halt all tasks
EN
End of Program
The program above is executed with the instruction XQ #TASK0,0 which designates TASK0 as the
main thread (i.e. Thread 0). #TASK1 is executed within TASK0.
Debugging Programs
The DMC-3425 provides commands and operands that 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 that can help to debug a program. Breakpoint and single stepping
commands are available to actively debug a program while in operation.
112 • Chapter 7 Application Programming
DMC-3425
Trace Command
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.
Error Code Command
When there is a program error, the DMC-3425 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 that 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.
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:
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 AMA;PR5000;BGA
<cntrl> Q
Add After Motion Done
Quit Edit Mode
Execute #A
:XQ #A
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-3425
has several useful commands. The command, DM ?, will return the number of array elements
DMC-3425
Chapter 7 Application Programming• 113
currently available. The command, DA?, will return the number of arrays which can be currently
defined. The DMC-3425 will have a maximum of 2000 array elements in up to 14 arrays. If an array
of 100 elements is defined, the command DM? will return the value 1900 and the command DA? will
return 13.
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
An operand is a value in the controller. Below is a list of specific operands that are particularly
valuable for program debugging. To display 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
_LFx contains the state of the forward limit switch for the 'x' axis
_LRx contains the state of the reverse limit switch for the 'x' axis
Breakpoints and single stepping
The DMC-3425 has commands which allow active debugging of programs. The BK command is a
breakpoint which may be set to trigger upon execution of a specified line and thread. Upon the
program executing the specified line, the program or thread will pause at that line. The SL command
may then be used to single step through the program from that breakpoint. See the command reference
for more information on the BK and SL command.
EEPROM Memory Interrogation Operands
When the DMC-3425 powers up, any data stored in the EEPROM memory is automatically loaded for
use. This data includes the user program, variables and arrays, and controller parameters. If the
EEPROM has been corrupted, the corresponding memory sector is flagged as in error. The operand
_RS contains the state of the EEPROM as follows:
Bit
Error Condition
Bit 3
Bit 2
Bit 1
Bit 0
Master reset error
Program checksum error
Parameter checksum error
Variable checksum error
114 • Chapter 7 Application Programming
DMC-3425
Program Flow Commands
The DMC-3425 provides instructions to control program flow. The DMC-3425 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-3425 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-3425 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-3425 can make decisions based on its own status or external events without
intervention from a host computer.
NOTE: Event triggers should only be used within a program and not sent to the controller as a direct
command.
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Chapter 7 Application Programming• 115
DMC-3425 Event Triggers
Command
Function
AM A B C D E F G 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 trippoint will clear and the stopcode
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.
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.
Example- Multiple Move Sequence
The AM trippoint 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.
116 • Chapter 7 Application Programming
DMC-3425
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
trippoint 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 trippoint 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.
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.
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Chapter 7 Application Programming• 117
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 feedrate 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
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
Wait a distance of 10,000 counts
New Speed
AMA
Wait until motion is completed
Wait 200 ms
WT 200
118 • Chapter 7 Application Programming
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PR -10000
SP 30000
AC 150000
BGA
New Position
New Speed
New Acceleration
Start Motion
End
EN
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
CB1
Loop
After 10 msec from reference,
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-3425 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-3425 to make decisions without a host
computer. For example, the DMC-3425 can decide between two motion profiles based on the state of
an input line.
Command Format - JP and JS
Format:
Description
JS destination, logical condition
JP destination, logical condition
Jump to subroutine if logical condition is satisfied
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.
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Chapter 7 Application Programming• 119
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-3425 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-3425 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-3425 executes operations from left to right. For further information on
Mathematical Expressions and the bit-wise operators ‘&’ and ‘|’, see pg. 127.
Example using variables named V1, V2, V3 and V4:
JP #TEST, (V1<V2) & (V3<V4)
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.
120 • Chapter 7 Application Programming
DMC-3425
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-3425 provides a structured approach to conditional statements using IF, ELSE and ENDIF
commands.
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).
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Chapter 7 Application Programming• 121
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 re-direction 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-3425 allows for IF conditional statements to be included within other IF conditional
statements. This technique is known as 'nesting' and the DMC-3425 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 <condition>
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 (@IN[1]=0)
IF conditional statement based on input 1
2nd IF executed if 1st IF conditional true
Message executed if 2nd IF is true
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
IF (@IN[2]=0)
MG "INPUT 1 AND INPUT 2 ARE ACTIVE"
ELSE
MG "ONLY INPUT 1 IS ACTIVE
ENDIF
ELSE
MG"ONLY INPUT 2 IS ACTIVE"
ENDIF
#WAIT
122 • Chapter 7 Application Programming
DMC-3425
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 500 counts per side is given below. The square is drawn
at vector position 1000,1000.
Instruction
Interpretation
#M
Begin Main Program
Clear Output Bit 1 (pick up pen)
Define vector position; move pen
Wait for after motion trippoint
Set Output Bit 1 (put down pen)
Jump to square subroutine
End Main Program
CB1
VP 1000,1000;LE;BGS
AMS
SB1
JS #Square;CB1
EN
#Square
Square subroutine
V1=500;JS #L
V1=-V1;JS #L
EN
Define length of side
Switch direction
End subroutine
#L;PR V1,V1;BGA
AMA;BGB;AMA
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.
Auto-Start and Auto Error Routine
The DMC-3425 has two special labels for automatic program execution. A program which has been
saved into the controllers non-volatile memory can be automatically executed upon power up or reset
by beginning the program with the label #AUTO. The program must be saved into non-volatile
memory using the command, BP.
If the program loaded onto the EEPROM has a checksum error at power-up, the routine #AUTOERR
will run instead, allowing the user to determine the nature of the checksum error. The _RS operand
may be used to determine what sector of the EEPROM has been corrupted.
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Chapter 7 Application Programming• 123
Automatic Subroutines for Monitoring Conditions
Often it is desirable to monitor certain conditions continuously without tying up the host or DMC-3425
program sequences. The DMC-3425 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, and having an application program actively executing on the controller. 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
#TCPERR
Position error exceeds limit specified by ER
Motion Complete timeout occurred. Timeout period set by TW command
Bad command given
Ethernet Communication Error
The following examples illustrate the use of the automatic subroutines:
Example - Limit Switch:
This simple program prints a message upon the occurrence of a limit switch. For the #LIMSWI sub-
routine to execute, the DMC-3425 must be executing an applications program from memory and the
controller must be commanding the motor to move. The RE command is used to return from the
#LIMSWI subroutine. The #LIMSWI subroutine will be re-executed if the limit switch remains active.
Instruction
#LOOP
Interpretation
Dummy Program
Jump to Loop
JP #LOOP;EN
#LIMSWI
Limit Switch Label
Print Message
MG "LIMIT OCCURRED"
RE
Return to main program
Example - Position Error
Instruction
:ED
Interpretation
Edit Mode
000 #LOOP
001 JP #LOOP;EN
002 #POSERR
003 V1=_TEA
Dummy Program
Loop
Position Error Routine
Read Position Error
Print Message
004 MG "EXCESS POSITION ERROR"
005 MG "ERROR=",V1=
006 RE
Print Error
Return from Error
Quit Edit Mode
Execute Dummy Program
Jog at High Speed
Begin Motion
<control> Q
:XQ #LOOP
:JG 100000
:BGA
124 • Chapter 7 Application Programming
DMC-3425
Example - Input Interrupt
This simple program jogs the A and C motors (C motor is the first motor of the first slave controller of
a distributed control system). When the first input of the master (input 1), goes low, the controller will
stop motion on both axes. When the input returns high, the motors will resume jogging.
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;AMAD
#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
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.
Instruction
#BEGIN
TW 1000
PA 10000
BGA
Interpretation
Begin main program
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
Example - Command Error
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.
Instruction
Interpretation
Begin main program
Prompt for speed
Begin motion
#BEGIN
IN "ENTER SPEED", SPEED
JG SPEED;BGA;
JP #BEGIN
Repeat
DMC-3425
Chapter 7 Application Programming• 125
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
#DONE
Return to main program
End program if other error
Zero stack
ZS0
EN
End program
OPERAND
_ED1
FUNCTION
Returns the number of the thread that generated an error
_ED2
Retry failed command (operand contains the location of the failed command)
_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
Where the “,1” at the end of the command line indicates a restart; therefore, the existing program stack
will not e removed when the above format executes.
The following example shows an error correction routine that uses the operands.
Example - Command Error w/Multitasking
The following program illustrates a common program problem. In this case, a variable is used as a
command argument and the variable is inadvertently set to an illegal value. This simple command
error subroutine recognizes the type of error, modifies the variable and continues the program at the
point of the error. If the program has an invalid command error, skip the command and continue to
execute the program. To demonstrate the program, while the simple loop #A is executing on thread 0
(XQ#A,0), begin execution of the second task, XQ#B,1
Instruction
#A
Interpretation
Begin thread 0 (continuous loop)
JP#A
EN
End of thread 0
#B
Begin thread 1
KP -1
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 “Number Out of Range” (-1).
Set N to a valid number
Retry KP N command
XQ _ED2,_ED1,1
ENDIF
IF( _TC=1)
If error is “Invalid Command” (TY)
126 • Chapter 7 Application Programming
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XQ _ED3,_ED1,1
Skip invalid command
ENDIF
EN
End of command error routine
Example – Ethernet Communication Error
This simple program executes in the DMC-3425 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
Mathematical and Functional Expressions
Mathematical Operators
For manipulation of data, the DMC-3425 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
DMC-3425
Chapter 7 Application Programming• 127
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-3425
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 that 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
Interpretation
#TEST
Begin main program
IN "ENTER",LEN{S6}
Input character string of up to 6 characters into
variable ‘LEN’
FLEN=@FRAC[LEN]
FLEN=$10000*FLEN
LEN1=(FLEN&$00FF)
Define variable ‘FLEN’ as fractional part of
variable ‘LEN’
Shift FLEN by 32 bits (IE - convert fraction,
FLEN, to integer)
Mask top byte of FLEN and set this value to
variable ‘LEN1’
LEN2=(FLEN&$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
128 • Chapter 7 Application Programming
DMC-3425
Functions
FUNCTION DESCRIPTION
@SIN[n]
Sine of n (n in degrees, with range of -32768 to 32767 and 16-bit fractional resolution)
@COS[n]
@TAN[n]
@ASIN*[n]
@ACOS* [n}
@ATAN* [n]
@COM[n]
@ABS[n]
@FRAC[n]
@INT[n]
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
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-3425 provides 126 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 RPMB70
DMC-3425
Chapter 7 Application Programming• 129
Programmable Variables
The DMC-3425 allows the user to create up to 126 variables. Each variable is defined by a name that
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 names should not be the same as
DMC-3425 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-3425 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
that must be in quotation.
Instruction
POSX=_TPA
SPEED=5.75
INPUT=@IN[2]
V2=V1+V3*V4
VAR="CAT"
Interpretation
Assigns returned value from TPA command to variable POSX.
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 VS*2000
Assign VS*2000 to SP command
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.
130 • Chapter 7 Application Programming
DMC-3425
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
VX=@AN[1]*20000
VY=@AN[2]*20000
JG VA,VB
JP#LOOP
Read joystick A
Read joystick B
Jog at variable VA,VB
Repeat
EN
End
Operands
Operands allow motion or status parameters of the DMC-3425 to be incorporated into programmable
variables and expressions. Most DMC-3425 commands have an equivalent operand - which are
designated by adding an underscore (_) prior to the DMC-3425 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-3425 registers. The axis designation is required following the
command.
Instruction
Interpretation
POSA=_TPA
Assigns value from Tell Position A to the variable POSA.
Assigns value from KPA multiplied by two to variable, VAR1.
Jump to #LOOP if the position error of A is greater than 5
Jump to #ERROR if the error code equals 1.
VAR1=_KPA*2
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
The DMC-3425 provides a few additional operands that give access to internal variables that are not
accessible by standard DMC-3425 commands.
Operand
_BGn
_BN
Function
*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
*Returns the number of available labels for programming
*Returns the available array memory
_DL
_DM
DMC-3425
Chapter 7 Application Programming• 131
_HMn
_LFn
_LRn
_UL
*Returns status of Home Switch (equals 0 or 1)
Returns status of Forward Limit switch input of axis ‘n’ (equals 0 or 1)
Returns status of Reverse Limit switch input of axis ‘n’ (equals 0 or 1)
*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 operands.
* These operands have corresponding commands while the operands _LF, _LR and TIME do not have
any associated commands. All operands are listed in the Command Reference Manual.
Examples
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-3425 provides array space for 2000 elements.
The arrays are one-dimensional and up to 14 different arrays may be defined. The array data is
available to both threads on each controller. When operating with multiple controllers, arrays are only
defined within the same controller.
31
Each array element has a 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.
132 • Chapter 7 Application Programming
DMC-3425
DM SPEED[10]
Dimension Speed Array
SPEED[1]=7650.2
SPEED[1]=
Assigns the first element of the array the value 7650.2
Returns array element value
POSX[10]=_TPA
CON[2]=@COS[POS]*2
TIMER[1]=TIME
Assigns the 11th element the position of A.
Assigns the 3rd element of the array the cosine of POS * 2.
Assigns the 2nd 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.
This 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. This
example can also be executed with the automatic data capture feature described below.
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
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-3425 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.
DMC-3425
Chapter 7 Application Programming• 133
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
RC n,m
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.
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
Switches (only bit 0-4 valid)
Stop code
Status bits
Torque (reports digital value +/-8097)
NOTE: B, C, D, E, F, G, or H may replace A 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
PR 10000,20000
Define A,B position arrays
Define A,B error arrays
Select arrays for capture
Select data types
Specify move distance
134 • Chapter 7 Application Programming
DMC-3425
RC1
Start recording now, at rate of 2 msec
Begin motion
Loop until done
Print message
End program
BG AB
#A;JP #A,RC=1
MG "DONE"
EN
#PLAY
Play back
N=0
Initial Counter
Exit if done
JP# DONE,N>300
N=
Print Counter
A POS[N]=
B POS[N]=
AERR[N]=
BERR[N]=
N=N+1
Print A position
Print B position
Print A error
Print B 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.
Outputting Numbers and Strings
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).
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 from which the data was requested. However, the
port can be specified with the specifier, {P1} for the main serial port or {Ea} for the Ethernet handle.
‘a’ will be the handle letter, A through H.
MG {P1} "Hello World"
Sends message to Serial
DMC-3425
Chapter 7 Application Programming• 135
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.
{$n.m} formats data in HEX instead of decimal. The actual numerical value will be formatted with n
characters to the left of the decimal and m characters to the right of the decimal. Leading zeros will be
used to display specified format.
For example::
MG "The Final Value is", RESULT {F5.2}
If the value of the variable RESULT is equal to 4.1, this statement returns the following:
The Final Value is 00004.10
If the value of the variable RESULT is equal to 999999.999, the above message statement returns the
following:
The Final Value is 99999.99
The message command normally sends a carriage return and line feed following the statement. The
carriage return and the line feed may be suppressed by sending {N} at the end of the statement. This is
useful when a text string needs to surround a numeric value.
Example:
#A
JG 50000;BGA;ASA
MG "The Speed is", _TVA {F5.1} {N}
MG "counts/sec"
EN
When #A is executed, the above example will appear on the screen as:
The speed is 50000 counts/sec
Using the MG Command to Configure Terminals
The MG command can be used to configure a terminal. Any ASCII character can be sent by using the
format {^n} where n is any integer between 1 and 255.
Example:
MG {^07} {^255}
sends the ASCII characters represented by 7 and 255 to the bus.
136 • Chapter 7 Application Programming
DMC-3425
Summary of Message Functions
Function
" "
Description
Surrounds text string
{Fn.m}
Formats numeric values in decimal n digits to the right of the
decimal point and m digits to the left
{P1}or {Ea}
{$n.m}
{^n}
Send message to Main Serial Port or Ethernet Port
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
BGA
AMA
After Motion
V1=_TPA
POSA[1]=_TPA
V1=
Assign Variable V1
Assign the first entry
Print V1
Interrogation Commands
The DMC-3425 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.
Using the PF Command to Format Response from Interrogation Commands
The command, PF, can change format of the values returned by these 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.
DMC-3425
Chapter 7 Application Programming• 137
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
$0015
:PF2
Hexadecimal value
Format 2 places
:TPA
Tell Position
99
Returns 99 if position greater than 99
Removing Leading Zeros from Response to Interrogation Commands
The leading zeros on data returned as a response to interrogation commands can be removed by the use
of the command, LZ.
LZ0
Disables the LZ function
TP
Tell Position Interrogation Command
Response (With Leading Zeros)
-0000000009, 0000000005
LZ1
Enables the LZ function
TP
Tell Position Interrogation Command
Response (Without Leading Zeros)
-9, 5
Local Formatting of Response of Interrogation Commands
The response of interrogation commands may be formatted locally. To format locally, use the
command, {Fn.m} or {$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
138 • Chapter 7 Application Programming
DMC-3425
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
V1=10
V1=
Interpretation
Assign V1
Return V1
:0000000010.0000
VF2.2
Response - Default format
Change format
Return V1
V1=
:10.00
Response - New format
Specify hex format
Return V1
VF-2.2
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.
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.
DMC-3425
Chapter 7 Application Programming• 139
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-3425 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-3425 has 3 uncommitted 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).
Example- Set Bit and Clear Bit
Instruction
Interpretation
SB3
Sets bit 3 of output port
Clears bit 2 of output port
CB2
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 3, COUNT [1]
Set Output 3 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
1
instruction allows a single command to define the state of the output port, where 2 is output 1, 2 is
output 2 and so on. A 1 designates that the output is on.
140 • Chapter 7 Application Programming
DMC-3425
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
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.
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-3425. 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
DMC-3425
Chapter 7 Application Programming• 141
Input Interrupt Function
The DMC-3425 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). The RI command (not EN) is used to return from
the #ININT subroutine
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
after the execution of the #ININT subroutine, the Zero Stack (ZS) command is used followed by
unconditional jump statements.
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-3425 provides two analog inputs. The value of these inputs in volts may be read using the
@AN[n] function where n is the analog input 1 or 2. The resolution of the standard Analog-to-Digital
conversion is 12 bits. Analog inputs are useful for reading special sensors such as temperature, tension
or pressure.
The following examples show programs that 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.
142 • Chapter 7 Application Programming
DMC-3425
Instruction
#Points
Interpretation
Label
SP 7000
Speed
AC 80000;DC 80000
#Loop
Acceleration
VP=@AN[1]*1000
PA VP
Read and analog input, compute position
Command position
Start motion
After completion
Repeat
BGA
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
BGA
#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-3425 Controller
The DMC-3425 controller offers an option for 64 additional I/O, called the daughter board DB-14064.
This I/O is known as extended I/O and can be configured as inputs or outputs in 8 bit increments
through software. The I/O points are accessed through 2 50-pin high-density connectors.
Configuring the I/O of the DMC-3425
The extended I/O can be configured as outputs in blocks of 8. The I/O is configured as all Inputs by
default. 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.
NOTE: The CO command must be sent to slave controllers using the SA command.
DMC-3425
Chapter 7 Application Programming• 143
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.
8-Bit I/O
Block
Block
Binary Representation
Decimal Value for
Block
17-24
25-32
20
2
3
1
2
1
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 given for I/O
points that are configured as inputs will be ignored. The following table describes the arguments used
to set the state of outputs.
144 • Chapter 7 Application Programming
DMC-3425
Argument
Blocks
0
Bits
Description
General Outputs
Extended I/O
Extended I/O
Extended I/O
Extended I/O
m
a
1-8
2,3
17-32
33-48
49-64
65-80
b
c
4,5
6,7
d
8,9
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-3425 2 50 Pin IDC connectors which are compatible with I/O mounting racks such as
Grayhill 70GRCM32-HL and OPTO-22 G4PB24. The 50 pin ribbon cables can 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 that 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.
DMC-3425
Chapter 7 Application Programming• 145
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.
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 (X-Y) 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
feedrate 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.
146 • Chapter 7 Application Programming
DMC-3425
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:
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
Feedrate
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
DMC-3425
Chapter 7 Application Programming• 147
BGS
AMS
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
148 • Chapter 7 Application Programming
DMC-3425
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
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 1028 counts, the required motor
position must be 5120 counts. The variable V3 changes the position ratio.
Instruction
#A
Interpretation
Label
V3=5
Initial position ratio
Define the starting position
Set motor in jog mode as zero
Start
DP0
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
DMC-3425
Chapter 7 Application Programming• 149
THIS PAGE LEFT BLANK INTENTIONALLY
150 • Chapter 7 Application Programming
DMC-3425
Chapter 8 Hardware & Software
Protection
Introduction
The DMC-3425 provides several hardware and software features to check for error conditions and to
inhibit the motor on error. These features help protect the 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-3425 is an
integral part of the machine, the engineer should design his overall system with protection against a
possible component failure on the DMC-3425. Galil shall not be liable or responsible for any
incidental or consequential damages.
Hardware Protection
The DMC-3425 includes hardware input and output protection lines for 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 an off-on-error condition is
enabled (OE1) and the abort command is given. Each axis amplifier has a separate enable line. This
signal also goes low when the watch-dog timer is activated. 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-1460 interface board. To make these changes, see section entitled ‘Amplifier Interface’.
Note: There is only one amplifier enable signal for the DMC-3425. Therefore, both amplifiers will be
controlled by the same enable output.
Error Output - The error output is a TTL signal that indicates an error condition in the controller.
This signal is available on the interconnect module as ERROR. When the error signal is low, this
indicates one 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.
3. There is a failure on the controller and the processor is resetting itself.
DMC-3425
Chapter 8 Hardware & Software Protection• 151
4. There is a failure with the output IC that drives the error signal.
Input Protection Lines
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.
Forward Limit Switch - Low input inhibits motion in forward direction. (The CN command can be
used to change the polarity of the limit switches.) 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).
Reverse Limit Switch - Low input inhibits motion in reverse direction. (The CN command can be
used to change the polarity of the limit switches.) 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).
Software Protection
The DMC-3425 provides a programmable error limit. The error limit refers to a difference in the
actual and commanded position of the motor. This limit can be set for any number between 1 and
32767 using the ER n command. The default value for ER is 16384.
Example:
ER 200,300
Set A-axis error limit for 200, B-axis error limit to 300
Set B-axis error limit to 1 count.
ER,1
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-3425 will generate signals to warn the host system of the error condition. These signals
include:
Signal or Function
State if Error Occurs
# POSERR
Jumps to automatic excess position error subroutine (if included in
program)
Error Light
Turns on
OE Function
AEN Output Line
Shuts motor off if OE1
Goes low
The Jump if Condition statement is useful for branching within the program due to an error. The
position error of A and B can be monitored during execution using the TE command.
Programmable Position Limits
The DMC-3425 provides programmable forward and reverse position limits. These are set by the BL
(Backwards Limit) and FL (Forward Limit) software commands. Once a position limit is specified, the
DMC-3425 will not accept position commands beyond the limit. Motion beyond the limit is also
prevented.
152 • Chapter 8 Hardware & Software Protection
DMC-3425
Example:
DP0,0,
Define Position
Set Reverse position limit
Set Forward position limit
Jog
BL -2000,-4000
FL 2000,4000
JG 2000,2000
BG AB
Begin
Execution of the above example will cause the motor to slew at the given jog speed until the forward
position limit is reached. Motion will stop once the limit is hit.
Off-On-Error
The DMC-3425 controller has a built in function that 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 and B axes. To disable this function, specify 0 for the axes. When the function is
enabled, the corresponding 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 Servo Here (SH) command. The SH command will clear any position
error and reset the commanded position to the actual position.
Examples:
OE 1,1
Enable off-on-error for A and B
OE 0,1
Enable off-on-error for B axis and disable off-on-error for A axis
Automatic Error Routine
The #POSERR label causes the statements following to be automatically executed if the error on any
axis exceeds the error limit specified by ER. The error routine should be closed with the RE command.
RE will cause the main program to be resumed where left off.
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
Servo motor here to clear error
Return to main program
SHA
RE
NOTE: An applications program must be executing for the #POSERR routine to function.
DMC-3425
Chapter 8 Hardware & Software Protection• 153
Limit Switch Routine
The DMC-3425 provides forward and reverse limit switches that 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. The RE command ends the
subroutine and resumes the main program where it left off.
The state of the forward and reverse limit switches may also be interrogated or used in a conditional
statement. The _LR condition specifies the reverse limit and _LF specifies the forward limit. A or B
following _LR or _LF specifies the axis. The CN command can be used to configure the polarity of the
limit switches.
Limit Switch Example:
Instruction
#A;JP #A;EN
#LIMSWI
Interpretation
Dummy Program
Limit Switch Utility
Check state of forward limit
Check state of reverse limit
Jump to #LF if forward limit = low
Jump to #LR if reverse limit = low
Jump to end
V1=_LFA
V2=_LRA
JP#LF,V1=0
JP#LR,V2=0
JP#END
#LF
#LF
MG "FORWARD LIMIT"
STA;AMA
Send message
Stop motion
PR-1000;BGA;AMA
JP#END
Move in reverse
End
#LR
#LR
MG "REVERSE LIMIT"
STA;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.
154 • Chapter 8 Hardware & Software Protection
DMC-3425
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 Damaged amplifier.
not stop the motor.
Replace amplifier.
Replace amplifier.
Check encoder wiring.
Same as above, but offset adjustment does Damaged amplifier.
not stop the motor.
Controller does not read changes in
encoder position.
Wrong encoder connections.
Same as above
Bad encoder
Check the encoder signals.
Replace encoder if necessary.
Same as above
Bad controller
Connect the encoder to
different axis input. If it works,
controller failure. Repair or
replace.
DMC-3425
Chapter 9 Troubleshooting• 155
Communication
Symptom
Cause
Remedy
Using terminal emulator, cannot
Selected comport 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 drifts
slowly.
Encoder noise
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.
156 • Chapter 9 Troubleshooting
DMC-3425
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
DMC-3425
Chapter 10 Theory of Operation• 157
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.
158 • Chapter 10 Theory of Operation
DMC-3425
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
DMC-3425
Chapter 10 Theory of Operation• 159
it too slowly, the temperature response will be slow, causing discomfort. Such a slow reaction is called
over damped response.
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 that 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
160 • Chapter 10 Theory of Operation
DMC-3425
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 = 0.004H
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
DMC-3425
Chapter 10 Theory of Operation• 161
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.
162 • Chapter 10 Theory of Operation
DMC-3425
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
DMC-3425
Chapter 10 Theory of Operation• 163
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 functions
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.
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
164 • Chapter 10 Theory of Operation
DMC-3425
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.
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
Amp/Volt
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 functions of the system elements are:
DMC-3425
Chapter 10 Theory of Operation• 165
Motor
Amp
2
M(s) = P/I = Kt/Js2 = 500/s [rad/A]
K = 4 [Amp/V]
a
DAC
K = 0.0003 [V/count]
d
Encoder
ZOH
K = 4N/2π = 318 [count/rad]
f
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.
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
166 • Chapter 10 Theory of Operation
DMC-3425
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°
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:
DMC-3425
Chapter 10 Theory of Operation• 167
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
Amp/Volt
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
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°
168 • Chapter 10 Theory of Operation
DMC-3425
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
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.
DMC-3425
Chapter 10 Theory of Operation• 169
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)
170 • Chapter 10 Theory of Operation
DMC-3425
Appendices
Electrical Specifications
Servo Control
ACMD Amplifier Command:
+/-10 Volts analog signal. Resolution 16-bit DAC or .0003
Volts. 3 mA maximum
A+,A-,B+,B-,IDX+,IDX- Encoder
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: 12MHz. Minimum IDX pulse width: 80 nsec.
Input/Output
Uncommitted Inputs, Limits, Home,
Abort Inputs:
TTL Can accept up to +12V signal.
TTL.
OUT[1] thru OUT[3] Outputs:
Power Requirements
+5V
400 mA
40 mA
40mA
+12V
-12V
Performance Specifications
Minimum Servo Loop Update Time:
DMC-3415
250 μsec / 125usec with fast firmware
(fast firmware only works on SLAVE controller)
375 μsec / 250 usec with fast firmware
(fast firmware only works on SLAVE controller)
+/-1 quadrature count
DMC-3425
Position Accuracy:
Velocity Accuracy:
DMC-3425
Appendices• 171
Long Term
Short Term
Phase-locked, better than .005%
System dependent
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 Size:
16 bit or 0.0003 V
126 user variables
Variable Range:
+/-2 billion
Variable Resolution:
-4
1 ⋅ 10
Array Size:
2000 elements, 14 arrays
500 lines x 80 characters
Program Size:
Connectors for DMC-3425
J3 DMC-3425 General I/O; 37- PIN D-type
1 Reset 1
20 Error
2 Amp Enable
3 Output 3
21 ACMDA (PWMA)
22 Output 2
4 Output 1
23 Circular Compare
24 Analog 2
5 Analog 1
6 Main Index B (Input 7) 1,2,3
7 Reverse Limit B (Input 5) 1,3
8 Input 3 1
25 Home B (Input 6) 1,3
26 Forward Limit B (Input 4) 1,3
27 Input 2 (and B latch) 1
28 Forward Limit A 1
29 Reverse Limit A 1
30 Home A 1
9 Input 1 (and A latch) 1
10 + 5V
11 Ground
12 +12V
31 -12v
13 Ground
32 A Encoder A+
33 A Encoder B+
34 A Encoder Index+
35 B Encoder A+
36 B Encoder B+
37 Abort 1
14 A Encoder A-
15 A Encoder B-
16 A Encoder Index-
17 B Encoder A-
18 B Encoder B-
19 ACMDY (SIGNA)
172 • Appendices
DMC-3425
J3 DMC-3425-Stepper General I/O; 37- PIN D-type
1 Reset 1
20 PWMB
2 SIGNB
21 PWMA
3 Output 3
22 Output 2
4 Output 1
23 Circular Compare
24 Analog 2
5 Analog 1
6 Main Index B (Input 7) 1,2,3
7 Reverse Limit B (Input 5) 1,3
8 Input 3 1
25 Home B (Input 6) 1,3
26 Forward Limit B (Input 4) 1,3
27 Input 2 (and B latch) 1
28 Forward Limit A 1
29 Reverse Limit A 1
30 Home A 1
9 Input 1 (and A latch) 1
10 + 5V
11 Ground
12 +12V
31 -12v
13 Ground
32 A Encoder A+
33 A Encoder B+
34 A Encoder Index+
35 B Encoder A+
36 B Encoder B+
37 Abort 1
14 A Encoder A-
15 A Encoder B-
16 A Encoder Index-
17 B Encoder A-
18 B Encoder B-
19 SIGNA
1
2
3
These inputs are TTL active low and will be activated when set to 0V.
All inputs are the same in terms of input range (+/-12); D13 can be used as Index B.
Pins 6, 7, 25 and 26 represent Index B, Home B, Reverse Limit B and Forward Limit B. The states
of these inputs are mapped to inputs 7, 6, 5 and 4 respectively. Standard input interrogation commands
can be used to read these inputs (TI, MG@IN[n]), as well as the TS and MG@LFB or MG@LRB
switch commands.
J5 POWER; 6 PIN MOLEX
1 +12V
2 +5V
3 +5V
4 Ground
5 Ground
6 -12V
DMC-3425
Appendices• 173
J1 RS232 Main port: DB-9 Pin Male:
PC
Galil
1 DCD
2 RX
3 TX
1 RTS
2 TX
3 RX
4 CTS
5 GND
6 RTS
7 CTS
8 RTS
9 --
4 DTR
5 GND
6 DSR
7 RTS
8 CTS
9 RI
Pin-Out Description
OUTPUTS
DESCRIPTION
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
Error
Signal to disable and enable an amplifier. Amp Enable goes low on Abort
and OE1.
The signal goes low when the position error on any axis exceeds the value
specified by the error limit command, ER.
Output 1-Output 3
These 3 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
DESCRIPTION
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.
A and B axis Encoder Once-Per-Revolution encoder pulse. Used in Homing sequence or Find
Index, I+ Index command to define home on an encoder index.
A and B axis Encoder, Differential inputs from encoder. May be input along with CHA, CHB for
A-, B-, I-
noise immunity of encoder signals. The CHA- and CHB- inputs are
optional.
174 • Appendices
DMC-3425
Abort input
Reset input
A low input stops commanded motion instantly without a controlled
deceleration. Also aborts motion program.
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 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.
Reverse Limit Switch 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.
Home Switch
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 3
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 used for the high-speed latch. Only
3 inputs for the DMC-3425.
Latch input
High speed position latch to capture axis position within 20 nano seconds on
occurrence of latch signal. AL command arms latch. Input 1 is latch for A
axis. Input 2 is latch for B axis if using DMC-3425
Analog input
12 bit resolution
ICM-1460 Interconnect Module
The ICM-1460, Rev F Interconnect Module provides easy connections between the DMC-3425 series
controllers and other system elements, such as amplifiers, encoders, and external switches. The ICM-
1460 accepts the 37-pin cable from the DMC-3425 and provides screw-type terminals. Each screw
terminal is labeled for quick connection of system elements.
The ICM-1460 is packaged as a circuit board mounted to a metal enclosure. A version of the ICM-
1460 is also available with a single PWM brush servo amplifier, or with a 20W linear brush servo
amplifier. (see AMP-1460 and ICM-1460-20W).
Features
• Breaks out 37-pin ribbon cable into individual screw-type terminals.
• Clearly identifies all terminals
• Available with on-board servo drive (see AMP-1460 or ICM-1460-20W).
• 10-pin IDC connectors for encoders.
• Option for Opto-isolation of all general purpose inputs, committed inputs, and digital outputs.
Specify at time of order with the –OPTO option.
Specifications
Dimensions: 6.9" x 4.9" x 2.6"
Weight: 1 pound
DMC-3425
Appendices• 175
Rev A-F
Rev G
Label
I/O
Description
Terminal#
Terminal#
1
1
+12V4
-12V4
AMPEN/SIGNY5
ACMDX/PULSE(X)
AN1
O
O
O
O
O
O
--
I
+12 Volts
2
2
-12 Volts
3
3
Amplifier enable X axis or Y Axis Sign Output for Stepper
4
4
X Axis Motor command or Pulse Output for Stepper
5
5
Analog Input 1
6
6
AI2
Analog Input 2
7
7
GND
Signal Ground
8
8
RESET
ERROR/PULSE(Y) 6
OUT3
Reset
9
9
O
O
O
O
O
O
--
I
Error signal or Y Axis Pulse Output for Stepper
Output 3
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
8
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
OUT2
Output 2
OUT1
CMP/ICOM 7
Output 1
Circular Compare / Input common for Opto option
+ 5 Volts
5V
GND
Signal Ground
IN7/INDY+
IN6/HOMY
IN5/RLSY
IN4/FLSY
IN3/IDY-
IN2
Input 7 (Y Axis Main Encoder Index + for DMC-1425)
Input 6 (Y Axis Home input for DMC-1425)
Input 5 (Y axis reverse limit on DMC-1425)
Input 4 (Y axis forward limit on DMC-1425)
Input 3 (Y axis main encoder index for DMC-1425)
Input 2
I
I
I
I
I
IN1/LTCH
FLSX
I
Input 1 / Input for Latch Function
Forward limit switch input
I
RLSX
I
Reverse limit switch input
HOMX
ABORT
GND
I
Home input
I
Abort Input
--
I
Signal Ground
X Axis Main Encoder A+ 5
X Axis Main Encoder A- 5
X Axis Main Encoder B+ 5
MA+
MA-
I
MB+
I
MB-
I
X Axis Main Encoder B- 5
IDX+
I
X Axis Main Encoder Index + 5
X Axis Main Encoder Index – 5
X Axis Auxiliary Encoder A+ (Y Axis Main Encoder A+ for DMC-1425)
X Axis Auxiliary Encoder A- (Y Axis Main Encoder A- for DMC-1425)
X Axis Auxiliary Encoder B+ (Y Axis Main Encoder B+ for DMC-1425)
X Axis Auxiliary Encoder B- (Y Axis Main Encoder B- for DMC-1425)
2nd Motor command Signal for Sine Amplifier or SIGNX for stepper
+ 5 Volts
IDX-
I
AA+
I
AA-
I
AB+
I
AB-
I
ACMD2/SIGNX
5V
O
O
--
39
40
GND
Signal Ground
176 • Appendices
DMC-3425
4The screw terminals for ACMDX and ACMDY can provide access to 2 sets of signals, depending on
the placement of the 2 jumpers on JP3.
5If the Opto-isolated input option is used, the output compare is NOT brought out to the ICM-1460. If
the output compare is to be used in conjunction with the opto-isolation, pin 23 of the Cable 37-Pin D
must be brought out externally. There are also options for using either terminal 1 or 2 as the Common
connection. Contact Galil for more information.
Opto-Isolation Option for ICM-1460
The ICM-1460 module from Galil has an option for opto-isolated inputs and outputs. This option is
specified as ICM-1460-OPTO*. With this option, the user is able to use voltages up to 24V on the
inputs and outputs of the controller.
The common point for the opto-isolation may be chosen from any of the following pins: pin 1 (labeled
as +12V), pin 2 (labeled as –12V) or pin 13 (labeled as CMP/ICOM). When pin 1 is used as
input/output common, the +12V output be comes inaccessible, when pin 2 is used, the –12V becomes
inaccessible, and when pin 13 is used, the output compare function is not available. This common
point must be specified at the time of ordering.
The ICM-1460 may also be configured such that the input/output common is jumpered to the internal
Vcc (+5V). By doing this, no screw connection is needed so no signals are lost.
A final option for the opto-isolation is for separate input/output commons. This allows the user to have
different voltage levels for the inputs and outputs. However, this requires the use of both pin 1 and pin
2 on the screw connection, making both +12V and –12V inaccessible on the screw terminals.
Opto-isolated inputs:
The signal "IN[x]" below is one of the isolated digital inputs where x stands for the digital input
terminals.
By connecting the OPTO-COMMON to the + side of an isolated power supply, the inputs will be
activated by sinking current. By connecting the OPTO-COMMON to the GND side of the power
supply, the inputs will be activated by sourcing current.
The opto-isolation circuit requires 1ma drive current with approximately 400 usec response time. The
voltage should not exceed 24V without placing additional resistance to limit the current to 11 mA.
DMC-3425
Appendices• 177
ICM-1460
TO CONTROLLER
CONNECTIONS
VCC
OPTO-COMMON
RP2 / RP4 = 2.2K
RP3 / RP1 = 4.7K OHMS
IN[x] (To controller)
IN[x]
Figure A-1
Opto-isolated outputs:
The signal “OUT[x]" below is one of the isolated digital outputs where x stands for the digital output
terminals.
The OPTO-COMMON needs to be connected to an isolated power supply. The OUT[x] can be used to
source current from the power supply. The maximum sourcing current for the OUT[x] is 25 ma.
Sinking configuration can also be specified. Please contact Galil for details.
The default state of the outputs may also be set through the resistor pack RP5. With this resistor in it’s
default state, the opto-isolator will be ON. By reversing RP5 in its socket, the opto-isolator will be
OFF by default.
Figure A-2
* Only available with ICM-1460
178 • Appendices
DMC-3425
64 Extended I/O of the DMC-3425 Controller
The DMC-3425 controller offers 64 extended I/O points, which can be interfaced to Grayhill and
OPTO-22 I/O mounting racks. These I/O points can be configured as inputs or outputs in 8 bit
increments through software. The I/O points are accessed through two 50-pin IDC connectors, each
with 32 I/O points.
Configuring the I/O of the DMC-3425 with DB-14064
The 64 extended I/O points of the DMC-3425 w/DB-14064 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.
Note: The CO command must be sent through the SA command to configure outputs for slave
controller extended I/O.
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.
8-Bit I/O Block
17-24
Block Binary Representation
Decimal Value for Block
0
2
1
2
2
25-32
3
4
5
6
7
8
9
1
2
3
4
5
6
7
2
2
2
2
2
2
2
33-40
41-48
49-56
57-64
65-72
73-80
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.
DMC-3425
Appendices• 179
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 that are given for
I/O points configured as inputs will be ignored. The following table describes the arguments used to
set the state of outputs.
Argument
Blocks
Bits
Description
M
A
B
C
D
0
1-8
General Outputs
Extended I/O
Extended I/O
Extended I/O
Extended I/O
2,3
17-32
33-48
49-64
65-80
4,5
6,7
8,9
180 • Appendices
DMC-3425
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).
Connector Description:
The DMC-3425 controller with DB-14064 has two 50 Pin IDC header connectors. The connectors are
compatible with I/O mounting racks such as Grayhill 70GRCM32-HL and OPTO-22 G4PB24.
Note for interfacing to 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.
J6 50-PIN IDC
Pin
Signal
Block
Bit @IN[n],
Bit No
@OUT[n]
40
1.
3.
5
7.
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
I/O
I/O
I/O
I/O
I/O
I/O
I/O
+5V
4
4
4
4
4
4
4
4
3
3
3
3
3
3
3
3
2
2
2
2
2
2
2
2
-
7
6
5
4
3
2
1
0
7
6
5
4
3
2
1
0
7
6
5
4
3
2
1
0
-
39
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
-
9.
11.
13.
15.
17.
19.
21.
23.
25.
27.
29.
31.
33.
35.
37.
39.
41.
43.
45.
47.
49.
DMC-3425
Appendices• 181
2.
4.
6.
8.
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
GND
GND
GND
GND
GND
GND
GND
GND
GND
GND
GND
GND
GND
GND
GND
GND
GND
5
5
5
5
5
5
5
5
-
-
-
-
-
-
-
-
-
-
-
-
-
48
47
46
45
44
43
42
41
-
-
-
-
-
-
-
-
-
-
-
-
-
0
1
2
3
4
5
6
7
-
-
-
-
-
-
-
-
-
-
-
-
-
10.
12.
14.
16.
18.
20.
22.
24.
26.
28.
30.
32.
34.
36.
38.
40.
42.
44.
46.
48.
50.
-
-
-
-
-
-
-
-
-
-
-
-
J8 50-PIN IDC
Pin
Signal
Block
Bit @IN[n],
Bit No
@OUT[n]
72
1.
3.
5
7.
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
I/O
I/O
I/O
I/O
I/O
I/O
I/O
+5V
8
8
8
8
8
8
8
8
7
7
7
7
7
7
7
7
6
6
6
6
6
6
6
6
-
7
6
5
4
3
2
1
0
7
6
5
4
3
2
1
0
7
6
5
4
3
2
1
0
-
71
70
69
68
67
66
65
64
63
62
61
60
59
58
57
56
55
54
53
52
51
50
49
-
9.
11.
13.
15.
17.
19.
21.
23.
25.
27.
29.
31.
33.
35.
37.
39.
41.
43.
45.
47.
49.
182 • Appendices
DMC-3425
2.
4.
6.
8.
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/O
GND
GND
GND
GND
GND
GND
GND
GND
GND
GND
GND
GND
GND
GND
GND
GND
GND
9
9
9
9
9
9
9
9
-
-
-
-
-
-
-
-
-
-
-
-
-
80
79
78
77
76
75
74
73
-
-
-
-
-
-
-
-
-
-
-
-
-
7
6
5
4
3
2
1
0
-
-
-
-
-
-
-
-
-
-
-
-
-
10.
12.
14.
16.
18.
20.
22.
24.
26.
28.
30.
32.
34.
36.
38.
40.
42.
44.
46.
48.
50.
-
-
-
-
-
-
-
-
-
-
-
-
IOM-1964 Opto-Isolation Module for Extended I/O
Controllers
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 100 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”
Works with extended I/O controllers
DMC-3425
Appendices• 183
High Current
Buffer chips (16)
Screw Terminals
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
100 pin high
density connector
Banks 2-7 are
standard banks.
provide high
power output
capability.
Figure A-3
Overview
The IOM-1964 is an input/output module that connects to the DB-14064 extended I/O daughter board
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 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 E-Series controllers have general purpose I/O connections. On a DMC-3425 and 3415 the standard
uncommitted I/O consists of: three TTL digital inputs, three TTL digital outputs, and two analog
inputs.
The DMC-34x5 with the DB-14064, however, has an additional 64 digital input/output points than the
6 described above for a total of 70 input/output points. The 64 I/O points on the DB-14064 are
attached via two 50-pin ribbon cable header connectors. A CB-50-80 adapter card is used to connect
the two 50-pin ribbon cables to an 80-pin high-density connector identical to the main axes connector.
An 80-pin shielded cable connects from the 80-pin connector of the CB-50-80 board to the 80-pin high
density connector J5 on the IOM-1964.
184 • Appendices
DMC-3425
Configuring Hardware Banks
The extended I/O on the DMC-34x5 with DB-14064 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-4
All of the banks have the same configuration pattern as diagrammed above in figure A-4. 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 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.
DMC-3425
Appendices• 185
Input Circuit
I/OCn
1/8 RPx4
1/4 NEC2505
To DMC-3425* I/O
DMC-3425* GND
x = bank number 0-7
n = input number 17-80
I/On
Figure A-5 – Input Circuit
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
There is one I/OC connection for each bank of eight inputs. Whether the input is connected as sinking
or sourcing, 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 DB-14064. When the switch is closed in either
circuit, current flows. This pulls the input on the DB-14064 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.
Sinking
Sourcing
I/OCn
I/On
I/OCn
I/On
+5V
GND
PNP
output
NPN
output
Current
Current
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.
186 • Appendices
DMC-3425
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 that 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.
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-3425 +5V
1/4 NEC2505
1/8 RPx2
IR6210
VCC
OUT
GND
IN
PWROUTn
DMC-3425 I/O
1/8 RPx3
I/On
OUTCn
Figure A-6
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-3425 controller/DB-14064 daughter
board from the output circuit.
I/OCn
VISO
PWROUTn
External
Isolated
Power
L
o
a
d
Supply
GNDISO
OUTCn
Figure A-7
DMC-3425
Appendices• 187
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. Figure A-8 is a schematic of the digital output circuit:
Internal Pullup
I/OCn
1/8 RPx3
To DMC-3425 +5V
1/4 NEC2505
1/8 RPx2
I/On
DMC-3425 I/O
OUTCn
Figure A-8 – Internal Pullup
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 10k ohm resistor pack will result in a low level voltage of
.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.
188 • Appendices
DMC-3425
Output Command
Result
CBn
SBn
Vout = GNDiso
Vout = Viso
The resistor pack RPx3 is removed to provide open collector outputs. The same calculations 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-3425 +5V
1/4 NEC2505
1/8 RPx2
I/On
DMC-3425 I/O
OUTCn
Figure A-9 – Open Collector
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
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
DMC-3425
Appendices• 189
•
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
m = 8 standard digital outputs
OP
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.
Returns the state of 8 digital inputs as binary converted to decimal, n is the bank
number +2.
CB n
OB n,m
TI n
_TI n
@IN[n]
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.
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
GND
Ground
N/A
2
2
5V
5V DC out
Ground
N/A
N/A
N/A
7
3
1
GND
4
4
5V
5V DC out
I/O bit 80
5
3
I/O80
I/O79
I/O78
I/O77
I/O76
I/O75
I/O74
I/O73
OUTC73-80
I/OC73-80
I/O72
I/O71
I/O70
I/O69
I/O68
I/O67
I/O66
6
6
I/O bit 79
7
7
5
I/O bit 78
7
8
8
I/O bit 77
7
9
7
I/O bit 76
7
10
11
12
13
14
15
16
17
18
19
20
21
10
9
I/O bit 75
7
I/O bit 74
7
12
11
14
13
16
15
18
17
20
19
I/O bit 73
7
Out common for I/O 73-80
I/O common for I/O 73-80
I/O bit 72
7
7
6
I/O bit 71
6
I/O bit 70
6
I/O bit 69
6
I/O bit 68
6
I/O bit 67
6
I/O bit 66
6
190 • Appendices
DMC-3425
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
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
51
54
53
56
55
58
57
60
59
62
61
64
63
66
I/O65
I/O bit 65
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
3
3
2
2
2
2
2
2
2
2
2
2
1
1
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
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
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
DMC-3425
Appendices• 191
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
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
96
95
98
97
100
99
102
101
104
103
I/O30
I/O bit 30
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
0
0
0
0
0
0
0
0
0
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
I/OC17-24
PWROUT24
PWROUT23
PWROUT22
PWROUT21
PWROUT20
PWROUT19
PWROUT18
PWROUT17
GND
Out common for I/O 17-24
I/O common for I/O 17-24
Out common for I/O 17-24
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
* Silkscreen on Rev A board is incorrect for these terminals.
192 • Appendices
DMC-3425
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 A and B axes, Va
and Vb.
2
2
=
+
Vs
Va Vb
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 A-B 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 A-B
coordinate system whose origin is the starting point of the sequence. Each linear segment is specified
by the A-B 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 A-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-10 is specified by the instructions:
VP
CR
VP
0,10000
10000, 180, -90
20000, 20000
B
C
D
2000
1000
B
A
A
1000
2000
DMC-3425
Appendices• 193
Figure A-10 - 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 A and B 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.
For example, the velocity profile corresponding to the path of Fig. A-10 may be specified in terms of
the vector speed and acceleration.
VS
100000
VA
2000000
The resulting vector velocity is shown in Fig. A-11.
Velocity
10000
time (s)
Ta
0.05
Ts
0.357
Ta
0.407
Figure A-11 - Vector Velocity Profile
The acceleration time, T , is given by
a
194 • Appendices
DMC-3425
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 A and B 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 A and B axes for the path shown in Fig. A-10 are given in Fig. A-
12.
Fig. A-12(a) 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 B axis. Therefore,
Vb = Vs
and
Va = 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.
B
C
(a)
(b)
(c)
A
D
time
Figure A-12 - Vector and Axes Velocities
DMC-3425
Appendices• 195
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 250,000 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 15 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
skillset-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-12:30 pm)
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 (8:00 am-5:00 pm)
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.
TIME: Two days (8:30 am-5:00 pm)
196 • Appendices
DMC-3425
Contacting Us
Galil Motion Control
3750 Atherton Road
Rocklin, CA 95765
Phone: 916-626-0101
Fax: 916-626-0102
Internet address: [email protected]
URL: www.galilmc.com
DMC-3425
Appendices• 197
WARRANTY
All products manufactured by Galil Motion Control are warranted against defects in materials and
workmanship. The warranty period for controller boards is 1 year. The warranty period for all other
products is 180 days.
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.
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.
198 • Appendices
DMC-3425
Index
64 Extended I/O of the DMC-3425 Contoller, 179
Abort, 73, 79, 151, 153, 171
Off-On-Error, 18, 39, 151, 153
Stop Motion, 74, 79, 125, 154
Absolute Position, 69–70, 116–17, 121
Absolute Value, 84, 121, 129, 152
Acceleration, 118, 140, 143–47, 194–95
Address, 133–34, 197
Circular Interpolation, 78–80, 133, 146–47
Clear Bit, 140
Clear Sequence, 73, 75, 79, 80
Clock, 132
CMDERR, 110, 124, 126
Code, 131, 134–35, 145–47, 148–49
Command
Syntax, 59–60
Jumpers, 43
Ampflier Gain, 5
Amplifier
Command Summary, 65, 70, 72, 75, 80, 132, 134
Commanded Position, 70–71, 82, 125, 134, 143, 157–
59
AMP-1460, 8
Communication, 4, 8
Baud Rate, 15, 43
Handshake, 44
Amplifier Enable, 39, 151
Amplifier Gain, 161, 165, 168
Amplifiers, 8
Serial Ports, 12
Connections, 175
Analog Input, 73, 129–31, 132, 135, 142–43, 149
Analysis
Conditional jump, 107, 115, 117–21, 142
Configuration
Jumper, 156
SDK, 27, 108
Arithmetic Functions, 107, 120, 128, 130, 140
Arm Latch, 105
Array, 4, 77, 91–93, 107, 113, 120, 128, 131–39, 140,
172
Contour Mode, 89–94
Control Filter
Damping, 27, 156, 160
Gain, 135
Integrator, 27, 160
Automatic Subroutine, 123, 124
CMDERR, 110, 124, 126
LIMSWI, 37, 110, 123–24, 152–54
MCTIME, 110, 116, 124, 125
POSERR, 110, 123–24, 152–53
Auxiliary Encoder, 98–97
Dual Encoder, 64, 134
Backlash Compensation
Dual Loop, 98–97
Baud Rate, 15, 43
Proportional Gain, 27, 160
Coordinated Motion, 60, 67–68, 78–80
Circular, 78–80, 133, 146–47
Contour Mode, 89–94
Ecam, 84–85, 87
Electronic Cam, 67–68, 83, 86
Electronic Gearing, 67–68, 82–83
Gearing, 67–68, 82–83
Linear Interpolation, 68, 73–75, 77, 89
Cosine, 69, 127–29, 133
Cycle Time
Begin Motion, 109–12, 117–18, 131, 135, 140, 142
Binary, 59, 62
Clock, 132
Bit-Wise, 120, 127
Burn
EEPROM, 4
Capture Data
DAC, 160, 164–66, 168
Damping, 27, 156, 160
Data Capture, 133–34
Data Output
Record, 91, 93, 132, 134
Circle, 146–47
Set Bit, 140
Debugging, 112
DMC-3425
Index• 199
Differential Encoder, 19, 21, 156
Digital Filter, 59, 164–65, 167–69
Gain, 8
Digital Input, 39, 129, 141
Digital Output, 129, 140
Clear Bit, 140
Gear Ratio, 82
Gearing, 67–68, 82–83
Halt, 74, 112–16, 117–19
Abort, 73, 79, 151, 153, 171
Off-On-Error, 18, 39, 151, 153
Stop Motion, 74, 79, 125, 154
Hardware, 37, 43, 140, 151
Address, 133–34, 197
Amplifier Enable, 39, 151
Clear Bit, 140
Dip Switch
Address, 133–34, 197
Download, 59, 107, 133
Dual Encoder, 64, 134
Dual Loop, 98–97
Jumper, 156
Dual Loop, 98–97
Ecam, 84–85, 87
Electronic Cam, 67–68, 83, 86
Edit Mode, 113
Offset Adjustment, 155
Output of Data, 135
Set Bit, 140
TTL, 6, 39, 151
Editor, 34, 108
EEPROM, 4
Home Input, 38, 101, 132
Homing, 38, 101
Electronic Cam, 67–68, 83, 86
Electronic Gearing, 67–68, 82–83
Ellipse Scale, 80
Find Edge, 38, 101
I/O
Amplifier Enable, 39, 151
Analog Input, 73
Enable
Amplifer Enable, 39, 151
Encoder
Clear Bit, 140
Digital Input, 39, 129, 141
Digital Output, 129, 140
Home Input, 38, 101, 132
Output of Data, 135
Set Bit, 140
Auxiliary Encoder, 98–97
Differential, 19, 21, 156
Dual Encoder, 64, 134
Index Pulse, 19, 38, 101
Quadrature, 6, 140, 145, 152, 163
Encoders
TTL, 6, 39, 151
ICB-1460, 8
Index, 174
Quadrature, 174
ICM-1100, 17, 18, 39, 151
Independent Motion
Jog, 72, 82, 88, 105, 117–18, 131, 149, 153
Index, 174
Index Pulse, 19, 38, 101
ININT, 110, 124–25, 142
Input
Error Code, 131, 134–35, 145–47, 148–49
Error Handling, 37, 110, 123–24, 152–54
Error Limit, 18, 20, 39, 151–53
Off-On-Error, 18, 39, 151, 153
Example
Wire Cutter, 145
Analog, 73
Execute Program, 34
Feedrate, 75, 79, 80, 118, 146–47
Filter Parameter
Input Interrupt, 110, 117, 142
ININT, 110, 124–25, 142
Inputs
Damping, 27, 156, 160
Gain, 135
Analog, 129–31, 132, 135, 142–43, 149
Index, 174
Integrator, 27, 160
PID, 21, 160, 170
Interconnect Module, 175
Installation, 8, 155
Proportional Gain, 27, 160
Stability, 155–56, 160, 166
Find Edge, 38, 101
Formatting, 136, 137–39
Variable, 35
Integrator, 27, 160
Interconnect Board, 8
Interconnect Module, 175
ICM-1100, 18, 39, 151
Interface
Frequency, 6, 166–68
Function, 38–39, 59, 74, 91–92, 104, 107, 111–16, 117,
120, 127–32, 135–37
Functions
Arithmetic, 107, 120, 128, 130, 140
Gain, 8, 135
Terminal, 59
Internal Variable, 120, 130
Interrogation, 27, 64, 75, 81, 135, 137
Interrupt, 110–12, 117, 123–25, 142, 175
Invert, 156
Jog, 72, 82, 88, 105, 117–18, 131, 149, 153
Joystick, 73, 131, 148–49
Proportional, 27, 160
200 • Index
DMC-3425
Jumper, 156
Operand
Jumpers, 43
Keyword, 120, 128, 130, 131–32
TIME, 132–33
Label, 73–74, 78, 87, 94, 102, 105, 107–14, 116–25,
131, 137, 140–43, 147, 149, 153
LIMSWI, 152–54
Internal Variable, 120, 130
Operators
Bit-Wise, 120, 127
Optoisolation
Home Input, 38, 101, 132
Output
POSERR, 152–53
Special Label, 110, 154
Latch, 64, 104
Arm Latch, 105
Data Capture, 133–34
Amplifier Enable, 39, 151
ICM-1100, 18, 39
Motor Command, 21, 165
Output of Data, 135
Clear Bit, 140
Position Capture, 104
Set Bit, 140
Record, 91, 93, 132, 134
Teach, 93
Limit
Outputs
Interconnect Module, 175
PID, 21, 160, 170
Torque Limit, 20
Play Back, 135
Limit Switch, 37–38, 110–12, 124, 132, 152–54, 156
LIMSWI, 37, 110, 123–24, 152–54
Linear Interpolation, 68, 73–75, 77, 89
Clear Sequence, 73, 75, 79, 80
Logical Operator, 119
POSERR, 110, 123–24, 152–53
Position Error, 110, 124, 131, 133–34, 143
Position Capture, 104
Latch, 64, 104
Teach, 93
Masking
Bit-Wise, 120, 127
Position Error, 18, 39, 110, 124, 131, 133–34, 143,
151–53, 156, 159
Math Function
Absolute Value, 84, 121, 129, 152
Bit-Wise, 120, 127
Cosine, 69, 127–29, 133
Logical Operator, 119
Sine, 69, 87, 129
Mathematical Expression, 120, 127, 129
MCTIME, 110, 116, 124, 125
Memory, 34, 59, 92, 107, 113, 119, 124, 131, 133
Array, 4, 77, 91–93, 107, 113, 120, 128, 131–39, 140,
172
POSERR, 110, 123–24
Position Follow, 142–43
Position Latch, 175
Position Limit, 152
Program Flow, 109, 115
Interrupt, 110–12, 117, 123–25, 142
Stack, 123, 126, 142
Programmable, 130–31, 140, 149, 152
EEPROM, 4
Programming
Halt, 74, 112–16, 117–19
Proportional Gain, 27, 160
Protection
Download, 59, 107, 133
Upload, 108
Message, 78, 102, 113, 124–25, 128, 135–36, 142, 153–
54
Error Limit, 18, 20, 39, 151–53
Torque Limit, 20
Modelling, 157, 160–61, 165
Motion Complete
MCTIME, 110, 116, 124, 125
Motion Smoothing, 100
S-Curve, 74, 100
PWM, 5, 173–74, 173–74
Quadrature, 6, 140, 145, 152, 163, 174
Quit
Abort, 73, 79, 151, 153, 171
Stop Motion, 74, 79, 125, 154
Record, 91, 93, 132, 134
Latch, 64, 104
Motor Command, 21, 165
Moving
Acceleration, 118, 140, 143–47, 194–95
Begin Motion, 109–12, 117–18, 131, 135, 140, 142
Circular, 78–80, 133, 146–47
Slew Speed, 175
Position Capture, 104
Teach, 93
Register, 131
Reset, 37, 40, 119, 151, 153, 172, 173
SB
Multitasking, 111
Halt, 74, 112–16, 117–19
OE
Set Bit, 140
Scaling
Off-On-Error, 151, 153
Off-On-Error, 18, 39, 151, 153
Offset Adjustment, 155
Ellipse Scale, 80
S-Curve, 74, 100
Motion Smoothing, 100
DMC-3425
Index• 201
SDK, 27, 108
Tell Code, 63
Selecting Address, 133–34, 197
Serial Port, 12
Servo Design Kit, 8
Tell Error, 64
Position Error, 110, 124, 131, 133–34, 143
Tell Position, 64
SDK, 27, 108
Tell Torque, 64
Set Bit, 140
Sine, 69, 87, 129
Terminal, 37, 59, 108, 130, 136
Theory, 27, 157
Single-Ended, 6, 19, 21
Slew, 69, 101, 116, 118, 145
Slew Speed, 175
Smoothing, 74, 75, 79, 80, 95–101
Software
Damping, 27, 156, 160
Digital Filter, 59, 164–65, 167–69
Modelling, 157, 160–61, 165
PID, 21, 160, 170
Stability, 155–56, 160, 166
Time
SDK, 27, 108
Terminal, 59
Clock, 132
Special Label, 110, 154
Specification, 74–75, 79
Stability, 155–56, 160, 166
Stack, 123, 126, 142
Zero Stack, 126, 142
Status, 59, 64, 75, 113–15, 131, 134
Interrogation, 27, 64, 75, 81, 135, 137
Stop Code, 64, 134, 156
Tell Code, 63
TIME, 132–33
Time Interval, 89–91, 93, 133
Timeout, 110, 116, 124, 125
MCTIME, 110, 116, 124, 125
Torque Limit, 20
Trigger, 107, 115, 159
Trippoint, 70, 74–75, 80, 91, 116, 122, 123
Trippoints, 34
Troubleshooting, 155
TTL, 6, 39, 151
Step Motor
KS, Smoothing, 74, 75, 79, 80, 95–101
Step Motors, 8–11
Tuning
SDK, 27, 108
PWM, 173–74, 173–74
Stop
Stability, 155–56, 160, 166
Upload, 108
Abort, 73, 79, 151, 153, 171
Stop Code, 64, 131, 134–35, 134, 145–47, 148–49, 156
Stop Motion, 74, 79, 125, 154
Stop Motion or Program, 175
Subroutine, 37, 78, 110, 119–25, 142, 152–53, 175
Automatic Subroutine, 123, 124
Synchronization, 6, 83
Syntax, 59–60
Teach, 93
Data Capture, 133–34
Latch, 64, 104
Play-Back, 135
Position Capture, 104
Record, 91, 93, 132, 134
User Unit, 140
Variable, 35
Internal, 120, 130
Vector Acceleration, 75–76, 80, 147
Vector Deceleration, 75–76, 80
Vector Mode
Circle, 146–47
Circular Interpolation, 78–80, 133, 146–47
Clear Sequence, 73, 75, 79, 80
Ellipse Scale, 80
Feedrate, 75, 79, 80, 118, 146–47
Vector Speed, 73–77, 80, 118, 147
Wire Cutter, 145
Zero Stack, 126, 142
202 • Index
DMC-3425
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