Installation Manual - Galil Motion Control
Contents
1. AGNE T 1av BV MADE IN LISA EXTENDED IG 31 1018 32 1022 aa END 34 1087 35 1030 3e END 37 1654 NE 38 GNE 401033 41 1042 42 1045 43 GND ANC 16 1017 17 029 18 023 19 1085 20 1028 21 1061 22 NC 23 1035 241097 25 Ne 26 1049 27 1043 28 048 28 048 30 ASV 11018 zi z 1024 41025 5 O23 81052 7 1693 B 1095 21008 ETHERNET AUX SERIAL m D 8 Fr ENCODER 8 EXTERNAL DRIVER A 0 60060906600 EXTERNAL DAIVEA A D sista 15 STPA 17 RES 32 PES 19 5TFD 33 SNC 18 DIRA DRE a 20 RES 35 FES 21 DIRD 38 GNE 22 AES 37 AENB 23 AENG AEC mW 39 END 25472V 40 MENA 25 RES ENCODER C 1248 11 AA ENCODER D 44 GMP 43007 Do4 41001 40GND wan 50 5V as FLSD gt 36 FLSC WAA D SE FLSA 26 GNO M0B 306 xip SI GNO 18 8V 14CFET 18 DOB 12 DOR 11GPWR 10HOMD SHOME SHOVE THOMA DMC 4000 ENGOGER E EXTERNAL DRIVER E Hj ENCODERF EXTERNAL DRIVER E H 16 STPE ENCODER G ENCODER H o o Se cue 430016 420012 41008 40 END BFH 39 FLSG FSF 39 FLSE SEND Pr ong 3e nno 31 GNE RESERVED iring wi DMC 4000 wi Figure 16 Wiring the Controller with internal SDM 44140 The basic wiring for a DMC 40x0 motion controller with included SDM 44140 stepper drivers 18 shown in Figure 17 The disconnect switch or circuit breaker for AC power must be installed in a location that is in close proximity to the equipment and withi2. Description Units Specification Maximum Input Voltage VDC 68 Minimum Input Voltage VDC 20 Maximum Current Output Amps 50 DMC 4080 D4140 D4140 Description Units Specification Maximum Input Voltage VDC 60 Minimum Input Voltage VDC 20 Maximum Current Output Amps 38 AMP 43040 Description Units Specification Supply Voltage VDC 20 68 Maximum Avg cont current per 4 axes Amps 6 Continuous Current per axis Amps 7 Peak Current per axis Amps 10 Nominal Amplifier Gain A V 0 7 Switching Freguency Hz 60 Minimum Load Inductance mH 0 2 Chopper Mode Brushless Motor Commutation angle 120 60 option available Supply Voltage Fuse Amps 30 SDM 44140 Description Units Specification DC Supply Voltage VDC 20 60 Max Current per axis Amps 3 0 Max Step Frequency MHz 6 Motor Type Bipolar 2 Phase Switching Frequency Hz 60 Minimum Load Inductance mH 0 5 Supply Voltage Fuse Amps 20 Fault Information The AMP 43040 and SDM 44140 are protected from the following fault conditions Fault Condition AMP 43040 SDM 44140 Over Current Protection yes yes Under Voltage Protection yes yes Over Temperature Protection yes yes Over Voltage Protection yes no Hall Error Detection yes no The Over Current protection circuit is shown in Figure 18 For further specifics on fault conditions see the DMC 40x0 User Manual 3 3V VIN AB AMP DRIVE 1UF 5V OVERCURRENT Figure 18 Overcurrent Circuit A2 Environmental
3. DMC 40x0 Installation Manual ETL DMC 40x0 Integrated Amplifier Installation Manual Manual Rev 1 0c By Galil Motion Control Inc Galil Motion Control Inc 270 Technology Way Rocklin California 95765 Phone 916 626 0101 Fax 916 626 0102 E mail Address support galilmc com URL www galilmc com Rev 03 18 10 Using This Manual This manual provides information for the wiring installation powering up and basic communication to the DMC 40x0 motion controller with the Galil internal amplifiers AMP 43040 and SDM 44140 The following list of part numbers are examples of configurations of the DMC 40x0 motion controller that are covered in this manual DMC 4080 D3040 D3040 DMC 4080 D4140 D4140 This manual covers the basic installation of the controller and amplifier modules For full operational information including specific I O installation detailed programming examples and additional internal driver information see the DMC 40x0 User Manual 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 machinery Galil shall not be liable or responsible for any incidental or consequential damages If the DMC 40x0 motion controller and included amplifiers or stepper drivers are not used in a manner specified by Galil Motion Control the protection provided by the controller amplifiers and drivers may be impai
4. IL MOTION CONTROL 12AB mi 2MB MADE IN USA iaae TME ay mn Figure 6 Label for DMC 40x0 D3040 D4120 DMC 40x0 D3040 D4140 amp Maximum Input Voltage 60VDC Maximum Output Current 44 Amps ENCODER STEPPER DMC 4080 Ve nnac HWA i olo HALD GAYO Si GALIL GALIL MOTION CONTROL t AB tg 2Mp MADE IN USA 11 Ads i Mh j M DMC 40x0 D4120 Maximum Input Voltage 60VDC Maximum Output Current 9 5 Amps ENCODER STEPPER DMC 4040 sx nase 1 icd EC GALIL GALIL MOTION CONTROL 12 AB br 3MBr SPI MADE IN USA WAA py TMb Figure 8 Label for DMC 40x0 D4120 ENCODER STEPPER DMC 4040 eed oA dm v gigi GALIL GALIL MOTION CONTROL e 4 Ez MADE IN USA ii Afe BW Mie Figure 9 Label for DMC 40x0 D4140 DMC 40x0 D4140 D3020 il O Maximum Input Voltage 60VDC lt Maximum Output Current 31 5 Amps A B C ENCODER STEPPER DMC 4080 idle oma 189 Ee GALIL GALIL MOTION CONTROL a de is El MADE IN USA 11 Ads Wi ink Figure 10 Label for DMC 40x0 D4140 D3020 DMC 40x0 D4140 D3040 X ey Maximum Input Voltage 60VDC e Maximum Output Current 44 Amps k A E C ENCODER STEPPER DMC 4080 WHALE 10 HALA Hs vlje GALIL GALIL MOTION CONTROL AE TA us El MADE IN USA 11 Ads B M ink DMC 40x0 D4140 Maximum Input Voltage 60VDC Maximum Output Current 18 Amps Figure 11 Label for DMC 40x0 D4140 D3040 DMC 40x0 D4140 D4120 Maximum Input Voltage 60VDC M
5. OTION CONTROL ap BW ag MADE IN USA HAM QE Mb Figure 1 Label for DMC 40x0 DMC 40x0 D3020 Maximum Input Voltage 68VDC Maximum Output Current 12 5 Amps DMC 4040 sa mmc m a oa 19 HALB 3 M r 9r GALIL GALIL MOTION CONTROL 12 AB mb 3MBr i MADE IN USA ii Ae BM 1 Mb Figure 2 Label for DMC 40x0 D3020 DMC 40x0 D3040 Maximum Input Voltage 68VDC Maximum Output Current 25 Amps ENCODER STEPPER DMC 4040 sx waa umm DT AC 13 HALB 3 N OF GALIL GALIL MOTION CONTROL 12 AB rl 3MBr MADE IN USA iiaae pg Mh Figure 3 Label for DMC 40x0 D3040 Maximum Output Current 37 5 Amps DMC 40x0 D3040 D3020 Or Maximum Input Voltage 68VDC gel ENCODER STEPPER DMC 4080 wm te a wma UA dap ola a HAB Sar 38A Be OP JB GALIL GALIL MOTION CONTROL 12 AB l4 2MB E MADE IN USA T ke au INR DMC 40x0 D3040 D3040 i O Maximum Input Voltage 6BVDC me Maximum Output Current 50 Amps DMC 4080 uu abc DRMA am GALIL GALIL MOTION CONTROL a S 3 MB MADE IN USA 11 Ads E i Mh Figure 5 Label for DMC 40x0 D3040 D3040 DMC 40x0 D3040 D4120 MG Maximum Input Voltage 60VDC E Maximum Output Current 34 5 Amps OE OE ON DEN OO SD NES CGU ONUS DNO CN UD OG OG GN DNO DER GN D SD ON OD ONES ON ON GU GN ND GENUS GN OG GUN GN NND SD OO ONES ONES OE OUO DN ON NS ONES OE UND ENCODER STEPPER DMC 4080 Zn TAE dle HAB dur ane OO B GALIL GAL
6. Specifications Description Units Specification storage Temperature C 40 to 125 Operating Temperature C 0 to 70 Operating Altitude feet 10 000 Humidity RH 20 95 non condensing A3 Mechanical Specifications DMC 4080 DMC 4080 D3040 D3040 Included Components Quantiy Description DMC 4080 Main Controller Board CMB 41012 Communications Board ICM 42000 2 Interconnect Module AMP 43040 2 Servo Amplifier Board DMC 4080 D4140 D4140 Included Components Quantiy Description DMC 4080 Main Controller Board CMB 41012 Communications Board ICM 42000 2 Interconnect Module AMP 43040 2 Servo Amplifier Board DMC 4080 Description Units Specification Weight Ib 4 35 DMC 4080 D3040 D3040 Length in 11 50 Width in 4 25 Height in 1 41 Wan Ml cw Kat L CE MOLLA ITD 080t OIWNQ Sold F LOE D A4 Mechanical Specifications DMC 4040 Description Units Specification Weight Ib 2 9 DMC 4040 D3040 Length in 8 05 Width in 7 25 Height in 1 41 80 201 4 PLCS DMC 4040 GALIL MOTION CONTROL MADE IN USA FP 6 75 HE oo am m T IG KDE DE ies ror Ded HT Eyi Dii ELS AMun 8
7. TEPFEA HERE AP ENCODERF SERVO Ea ENCODER G EXTERNAL DRIVER E H 3 STPF 22 RES S8GNO S4DIRF SG RES 36GND 16 STPE TF RES 18STPH 1 DIRE 25 RES 21 DIRH 22 AECI C ANDI 000 ENCODERH 430015 42 R012 41608 40 SND AFH 38 FLSG FSF 38FLSE END MONG PEN ong a1 END RESERVED 20 60VDC z r BREAKER OR RELAY zr ith SDM 44140 iring w DMC 4000 wi Figure 17 Communication Connection Connect the serial cable or the Ethernet cable from your PC to the DMC 40x0 motion controller The Ethernet cable may be connected through a hub or switch or directly to the PC If the controller is connected to a DHCP enabled network the IP address will automatically be assigned to the controller Additional Wiring Additional wiring to the Analog and Digital I O encoders limit switches and other connections found on the D Subs on the DMC 40x0 motion controller will be required to complete your applications For detailed information regarding these connections see the DMC 40x0 User Manual Powering the Controller Once the connections have been made from the DC power supply to the DMC 40x0 motion controller the controller and internal amplifiers may be powered up At this time the Power LED should be illuminated and the LCD should turn on and indicate the status of the axes available on the controller Communication with Galil Software To communicate with th
8. available AMP 43040 Servo Amplifier D3040 The AMP 43040 four axis and AMP 43020 two axis are multi axis brush brushless trans conductance PWM amplifiers that are capable of handling 7Amps of continuous current and 10Amps of peak current with any one axis The average continuous current per four axis amplifier is 6A with a maximum current output of 25A The AMP 43040 43020 Brushless drive modules are connected to a DMC 40x0 The standard amplifier accepts DC supply voltages from 20 68 VDC NOTE When the AMP 43040 is ordered with the ETL option Chopper mode must be used See the AU command in the DMC 40x0 Command Reference for more information on setting the AMP 43040 into Chopper Mode SDM 44140 Stepper Amplifier D4140 The SDM 44140 microstepper module drives four bipolar two phase stepper motors with 1 64 microstep resolution the SDM 44140 drives two The current is selectable with options of 0 5 1 0 2 0 amp 3 0 Amps per axis The standard SDM 44140 accepts DC supply voltages from 20 60 VDC Chapter 2 Installation Pre Installation Operating Environment The location for use of the DMC 40x0 AMP 43040 and SDM 44140 must meet the following requirements Description Units Specification Ambient Temperature C 0 to 70 Altitude feet 10 000 Humidity RH 20 95 non condensing Mounting Location The DMC 40x0 motion controller must be mounted on a flat surface using the 4 mounting holes found on the metal base pla
9. aximum Output Current 28 5 Amps uu au ui ua uu ua ua ua aa ua ua ua aa ua ua ua ua ua aa aaa aa aa OD SD GNO ONES ONES ON ON GU GS D SD OUO GUESS GN ON GO GN NND ED GNO OE ON CUNEO E ON SO GE NO UND DMC 4080 Ws om ime GALIL GALIL MOTION CONTROL AR Du 1MB MADE IN USA TA au TNR CO DMC 40x0 D4140 D4140 C Maximum Input Voltage 60VDC inel Maximum Output Current 38 Amps A B C ENCCDER STEPPER DMC 4080 xd ww dt ue GALIL GALIL MOTION CONTROL im m dr F GG B MADE IN USA mare MES qu Figure 13 Label for DMC 40x0 D4140 D4140 P ETL LISTED AD CONFORMS TO ENDIE UL STO 61010 1 137106 CERTIFIED TO CAN CSA STD 22 2 MO 61010 1 Figure 14 ETL Mark Installation Mounting the Controller The DMC 40x0 motion controller must be mounted to a flat surface with 4 410 pan head screws through each mounting hole found on the controller base as shown in Figure 15 If the controller is mounted on a wall the controller should be mounted so that the bottom of the controller 1s horizontal to the floor as shown in Figure 15 If the AMP 43040 internal amplifiers are being used it should be determined at this time whether or not an additional heat sink will be required This 1s determined based upon the continuous current requirements of the system as defined in the Additional Mounting Consideration when using the AMP 43040 section above The Motor Sizer tool found o
10. e controller the GalilTools communications software must first be installed A free version of GalilTools GalilTools Lite may also be used These software applications can be found on the software installation CD shipped with the controller or online at http www galilmc com support software downloads php Installation instructions for your operating system can be found in the GalilTools user manual http www galilmc com support manuals galiltools introduction html Once the software has been installed run GalilTools or GalilTools Lite and choose your controller RS 232 connection If you are using over a serial connection the standard baud rate of the DMC 40x0 motion controller is 115200 For a standard serial connection over COMI choose COMI 115200 in the connections dialog window Ethernet connection If you are connected to the controller via an Ethernet connection and your network is DHCP enabled then the controller will automatically have an IP addressed assigned to it If your network is not DHCP enabled or the connection is only between the PC and the controller then the controller be found with the software as no IP address assigned The GalilTools software will allow you to assign the controller with an IP address See the GalilTools documentation for detailed information on using the software to assign the controller IP address Appendix Specifications Al Electrical Specifications DMC 4080 D3040 D3040
11. n easy reach of the operator It must also be marked as the disconnect device for the equipment Connectors for SDM 44140 On Board Connector Terminal Pins POWER 6 pin MATE N LOK MOLEX 39 01 2065 MOLEX 44476 3112 A B C D 4 pin Motor 4 pin MATE N LOK Power Connectors MOLEX 39 01 2045 MOLEX 44476 3112 For mating connectors see http www molex com Power Connector Motor Connector Power Connector Pin Number Connection 1 2 3 DC Power Supply Ground 4 5 6 VS DC Power Motor Connector B 2 A 3 B 4 A i JJ 3 DMC 4080 SALIL MOTION CONTROL MALE IN LISA ANALOG S ACNE 1542 n A4 AG RAS MNC 1 42V EXTENDED I O 1 AGNE EAI 3A3 AA SAT BAGND 742 BY MAIN SERIAL EXTENDED Q 31 1019 32 1022 33 GNE 34 1027 35 1060 36 GNE ar 1084 ENE 38 GND 47 1008 4 i 421045 43 GNE ANC 181017 171000 18 1023 3 024 18 i25 41028 20 Cv 5 029 21 61 8 1082 BENT os 23 1085 1 1098 24 OG 1988 10NC 9649 11 1041 27 Na 12044 BOR quo za 48 MNC mAV 15 RES 1101 21021 AUX SERIAL lt m uu g ul EXTERNAL DRIVER A C EXTERNAL DRIVER A D 15 STPA 17 RES 19 STED 19 IRA 20 HES 21 DIRD 22 AESI 23 AENG DMC 4000 BERG ARES 7 AENA 8AEND ING ENCODER C 1549 14 HALE 18 HALB 12 AB 11 AA ENCODER 10 HALA SAA BMA TM BM ENCODER D ENCODER E EXTERNAL DRIVER E Hj S
12. n our website can be used to determine this value http www galilmc com learning motorsizer php 10 PAN HEAD SCREW 4 PLACES Bottom of Controller Figure 15 Mounting the DMC 4000 Wiring the Controller with internal AMP 43040 The basic wiring for a DMC 40x0 motion controller with included AMP 43040 servo amplifiers is shown in Figure 16 The disconnect switch or circuit breaker for AC power must be installed in a location that is in close proximity to the equipment and within easy reach of the operator It must also be marked as the disconnect device for the equipment Connectors for AMP 43040 On Board Connector Terminal Pins POWER 6 pin MATE N LOK MOLEX 39 31 0060 MOLEX 44476 3112 A B C D 4 pin Motor 4 pin MATE N LOK Power Connectors MOLEX 39 31 0040 MOLEX 44476 3112 For mating connectors see http www molex com naa Power Connector Motor Connector Power Connector Pin Number Connection 1 2 3 DC Power Supply Ground 4 5 6 VS DC Power Motor Connector Phase C N C for Bushed Motors 2 Phase B 3 No Connect 4 Phase A 20 68VDC BZ r BREAKER OR RELAY Z r th AMP 43040 C D POWER E F G H POWER ENGODER STEPPER SERVO POWER D M C 4080 arm OHA Hegle ge E ess 18 HALB B jojo C GND EXTENDED I O 9 SAUL MOTION CONTROL ANALOG 7 ACNE LE 11A4 AG TAR MN 15 12V 1AGND 2A1 FAR 4A B T
13. red Chapter 1 Overview Introduction DMC 40x0 Motion Controller The DMC 40x0 Series are Galil s highest performance stand alone controller The controller series offers many enhanced features including high speed communications non volatile program memory faster encoder speeds and improved cabling for EMI reduction Each DMC 40x0 provides two communication channels high speed RS 232 2 channels up to 115K Baud and 10BaseT Ethernet The controllers allow for high speed servo control up to 22 million encoder counts sec and step motor control up to 6 million steps per second Sample rates as low as 31 25 usec per axis are available A Flash EEPROM provides non volatile memory for storing application programs parameters arrays and firmware New firmware revisions are easily upgraded in the field The DMC 40x0 is available with up to eight axes in a single stand alone unit The DMC 4010 4020 4030 4040 are one thru four axes controllers and the DMC 4050 4060 4070 4080 are five thru eight axes controllers All eight axes have the ability to use Galil s integrated amplifiers or drivers and connections for integrating external devices Commands can be sent in either Binary or ASCII Additional software is available for automatic tuning trajectory viewing on a PC screen CAD translation and program development using many environments such as Visual Basic C C etc Drivers for Windows XP 32 amp 64 bit and Linux are
14. tch or circuit breaker for AC power to DC Power Supply Unpacking the Controller Caution The DMC 40x0 motion controller and included internal amplifier include electrostatic sensitive components Observe standard precautions for handling ESD sensitive devices when handling the controller 1 Verify that the following components have been shipped along the motion controller e Connectors and mating pins for motor power and amplifier power o Qty 4 4 pin molex connectors for EACH internal amplifier o Qtyl1 6 pin molex connector for EAH internal amplifier e Galil Software Installation CD Note X Connectors and or software installation CD may not be shipped to existing OEM customers 2 Check that no visible damage has occurred to the controller or internal amplifiers If any damage has occurred to the controller or the components shipped with the controller contact Galil Motion Control immediately Contact information can be found in the beginning of this manual 3 Verify the controller that has been shipped to you is in fact the controller that you have ordered from Galil or your authorized Galil distributor To do this check the labeling on the controller and compare it to the part number that was ordered Maximum Input Voltage 68VDC e Maximum Input Current 1 Amp j aaa X D M te ENCODER ETEP ER VL LT MEN 5 GNO IL LL C 4040 ang HAA Gam toto lee TE HALE 25 JM A Of B GALIL GALIL M
15. te The grating found on the side of the metal must not be obstructed In order provide proper air flow for adequate heat dissipation The dimensions for a 1 4 axis controller are smaller than that of a 4 8 axis controller these dimensions and the mounting hole locations are found in Appendices A3 and A4 Additional Mounting Consideration when using the AMP 43040 When operating a DMC 4080 D3040 D3040 or a DMC 4040 D3040 special mounting considerations must be made if the total continuous current output for the controller is greater than 15A for a 3 4 axis controller and greater than 30A for a 5 8 axis controller standard mounting is adequate for a 1 or 2 axis controller In this case the controller base must be mounted to an addition heat sink Elements Needed for Installation 1 DC power supply a Ratings found in Appendix AI 2 Power Supply Cable a Cable from DC power supply to power input for AMP 43040 or SDM 44140 b DMC 4080 controller requires 2 cables 3 PCorlaptop with Ethernet and or RS 232 ports 4 GalilTools or GalilTools Lite software package 5 Ethernet Cable a Recommended shielded Cat 5 STP cable Straight through or Cross over 6 RS 232 straight through serial cable a 9 pin D sub female 7 Molex pin Crimp Tool 8 Additional cables may be required for connection to motors external amplifiers digital or analog I O and other devices See the full DMC 40x0 User Manual for further information 9 Disconnect swi
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