Galil Motion Control DMC-40 0 Series Installation Manual
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Galil Motion Control DMC-40 0 Series Installation Manual

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UL INSTALLATION MANUAL
DMC-40x0
Manual Rev. 1.0a
Galil Motion Control, Inc.
270 Technology Way
Rocklin, California
916.626.0101
support@galil.com
galil.com
11/2022

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  • Page 1 UL INSTALLATION MANUAL DMC-40x0 Manual Rev. 1.0a Galil Motion Control, Inc. 270 Technology Way Rocklin, California 916.626.0101 support@galil.com galil.com 11/2022...
  • Page 2 WARNING 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 impaired. ▫ ii...

  • Page 3: Table Of Contents

    Contents Contents Chapter 1 Overview Introduction ........................1 Chapter 2 Specifications Certifications ......................... 2 Environmental Specifications ..................2 Mechanical Specifications .................... 3 Electrical Specifications ....................4 Chapter 3 Installation Pre-Installation ......................6 Mounting the Controller ....................7 Wiring Connections ...................... 11 Chapter 4 Maintenance Overview ........................

  • Page 4: Chapter 1 Overview

    Chapter 1 Overview Introduction 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 100 BaseT Ethernet.

  • Page 5: Chapter 2 Specifications

    Chapter 2 Specifications Certifications Certifications, Accreditation, and Ratings Certification Rating UL 61800-5-1 EN55022 EN61000-3-2, -3-3, -4-2, -4-3, -4-4, -4-5, -4-6, -4-11 EN61010-1 RoHS RoHS 3 Ingress Protection IP10 Rating Table 2.1: DMC-40x0 Certifications Environmental Specifications Climatic Conditions Climatic Rating Notes Temperature 0-70 °C Operating environment...

  • Page 6: Mechanical Specifications

    Table 2.4: IO Cabling Requirements Note – Cabling available from Galil may or may not meet the above requirements. For technical support, contact Galil Motion Control to speak with an Applications Engineer. Chapter 2 Specifications▫ 3 DMC-40x0 UL Installation Manual...

  • Page 7: Electrical Specifications

    Electrical Specifications Inputs Rated Voltage Input Notes 2.2 kΩ resistor in series with opto-isolator Opto-isolated Digital 5-24 ≥ 1 mA = ON; ≤ 0.5 mA = OFF Inputs [8] for 1-4 axis models, [16] for 5-8 axis models 2.2 kΩ resistor in series with opto-isolator Limit Switch Inputs 5-24 ≥...
  • Page 8 Outputs Rated Voltage Rated Current Input Notes (mA) Opto-isolated Digital Sourcing 12-24 Outputs [8] for 1-4 axis models, [16] for 5-8 axis models 16-bit DAC Analog Output / ±10 500 Ω Output impedance Motor Command [1] output per axis TTL level at 50% duty cycle Step/Direction [1] Step per axis, [1] Direction per axis Sinking/Sourcing...

  • Page 9: Chapter 3 Installation

    2. Check and confirm that there is no visible damage to the controller or internal amplifier. If damage has occurred, contact Galil Motion Control. 3. Check the labeling on the controller and verify that the controller received matches the part number of the controller purchased.

  • Page 10: Mounting The Controller

    Mounting the Controller The DMC-40x0 with internal Galil amplifiers should be mounted to an additional heat sink. Thermally conductive compound should be applied between the base plate and the heat sink in order to assist with heat dissipation. The grating found on the side of the metal enclosure must not be obstructed in order to allow for proper air flow and adequate heat dissipation.
  • Page 11 Figure 3.2: DMC-4040-C022-I000-D3740 Dimensions/Mounting (US Customary Units) Chapter 3 Installation ▫ 8 DMC-40x0 UL Installation Manual...
  • Page 12 Figure 3.3: DMC-4080 with -D3040, -D3240, -D3540, -D3547, -D3640, -D4040, -D4140 Dimensions/Mounting (US Customary Units) Chapter 3 Installation▫ 9 DMC-40x0 UL Installation Manual...
  • Page 13 Figure 3.4: DMC-4080-C022-I000-I000-D3740-D3740 Dimensions/Mounting (US Customary Units) Chapter 3 Installation ▫ 10 DMC-40x0 UL Installation Manual...

  • Page 14: Wiring Connections

    Commissioning tests are tests on a device or equipment performed to confirm the correctness of installation and operation. These tests should be developed by the Original Equipment Manufacturer (OEM) and will be unique to each OEM application. For technical support, contact Galil Motion Control to speak with an Applications Engineer. Chapter 3 Installation▫ 11...
  • Page 15 Wiring the Optoisolated Digital Inputs To take full advantage of optoisolation, an isolated power supply should be used to provide the voltage at the input common connection. Connecting the ground of the isolated power to the ground of the controller will bypass optoisolation and is not recommended if true optoisolation is desired.
  • Page 16 Figure 3.8: ELO, Abort and Reset Inputs Figure 3.9: Limit Switch Inputs for Axes A-D Figure 3.10: Limit Switch Inputs for Axes E-H Chapter 3 Installation▫ 13 DMC-40x0 UL Installation Manual...
  • Page 17 Wiring the Optoisolated Outputs The output power supply will be connected to Output PWR (labeled OPWR) and the power supply return will be connected to Output GND (labeled ORET). Note that the load is wired between DO and Output GND. The wiring diagram for Bank 0 is shown in Figure 3.11 and Bank 1 in Figure 3.12.
  • Page 18 Cable Shielding For proper shielding, the shield's drain wire should be terminated on only one side of the cable. The following diagrams illustrate the best means of achieving this with the DMC-40x0, with the expectation that the controller's base-plate is mounted to something with a secure connection to Earth Ground. Figure 3.13 shows how to connect the encoder cable's shield drain wire.

  • Page 19: Chapter 4 Maintenance

    Overview Repair / RMA Maintenance for the DMC-40x0 controller should be completed using the RMA process with Galil Motion Control. Do not open the metal enclosure of the DMC-40x0 controller. Removing the metal enclosure will void the warranty. If the DMC-40x0 controller appears damaged, or is exhibiting unexpected behavior, contact Galil Motion Control to speak with an Applications Engineer.

  • Page 20: Chapter 5 Integrated Components

    Chapter 5 Integrated Components Overview When ordered, the following components will reside inside the box of the DMC-40x0 motion controller. The integrated amplifiers and stepper drivers provide power to the motors in the system, and the interconnect modules and communication boards provide the connections for the signals and communications. AMP-430x0 (-D3040,-D3020): 500W Trapezoidally Commutated Amplifiers The AMP-43040 (4-axis) and AMP-43020 (2-axis) are trapezoidally commutated transconductance, PWM amplifiers...
  • Page 21 AMP-43547 (-D3547, -D3527): 600W Configurable Servo Amps/Stepper Drives This amplifier is unique in that it can run either servo or stepper motors on any axis. The AMP-43547 (4-axis) and AMP-43527 (2-axis) are sinusoidally commutated, 16 bit PWM amplifiers for driving brushless and brush-type servo motors.
  • Page 22 ICM-42000 (-I000): Interconnect Module (Standard) The ICM-42000 breaks out the internal CPU connector into convenient D-sub connectors for interface to external amplifiers and I/O devices. ICM-42100 (-I100): Sinusoidal Encoder Interpolation Module The ICM-42100 accepts sinusoidal encoder signals instead of digital encoder signals as accepted by the ICM-42000 and the ICM-42200.

  • Page 23: Amp-430X0 (-D3040,-D3020)

    AMP-430x0 (-D3040,-D3020) Description The AMP-43040 resides inside the DMC-40x0 enclosure and contains four trapezoidally commutated transconductance, PWM amplifiers for driving brushless or brush-type servo motors. Each amplifier drives motors operating at up to 7 Amps continuous, 10 Amps peak, 20–60 VDC. The gain settings of the amplifier are user- programmable at 0.4 Amp/Volt, 0.7 Amp/Volt and 1 Amp/Volt.
  • Page 24 Electrical Specifications Servo (Brushless/Brushed) Supply Voltage 20-60 VDC Continuous Current 7 Amps Peak Current 10 Amps Switching Frequency 66 kHz (up to 140 kHz available) Amplifier Gains 0.4, 0.7, 1.0 Amps/Volt Brushless Commutation Angle 120° (60° option available) PWM Output Operation Inverter or Chopper (user configurable) Vs(V ) L(mH )=...

  • Page 25: Amp-43240 (-D3240)

    AMP-43240 (-D3240) Description The AMP-43240 resides inside the DMC-40x0 enclosure and contains four trapezoidally commutated transconductance, PWM amplifiers for driving brushless or brush-type servo motors. Each amplifier drives motors operating at up to 10 Amps continuous, 20 Amps peak, 20–60 VDC. The gain settings of the amplifier are user- programmable at 0.5 Amp/Volt, 1.0 Amp/Volt and 2.0 Amp/Volt.
  • Page 26 Electrical Specifications Servo (Brushless/Brushed) Supply Voltage 20-60 VDC Continuous Current 10 Amps Peak Current 20 Amps Switching Frequency 24 kHz Amplifier Gains 0.5, 1.0, 2.0 Amps/Volt Brushless Commutation Angle 120° (60° option available) PWM Output Operation Chopper Vs (V ) L(mH )= Minimum Load Inductance 192∗I...

  • Page 27: Amp-43540 (-D3540, -D3520)

    AMP-43540 (-D3540, -D3520) Description The AMP-43540 is a sinusoidally commutated, 16 bit PWM amplifier. It can also be ordered in a two axis configuration specified as -D3520. The AMP-43540 can be configured for the motors below with just a few commands.
  • Page 28 Electrical Specifications Servo (Brushless/Brushed) Supply Voltage 20-60 VDC Continuous Current 8 Amps Peak Current 15 Amps Switching Frequency 33 kHz Amplifier Gains 0.4, 0.8, 1.6 Amps/Volt Vs (V ) L( mH )= Minimum Load Inductance 264∗I ( A) Ripple Vs = Supply Voltage, I = 10% of the maximum current at chosen gain ripple Table 4.7: Amplifier Electrical Specifications...

  • Page 29: Amp-43547 (-D3547, -D3527)

    AMP-43547 (-D3547, -D3527) Description The AMP-43547 is a sinusoidally commutated, 16 bit PWM amplifier that can also be configured as a microstepping drive. This amplifier is unique in that it can run either servo or stepper motors on any axis. The AMP-43547 can be configured for all of the motors below with just a few commands.
  • Page 30 Electrical Specifications Servo (Brushless/Brushed) Stepper Supply Voltage 20-60 VDC Continuous Current 8 Amps Peak Current 15 Amps Maximum Current per Phase 6 Amps Step Resolution 256 microsteps/full step Switching Frequency 33 kHz Amplifier Gains 0.4, 0.8, 1.6 Amps/Volt 0.75, 1.5, 3, 6 Amps/Phase Vs (V ) L( mH )= Minimum Load Inductance...

  • Page 31: Amp-43640 (-D3640)

    AMP-43640 (-D3640) Description The AMP-43640 contains four linear drives for sinusoidally commutating brushless motors. The AMP-43640 requires a single 15–40VDC input. Output power delivered is typically 20 W per amplifier or 80 W total. The gain of each transconductance linear amplifier is 0.2 A/V. When used with a 24VDC power supply, the amplifier will deliver 1A continuous and 2A peak.
  • Page 32 Electrical Specifications Servo (Brushless/Brushed) Supply Voltage 15-40 VDC (15-20 VDC requires ISCNTL option) Continuous Current 1.0 Amps Peak Current 2.0 Amps Amplifier Gains 0.2 Amps/Volt Power Output (per channel) 20 W Total Max Power Output 80 W Table 4.13: Amplifier Electrical Specifications Mating Connectors Cable Connectors Terminal Pins...

  • Page 33: Amp-43740 (-D3740)

    AMP-43740 (-D3740) Description The AMP-43740 is a sinusoidally commutated, 16 bit PWM amplifier. The AMP-43740 can be configured for the motors below with just a few commands. Brushless Motors • Brushed Motors • Do not “hot swap” the motor power or supply voltage power input connections. If the amplifier is enabled when the motor connector is connected or disconnected, damage to the amplifier can WARNING occur.
  • Page 34 Electrical Specifications Servo (Brushless/Brushed) Supply Voltage 20-60 VDC Continuous Current 16 Amps Peak Current 30 Amps Switching Frequency 20 kHz Amplifier Gains 0.8, 1.6, 3.2 Amps/Volt Vs (V ) L( mH )= Minimum Load Inductance 160∗I ( A) Ripple Vs = Supply Voltage, I = 10% of the maximum current at chosen gain ripple Table 4.16: Amplifier Electrical Specifications...

  • Page 35: Sdm-440X0 (-D4040,-D4020)

    SDM-440x0 (-D4040,-D4020) Description The SDM-44040 resides inside the DMC-40x0 enclosure and contains four drives for operating two-phase bipolar step motors. The SDM-44040 requires a single 12-30 VDC input. The unit is user-configurable for 1.4 A, 1.0 A, 0.75 A, or 0.5 A per phase and for full-step, half-step, 1/4 step or 1/16 step. A two-axis version, the SDM-44020 is also available.
  • Page 36 Electrical Specifications Stepper Supply Voltage 20-30 VDC (12-30 VDC available with ISCNTL) Max Current (Per Axis) 1.4 Amps/Phase (user-configurable) Amplifier Gains (Amps/Phase) 0.5, 0.75, 1.0, 1.4 Max Step Frequency 6 MHz Motor Type Bipolar 2-Phase Table 4.19: Amplifier Electrical Specifications Mating Connectors Cable Connectors Terminal Pins...

  • Page 37: Sdm-44140 (-D4140)

    SDM-44140 (-D4140) Description The SDM-44140 resides inside the DMC-40x0 enclosure and contains four microstepping drives for operating two- phase bipolar stepper motors. The drives produce 64 microsteps per full step which results in 12,800 steps/rev for a standard 200-step motor. The maximum step rate generated by the controller is 6,000,000 microsteps/second. The SDM-44140 drives motors operating at up to 3 Amps at 20 to 60 VDC (available voltage at motor is 10% less).
  • Page 38 Electrical Specifications Stepper Supply Voltage 20-60 VDC Max Current (Per Axis) 3.0 Amps/Phase (user-configurable) Amplifier Gains (Amps/Phase) 0.5, 1.0, 2.0, 3.0 Max Step Frequency 6 MHz Minimum Load Inductance 0.5 mH Motor Type Bipolar 2-Phase Table 4.22: Amplifier Electrical Specifications Mating Connectors Cable Connectors Terminal Pins...

  • Page 39: Cmb-41012 (-C012)

    CMB-41012 (-C012) Description The CMB-41012 provides the connections for the Ethernet and Serial communication as well as the D-Sub connector for the Extended I/O. The CMB-41012 also contains the 8x2 character LCD. For more details, refer to the DMC-40x0 User Manual. Chapter 5 Integrated Components ▫...
  • Page 40 Connectors for CMB-41012 Interconnect Board CMB-41012 Extended I/O 44 pin HD D-Sub Connector (Male) Pin # Label Description Pin # Label Description Pin # Label Description IO18 I/O bit 18 IO17 I/O bit 17 IO19 I/O bit 19 IO21 I/O bit 21 IO20 I/O bit 20 IO22...
  • Page 41 RJ45 Connector - Ethernet The Ethernet connection is Auto MDIX, 100bT/10bT. Pin # Signal Name Jumper Description for CMB-41012 Jumper Label Function (If jumpered) Option Jumper Reserved Motor Off Jumper When controller is powered on or reset, Amplifier Enable lines will be in a Motor Off state.

  • Page 42: Cmb-41022 (-C022)

    CMB-41022 (-C022) Description The CMB-41022 differs from the CMB-41012 (default) in that it has second Ethernet port, as shown in the figure above. The CMB provides the connections for both Ethernet and Serial communication as well as the 44-pin HD D- Sub connector for the Extended I/O.
  • Page 43 Connectors for CMB-41022 Interconnect Board CMB-41022 Extended I/O 44 pin HD D-Sub Connector (Male) Label Description Label Description Label Description IO18 I/O bit 18 IO17 I/O bit 17 IO19 I/O bit 19 IO21 I/O bit 21 IO20 I/O bit 20 IO22 I/O bit 22 IO24...
  • Page 44 RJ45 Connector - Ethernet The Ethernet connection is Auto MDIX, 100bT/10bT. Pin # Signal Name On the each Ethernet port there are two LEDs that indicate the status of the port's Ethernet connection. Green Link LED (LNK): The green LED indicates there is a valid Ethernet connection. This LED will show that the physical Ethernet layer (the cable) is connected.

  • Page 45: Icm-42000 (-I000)

    ICM-42000 (-I000) Description The ICM-42000 resides inside the DMC-40x0 enclosure and breaks out the internal CPU board connector into convenient D-sub connectors for interface to external amplifiers and I/O devices. The ICM-42000 provides a 15-pin HD D-sub connector for the encoders on each axis, a 15-pin D-sub for analog inputs, a 44-pin HD D-sub for I/O, and a 44-pin D-sub for the motor command signals.
  • Page 46 Connectors for ICM-42000 Interconnect Board ICM-42000 I/O (A-D) 44 pin HD D-Sub Connector (Female) Label Description Label Description Label Description Error Output Reset Input Digital Ground Digital Input 1/ A latch INCOM Input Common Digital Input 2 / B latch Digital Input 4 / D latch Digital Input 3 / C latch Digital Input 5...
  • Page 47 ICM-42000 External Driver (A-D) 44 pin HD D-Sub Connector (Male) Label Description Label Description Label Description STPA Step A STPB Step B Reserved / Step A_N STPC Step C Reserved / Step B_N Reserved / Step C_N STPD Step D Digital Ground Reserved / Step D_N DIRA...
  • Page 48 ICM-42000 Encoder 15 pin HD D-Sub Connector (Female) Label Description I+ Index Pulse Input B+ Main Encoder Input A+ Main Encoder Input B+ Aux Encoder Input Digital Ground I- Index Pulse Input B- Main Encoder Input A- Main Encoder Input A- Aux Encoder Input HALA A Channel Hall Sensor...
  • Page 49 ICM-42000 Analog 15 pin D-sub Connector (Male) Label Description AGND Analog Ground Analog Input 1 Analog Input 3 Analog Input 5 Analog Input 7 AGND Analog Ground -12V -12V AGND Analog Ground Analog Input 2 Analog Input 4 Analog Input 6 Analog Input 8 No Connect +12V...

  • Page 50: Icm-42100 (-I100)

    ICM-42100 (-I100) Description The ICM-42100 (-I100) option resides inside the DMC-40x0 enclosure and accepts sinusoidal encoder signals in addition to standard, differential quadrature encoder signals . The -I100 board can provide interpolation for up to four 1 V differential sinusoidal encoders resulting in a higher position resolution. pk-pk For more information regarding the Amplifier Enable Operation, see Chapter 3 of the DMC-40x0 User Manual.
  • Page 51 Connectors for ICM-42100 Interconnect Board ICM-42100 I/O (A-D) 44 pin HD D-Sub Connector (Female) Label Description Label Description Label Description Error Output Reset Input Digital Ground Digital Input 1/ A latch INCOM Input Common Digital Input 2 / B latch Digital Input 4 / D latch Digital Input 3 / C latch Digital Input 5...
  • Page 52 ICM-42100 External Driver (A-D) 44 pin HD D-Sub Connector (Male) Label Description Label Description Label Description Reserved / Step A_N STPA Step A STPB Step B Reserved / Step B_N Reserved / Step C_N STPC Step C Reserved / Step D_N STPD Step D Digital Ground...
  • Page 53 ICM-42100 Encoder 15 pin HD D-Sub Connector (Female) Label Sin/Cos Feedback Standard Quadrature + Index Pulse Input I+ Index Pulse Input + Main Encoder Input B+ Main Encoder Input + Main Encoder Input A+ Main Encoder Input B+ Aux Encoder Input Digital Ground - Index Pulse Input I- Index Pulse Input...

  • Page 54: Icm-42200 (-I200)

    ICM-42200 (-I200) Description The ICM-42200 interconnect option resides inside the DMC-40x0 enclosure and provides a pin-out that is optimized for easy connection to external drives. The ICM-42200 uses 26-pin HD D-sub connectors for each axis that includes encoder, limit, home, and motor command signals. Other connectors include a 44-pin HD D-sub for digital I/O, and a 15-pin LD D-sub for analog I/O.
  • Page 55 Connectors for ICM-42200 Interconnect Board ICM-42200 I/O (A-D) 44 pin HD D-Sub Connector (Female) Label Description Label Description Label Description Error Output Reset Input Digital Ground Digital Input 1/ A latch INCOM Input Common Digital Input 2 / B latch Digital Input 4 / D latch Digital Input 3 / C latch Digital Input 5...
  • Page 56 ICM-42200 Encoder 26 pin HD D-Sub Connector (Female) Label Description Label Description Reserved / Hall 2 / MCMD_N Forward Limit Switch Input Amplifier Enable B+ Aux Encoder Input Direction I- Index Pulse Input HOM Home B+ Main Encoder Input LSCOM Limit Switch Common Digital Ground A- Aux Encoder Input MCMD...
  • Page 57 ICM-42200 Analog 15 pin D-sub Connector (Male) Label Description AGND Analog Ground Analog Input 1 Analog Input 3 Analog Input 5 Analog Input 7 AGND Analog Ground -12V -12V AGND Analog Ground Analog Input 2 Analog Input 4 Analog Input 6 Analog Input 8 No Connect +12V...

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