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Galil Motion Control DMC-41x3 User Manual

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USER MANUAL
DMC-41x3
Manual Rev. 1.3h
Galil Motion Control, Inc.
270 Technology Way
Rocklin, California
916.626.0101
support@galil.com
galil.com
07/2022

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Summary of Contents for Galil Motion Control DMC-41x3

  • Page 1 USER MANUAL DMC-41x3 Manual Rev. 1.3h Galil Motion Control, Inc. 270 Technology Way Rocklin, California 916.626.0101 support@galil.com galil.com 07/2022...

  • Page 2: Using This Manual

    Galil Website. http://galil.com/downloads/manuals-and-data-sheets Your DMC-41x3 motion controller has been designed to work with both servo and stepper type motors. Installation and system setup will vary depending upon whether the controller will be used with stepper motors or servo motors. To make finding the appropriate instructions faster and easier, icons will be next to any information that applies exclusively to one type of system.

  • Page 3: Table Of Contents

    Overview of Motor Types ..................... 6 Galil Internal Amplifiers and Drivers ................6 Overview of External Amplifiers .................. 7 DMC-41x3 Functional Elements .................. 8 Chapter 2 Getting Started Elements You Need ...................... 11 Installing the DMC, Amplifiers, and Motors ..............12 Chapter 3 Connecting Hardware Overview ........................
  • Page 4 WARRANTY ....................... 186 Integrated Components Overview ........................187 A1 – AMP-430x0 (-D3040,-D3020) Description ........................189 Electrical Specifications ....................190 Servo Motor Operation ....................191 Error Monitoring and Protection ................... 194 A2 – AMP-43140 (-D3140) DMC-41x3 User Manual Rev. 1.3h Contents ▫ iii...
  • Page 5 Stepper Motor Operation ....................237 Error Monitoring and Protection ................... 238 A9 – SDM-44140 (-D4140) Description ........................239 Electrical Specifications ....................240 Stepper Motor Operation ....................241 Error Monitoring and Protection ................... 242 DMC-41x3 User Manual Rev. 1.3h Contents ▫ iv...

  • Page 6: Chapter 1 Overview

    New firmware revisions are easily upgraded in the field. The DMC-41x3 is available with up to eight axes in a single stand alone unit. The DMC-4113, 4123, 4133, 4143 are one through four axis controllers and the DMC-4153, 4163, 4173, 4183 are five through eight axis controllers. All eight axes have the ability to use Galil’s integrated amplifiers or drivers and connections for integrating external...

  • Page 7: Part Numbers

    The DMC-41x3 comes with two form factors: the 1-4 axis models (labeled A-D) and 5-8 axis models (labeled E-H). The number of axis is designated by x in the part number DMC-41x3. In addition, Axis A-D and Axis E-H have their own set of axis-specific options that can be ordered.
  • Page 8 The full DMC-41x3 part number is a combination of the DMC controller part number (DMC-41x3), form factor (“- XXXX(Y)), axis-specific options (-ABCD(Y) and -EFGH(Y)), and optional amplifier types (-DXXXX(Y)), where Y is customization options for that specific board or set of axis. The layout of the full DMC-41x3 part number is shown in Figure 1.3 below.
  • Page 9 Figure 1.2 and the second AMP/SDM (Axis E-H) will be placed in the AMP(2) spot. Many “Y” options can be ordered per board or set of axis if separated by a comma. Please use the DMC-41x3 part number generator to check the validity of all part numbers before ordering: http://galil.com/order/part-number-generator/dmc-41x3...
  • Page 10 SR-49000 Shunt regulator option Solid state relay 100mA 100mA current Not available for all amplifier options, see the proper -D3140 option only documentation. HALLF Filtered hall inputs Table 1.4: Brief list of amplifier options Chapter 1 Overview ▫ 5 DMC-41x3 User Manual...

  • Page 11: Overview Of Motor Types

    Stepper Motor with Step and Direction Signals The DMC-41x3 can control stepper motors. In this mode, the controller provides two signals to the driver of the stepper motor: Step and Direction. For stepper motor operation, the controller does not require an encoder and operates the stepper motor in an open loop fashion.

  • Page 12: Overview Of External Amplifiers

    The velocity gain should be set such that an input signal of 10V runs the motor at the maximum required speed. Stepper Motor Amplifiers For step motors, the amplifiers should accept step and direction signals. Chapter 1 Overview ▫ 7 DMC-41x3 User Manual...

  • Page 13: Dmc-41X3 Functional Elements

    DMC-41x3 Functional Elements The DMC-41x3 circuitry can be divided into the following functional groups as shown in Figure 1.4 and discussed below. Figure 1.4: DMC-41x3 Functional Elements Microcomputer Section The main processing unit of the controller is a specialized Microcomputer with RAM and Flash EEPROM. The RAM provides memory for variables, array elements, and application programs.

  • Page 14: System Elements

    A high speed encoder compare output is also provided. System Elements As shown in Figure 1.5, the DMC-41x3 is part of a motion control system which includes amplifiers, motors and encoders. These elements are described below.

  • Page 15: Watchdog Timer

    12 Volts can be input directly to the DMC-41x3. Single-ended 12 Volt signals require a bias voltage input to the complementary inputs. The DMC-41x3 can accept analog feedback (±10v) instead of an encoder for any axis. For more information see the command in the command reference.

  • Page 16: Chapter 2 Getting Started

    6. PC running Windows 7 or newer (64 bit) or Linux (64 bit) 7. Ethernet cable or USB cable 8. GDK software GDK is recommended for first time users of the DMC-41x3. It provides interactive instructions for system connection, tuning, and analysis. Chapter 2 Getting Started ▫ 11...

  • Page 17: Installing The Dmc, Amplifiers, And Motors

    The following instructions are given for Galil products only. If wiring an non-Galil device, follow the NOTE instructions provided with that product. Galil shall not be liable or responsible for any incidental or consequential damages that occur to a 3 party device. Chapter 2 Getting Started ▫ 12 DMC-41x3 User Manual...
  • Page 18 The type of feedback the controller is capable of interfacing with depends on the additional options ordered for the controller. Table 2.1 shows the different encoder feedback types available for the DMC-41x3 including which options are required. Note that each feedback type has a different configuration command. See the Command Reference for full details on how to properly configure each axis.
  • Page 19 Table 2.3: Amplifier documentation location, commutation method(s), and hall sensor requirements for each internal amplifier. Pin-outs for the hall sensor inputs can be found in the Encoder 26 pin HD D-Sub Connector (Female) section on page 180. Chapter 2 Getting Started ▫ 14 DMC-41x3 User Manual...
  • Page 20 System connection procedures will depend on system components and motor types. Any combination of motor types can be used with the DMC-41x3. There can also be a combination of axes running from Galil integrated amplifiers and drivers and external amplifiers or drivers.
  • Page 21 Step C. Connect the command signals The DMC-41x3 has two ways of controlling amplifiers: 1. Using a motor command line (±10V analog output). The motor and the amplifier may be configured in torque or velocity mode. In the torque mode, the amplifier gain should be such that a 10V signal generates the maximum required current.
  • Page 22 GDK will automatically setup the computer for serial communication. For Ethernet communication, see this video for how to configure your NIC card using Windows to connect to a DMC controller: http://galil.com/learn/online-videos/basics-galil-design-kit-manager-terminal-and-editor See the GDK manual for using the software to communicate: http://galil.com/sw/pub/all/doc/gdk/man/ Chapter 2 Getting Started ▫ 17 DMC-41x3 User Manual...
  • Page 23 (#LIMSWI), large following error (#POSERR), amplifier errors (TA, #AMPERR), and more. For a full list of features and how to program each see Chapter 8 Hardware & Software Protection, pg 149. Chapter 2 Getting Started ▫ 18 DMC-41x3 User Manual...
  • Page 24 For additional tuning resources and guides, see the following Application Notes: Manual Tuning Methods: http://www.galil.com/download/application-note/note3413.pdf Manual Tuning using the Velocity Zone method: http://www.galil.com/download/application- note/note5491.pdf For information about the Autotuning Tool in GDK: http://galil.com/sw/pub/all/doc/gdk/man/tuner.html Chapter 2 Getting Started ▫ 19 DMC-41x3 User Manual...

  • Page 25: Chapter 3 Connecting Hardware

    Chapter 3 Connecting Hardware Overview The DMC-41x3 provides optoisolated digital inputs for forward limit, reverse limit, home, and abort signals. The controller also has 8 optoisolated, uncommitted inputs (for general use) as well as 8 optoisolated outputs and 8 analog inputs configured for voltages between ±10 volts. Controllers with 5 or more axes have an additional 8 optoisolated inputs and an additional 8 optoisolated outputs.
  • Page 26 A transition in the logic state of the Home input will cause the controller to execute a homing routine specified by the user. There are three homing routines supported by the DMC-41x3: Find Edge (FE), Find Index (FI), and Standard Home (HM).

  • Page 27: Abort Input

    When the Reset line is triggered the controller will be reset. The reset line and reset button will not Master Reset the controller unless the MRST jumper is installed during a controller reset. Uncommitted Digital Inputs The DMC-41x3 has 8 optoisolated inputs. These inputs can be read individually using the function @IN[n] where specifies the input number (1 through 8).

  • Page 28: Optoisolated Input Electrical Information

    See the Input Current Limitations section on pg. 178 for more details. The DMC-41x3's optoisolated inputs are rated to operate with a supply voltage of 5-24 VDC. The optoisolated inputs are powered in banks. For example, INCOM (Bank 0), located on the 44-pin I/O (A-D) D-sub connector, provides power to DI[8:1] (digital inputs), the abort input (ABRT), reset (RST), and electric lock-out (ELO).
  • Page 29 INCOM/LSCOM (Bank 1) and their corresponding inputs. NOTE: 's Step-By-Step tool provides an interactive guide to wiring and configuring the home and limit switches. Figure 3.1: Digital Inputs 1-8 (DI[8:1]) Figure 3.2: Digital Inputs 9-16 (DI[16:9]) Chapter 3 Connecting Hardware ▫ 24 DMC-41x3 User Manual...
  • Page 30 Figure 3.3: Limit Switch Inputs for Axes A-D Figure 3.4: Limit Switch Inputs for Axes E-H Figure 3.5: ELO, Abort and Reset Inputs Chapter 3 Connecting Hardware ▫ 25 DMC-41x3 User Manual...

  • Page 31: Optoisolated Outputs

    4mA Sinking Optoisolated Outputs (Default) Description The default outputs of the DMC-41x3 are capable of 4mA and are configured as sinking outputs. The voltage range for the outputs is 5-24 VDC. These outputs should not be used to drive inductive loads directly.
  • Page 32 Bank 1 in Figure 3.9. Refer to Pin-outs in the Appendix for pin-out information. Figure 3.8: 25mA sinking wiring diagram for Bank 0, DO[8:1] Figure 3.9: 25mA sinking wiring diagram for Bank 1, DO[16:9] Chapter 3 Connecting Hardware ▫ 27 DMC-41x3 User Manual...
  • Page 33 Figure 3.10 and Bank 1 in Figure 3.11. Refer to Pin-outs in the Appendix for pin-out information. Figure 3.10: 25mA sourcing wiring diagram for Bank 0, DO[8:1] Figure 3.11: 25mA sourcing wiring diagram for Bank 1, DO[16:9] Chapter 3 Connecting Hardware ▫ 28 DMC-41x3 User Manual...
  • Page 34 Figure 3.12 and Bank 1 in Figure 3.13. Refer to Pin-outs in the Appendix for pin-out information. Figure 3.12: 500mA sourcing wiring diagrams for Bank 0, DO[8:1] Figure 3.13: 500mA sourcing wiring diagram for Bank 1, DO[16:9] Chapter 3 Connecting Hardware ▫ 29 DMC-41x3 User Manual...

  • Page 35: Ttl Inputs And Outputs

    '+' inputs are internally pulled-up to 5V through a 4.7kΩ resistor '-' inputs are internally biased to ~1.3V pulled up to 5V through a 7.1kΩ resistor pulled down to GND through a 2.5kΩ resistor Chapter 3 Connecting Hardware ▫ 30 DMC-41x3 User Manual...

  • Page 36: Output Compare

    I/O (E-H) D-Sub connector. For additional information see Error Light (Red LED) in Chapter 9 Troubleshooting. Electrical Specifications Output Voltage 0 – 5 VDC Current Output 20 mA Sink/Source Chapter 3 Connecting Hardware ▫ 31 DMC-41x3 User Manual...

  • Page 37: Analog Inputs

    Analog Inputs The DMC-41x3 has eight analog inputs configured for the range between -10V and 10V. The inputs are decoded by a 12-bit A/D decoder giving a voltage resolution of approximately .005V. A 16-bit ADC is available as an option (Example: DMC-4123-CARD(-16bit)).

  • Page 38: External Amplifier Interface

    External Servo Control The DMC-41x3 command voltage ranges between ±10V and is output on the motor command line - MCMn (where n is A-H). This signal, along with GND, provides the input to the motor amplifiers. The amplifiers must be sized to drive the motors and load.
  • Page 39 Chapter 3 Connecting Hardware ▫ 34 DMC-41x3 User Manual...
  • Page 40 Chapter 3 Connecting Hardware ▫ 35 DMC-41x3 User Manual...
  • Page 41 Chapter 3 Connecting Hardware ▫ 36 DMC-41x3 User Manual...
  • Page 42 Chapter 3 Connecting Hardware ▫ 37 DMC-41x3 User Manual...

  • Page 43: Chapter 4 Software Tools And Communication

    USB port back through the USB port, and to commands which are sent via the Ethernet port back through the Ethernet port. For instructions that return data, such as Tell Position (TP), the DMC-41x3 will return the data followed by a carriage return, line feed and colon.

  • Page 44: Unsolicited Messages Generated By Controller

    In this case, characters will continue to build up in the controller until the FIFO is full. For more information, see the command in the Command Reference. Chapter 4 Software Tools and Communication ▫ 39 DMC-41x3 User Manual...

  • Page 45: Usb And Rs-232 Ports

    USB Port The USB port on the DMC-41x3 is a USB to serial converter. It should be setup for 115.2kB, 8 Data bits, No Parity, 1 Stop Bit and Flow Control set for Hardware. The baud rate can be changed to 19200 baud by installing the 19.2 jumper on JP1, but this configuration is only recommended if a slower baud rate is required from the host communication.
  • Page 46 RTS and CTS lines. The RTS line will go high whenever the DMC-41x3 is not ready to receive additional characters. The CTS line will inhibit the DMC-41x3 from sending additional characters. Note, the CTS line goes high for inhibit.

  • Page 47: Ethernet Configuration

    0. Either a BOOT-P server on the internal network or the Galil software may be used. When opening the Galil Software, it will respond with a list of all DMC-41x3’s and other controllers on the network that do not currently have IP addresses. The user must select the board and the software will assign the specified IP address to it.
  • Page 48 The third level of Ethernet addressing is the UDP or TCP port number. The Galil board does not require a specific port number. The port number is established by the Client each time it connects to the DMC-41x3 board. Typical...

  • Page 49: Using Third Party Software

    Read Holding Registers (Read Words) Preset Multiple Registers (Write Words) When the DMC-41x3 is setup as a Client, the DMC-41x3 can read from and write to the memory space of a Server by using the command. When the DMC-41x3 is setup as a Server, the Client can read from or write to 1000 elements of the array space of the DMC-41x3.
  • Page 50 16 bits where as step 3b will only set the specified bits and will have no affect on the others. Bit Number Status Bit Number Status Chapter 4 Software Tools and Communication ▫ 45 DMC-41x3 User Manual...
  • Page 51 3. Send the appropriate MB command. Use function code 16. Start at address 30000 and write to 2 registers using the data in the array pump[] MBB=,16,30000,2,pump[] Results: Analog output will be set to 0x40933333 which is 4.6V Chapter 4 Software Tools and Communication ▫ 46 DMC-41x3 User Manual...

  • Page 52: Data Record

    Data Record The DMC-41x3 can provide a binary block of status information with the use of the commands. These commands, along with the command can be very useful for accessing complete controller status. The command will return 4 bytes of header information and specific blocks of information as specified by the...
  • Page 53 D User defined variable (ZAD) 366-369 H User defined variable (ZAH) Will be either a Signed Word or Unsigned Word depending upon AQ setting. See AQ in the Command Reference for more information. Chapter 4 Software Tools and Communication ▫ 48 DMC-41x3 User Manual...
  • Page 54 BIT 4 BIT 3 BIT 2 BIT 1 BIT 0 State of Latch State of State of Reverse State of Home Stepper Mode Latch Occurred Input Forward Limit Limit Input Chapter 4 Software Tools and Communication ▫ 49 DMC-41x3 User Manual...
  • Page 55 Number of Bytes in each axis block of data record Chapter 4 Software Tools and Communication ▫ 50 DMC-41x3 User Manual...

  • Page 56: Galil Software

    For new applications, Galil recommends the current generation communication libraries located on the Galil Website: http://galil.com/downloads/api Please visit the API examples page under the Learn section for details on getting started developing custom software interfaces for Galil controllers: http://galil.com/learn/api-examples Chapter 4 Software Tools and Communication ▫ 51 DMC-41x3 User Manual...

  • Page 57: Chapter 5 Command Basics

    Combining commands into groups for later execution is referred to as Applications Programming and is discussed in the following chapter. This section describes the DMC-41x3 instruction set and syntax. A summary of commands as well as a complete listing of all DMC-41x3 instructions is included in the Command Reference.
  • Page 58 Request B value only Explicit Notation The DMC-41x3 provides an alternative method for specifying data. Here data is specified individually using a single axis specifier such as A, B, and D. An equals sign is used to assign data to that axis. For example:...

  • Page 59: Controller Response To Data

    Interrogation Commands The DMC-41x3 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.

  • Page 60: Command Summary

    The controller can also be interrogated with operands. Operands Most DMC-41x3 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...

  • Page 61: Chapter 6 Programming Motion

    Chapter 6 Programming Motion Overview The DMC-41x3 provides several modes of motion, including independent positioning and jogging, coordinated motion, electronic cam motion, and electronic gearing. Each one of these modes is discussed in the following sections. The DMC-4113 is a single axis controller and uses A-axis motion only. Likewise, the DMC-4123 uses A and B, the DMC-4133 uses A, B and C, and the DMC-4143 uses A, B, C and D.

  • Page 62: Independent Axis Positioning

    Motion is complete when the last position command is sent by the DMC-41x3 profiler. The actual motor motion may not be complete when the profile has been completed, however, the next motion command may be specified.
  • Page 63 'begin motion on the A axis 'wait 20 msec 'begin motion on the B axis 'wait 20 msec 'begin motion on C axis ABC; 'disable A, B, and C axes 'end Program Chapter 6 Programming Motion ▫ 58 DMC-41x3 User Manual...

  • Page 64: Independent Jogging

    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-41x3 converts the velocity profile into a position trajectory and a new position target is generated every sample period.

  • Page 65: Position Tracking

    In this mode, the position can be updated randomly or at a fixed time rate, but the velocity profile will always be trapezoidal with the parameters Chapter 6 Programming Motion ▫ 60 DMC-41x3 User Manual...
  • Page 66 'disable A axis 'end program The output from this code can be seen in Figure 6.2, a screen capture from the GDK scope. Figure 6.2: Position vs Time (msec) - Motion 1 Chapter 6 Programming Motion ▫ 61 DMC-41x3 User Manual...
  • Page 67 'move forward to absolute position 4200 2000; 'change end point position to position 2000 'after motion 'disable A axis 'end program Figure 6.3: Position and Velocity vs Time(msec) for Motion 2 Chapter 6 Programming Motion ▫ 62 DMC-41x3 User Manual...
  • Page 68 DC. Figure 6.4: Position and Velocity vs Time (msec) for Motion 3 Figure 6.5: Position and Velocity vs Time (msec) for Motion 3 with IT 0.1 Chapter 6 Programming Motion ▫ 63 DMC-41x3 User Manual...

  • Page 69: Linear Interpolation Mode

    Table 6.4: List of commands for Position Tracking Mode Linear Interpolation Mode The DMC-41x3 provides a linear interpolation mode for 2 or more axes. In linear interpolation mode, motion between the axes is coordinated to maintain the prescribed vector speed, acceleration, and deceleration along the specified path.
  • Page 70 This function allows the host computer to determine which segment is being processed. Additional Commands The commands VS, VA, and are used to specify the vector speed, acceleration and deceleration. The DMC-41x3 computes the vector speed based on the axes specified in the mode. For example, designates linear interpolation for the A,B and C axes.
  • Page 71 Linear End- Required at end of LI command sequence Trippoint for After Sequence complete Trippoint for After Relative Vector distance S curve smoothing constant for vector moves Table 6.5: List of commands for Linear Interpolation Mode Chapter 6 Programming Motion ▫ 66 DMC-41x3 User Manual...
  • Page 72 Note that the above program specifies the vector speed, VS, and not the actual axis speeds VC and VD. The axis speeds are determined by the controller from: √ The result is shown in Figure 6.6: Linear Interpolation on the next page. Chapter 6 Programming Motion ▫ 67 DMC-41x3 User Manual...
  • Page 73 'specify linear segment count=count+1; 'increment array counter JP#loop2,(count<750); 'repeat until array done 'end linear move 'after move sequence done "DONE"; 'send message 'end program #c;BG S;AM S;MO AB;EN; 'begin motion subroutine Chapter 6 Programming Motion ▫ 68 DMC-41x3 User Manual...

  • Page 74: Vector Mode: Linear And Circular Interpolation Motion

    Vector Mode: Linear and Circular Interpolation Motion The DMC-41x3 allows a long 2-D path consisting of linear and arc segments to be prescribed. Motion along the path is continuous at the prescribed vector speed even at transitions between linear and circular segments. The DMC-41x3 performs all the complex computations of linear and circular interpolation, freeing the host PC from this time intensive task.

  • Page 75: Additional Commands

    2000 Compensating for Differences in Encoder Resolution By default, the DMC-41x3 uses a scale factor of 1:1 for the encoder resolution when used in vector mode. If this is not the case, the command, can be used to scale the encoder counts. The command accepts two arguments which represent the number of counts for the two encoders used for vector motion.
  • Page 76 Tangent scale and offset Ellipse scale factor S curve smoothing constant for coordinated moves Specifies which coordinate system is to be active, S or T Table 6.7: List of commands related to Vector Mode Chapter 6 Programming Motion ▫ 71 DMC-41x3 User Manual...
  • Page 77 _AVm Contains the vector distance from the start of the sequence for the 'm' coordinate system Number of available spaces for linear and circular segments in DMC-41x3 sequence buffer _LMm 0 means buffer is full, 511 means buffer is empty...
  • Page 78  k  Where Xk and Yk are the changes in X and Y positions along the linear segment. The length of the circular arc is   2 360  Chapter 6 Programming Motion ▫ 73 DMC-41x3 User Manual...
  • Page 79 Figure 6.10 on the next page shows the vector velocity. It also indicates the position point along the path starting at A and ending at D. Between the points A and B, the motion is along the Y axis. Therefore, Vy = Vs Vx = 0 Chapter 6 Programming Motion ▫ 74 DMC-41x3 User Manual...

  • Page 80: Electronic Gearing

    1:1 when the gearing is engaged, the Follower will instantly develop following error, and command maximum current to the motor. This can be a large shock to the system. For many applications it is acceptable to slowly ramp Chapter 6 Programming Motion ▫ 75 DMC-41x3 User Manual...
  • Page 81 'disable C axis for Master GA C, 'specify C axis as the Master axis for both A and B axes 6000,6000; 'specify ramped gearing over 6000 counts of the Master axis Chapter 6 Programming Motion ▫ 76 DMC-41x3 User Manual...
  • Page 82 'specify gear ratios Now suppose the gear ratio of the axis is to change on-the-fly to 2. This can be achieved by commanding: 'specify gear ratio for A axis to be 2 Chapter 6 Programming Motion ▫ 77 DMC-41x3 User Manual...
  • Page 83 Example - Gantry Mode In applications where both the Master and the Follower are controlled by the DMC-41x3 controller, it may be desired to synchronize the Follower with the commanded position of the Master, rather than the actual position. This eliminates the coupling between the axes which may lead to oscillations.

  • Page 84: Electronic Cam

    The table elements start at zero and may go up to 256. The parameters indicate the corresponding Follower position. ET[0]=,0 ET[1]=,3000 ET[2]=,2250 ET[3]=,1500 The ECAM table has now been completed. Step 5. Enable the ECAM command enables the ECAM mode. Chapter 6 Programming Motion ▫ 79 DMC-41x3 User Manual...
  • Page 85 'loop to construct table from equation p=n*3.6; '3.6 = 0.18 * 20 s=@SIN[p]*100; 'define sine position y=n*10+s; 'define Follower position ET[n]= 'define table n=n+1; 'increment index JP#loop, (n<=100); 'repeat the process 'end program Chapter 6 Programming Motion ▫ 80 DMC-41x3 User Manual...
  • Page 86 Contains size of cycle for each axis Contains value of the ECAM table interval Contains ECAM status for each axis _EQm Set ECAM cycle count Table 6.11: List of operands related to Electronic CAM Chapter 6 Programming Motion ▫ 81 DMC-41x3 User Manual...
  • Page 87 ECAM cycles. The first trace is for the axis, the second trace shows the cycle on the axis and the third trace shows the cycle of the axis. Figure 6.14: ECAM cycle with C axis as Master Chapter 6 Programming Motion ▫ 82 DMC-41x3 User Manual...

  • Page 88: Pvt Mode

    PVT Mode The DMC-41x3 controllers now supports a mode of motion referred to as “PVT.” This mode allows arbitrary motion profiles to be defined by position, velocity and time individually on all 8 axes. This motion is designed for systems where the load must traverse a series of coordinates with no discontinuities in velocity.
  • Page 89 . 1 ( p(1 to 1.25) = 245 937.5  . 1 ( p(1.25 to 1.5) = 214  p(1.5 to 1.75) = 151 . 1 ( 437.5 p(1.75 to 2) =57 Chapter 6 Programming Motion ▫ 84 DMC-41x3 User Manual...
  • Page 90 In this example we will have a 2 dimensional stage that needs to follow a specific profile. The application requires that the certain points be met however the path between points is not important. Smooth motion between points is critical. Chapter 6 Programming Motion ▫ 85 DMC-41x3 User Manual...
  • Page 91 X vs Y Commanded Positions 6000 5000 4000 3000 2000 1000 1000 2000 3000 4000 5000 6000 7000 8000 -1000 X Axis (Counts) Figure 6.17: X vs Y Commanded Positions for Multi-Axis Coordinated Move Chapter 6 Programming Motion ▫ 86 DMC-41x3 User Manual...

  • Page 92: Contour Mode

    Contour Mode The DMC-41x3 also provides a contouring mode. This mode allows any arbitrary position curve to be prescribed for 1 to 8 axes. This is ideal for following computer generated paths such as parabolic, spherical or user-defined profiles. The path is not limited to straight line and arc segments and the path length may be infinite.
  • Page 93 Note that the velocity, ω, in count/ms, is ω = 50 [1 - cos 2π T/120] The DMC-41x3 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 Figure 6.19: Velocity Profile with Sinusoidal Acceleration...
  • Page 94 Several applications require teaching the machine a motion trajectory. Teaching can be accomplished using the DMC-41x3 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:...

  • Page 95: Virtual Axis

    Virtual Axis The DMC-41x3 controller has two additional virtual axes designated as the axes. These axes have no encoder and no DAC. However, they can be commanded by the commands: AC, DC, JG, SP, PR, PA, BG, IT, GA, VM, VP, CR, ST, DP, The main use of the virtual axes is to serve as a virtual Master in ECAM modes, and to perform an unnecessary part of a vector mode.

  • Page 96: Stepper Motor Operation

    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, (Reference Position). gives the absolute value of the position as determined by the motion profiler. Chapter 6 Programming Motion ▫ 91 DMC-41x3 User Manual...

  • Page 97: Stepper Position Maintenance Mode (Spm)

    Contains the value of the Stepper Motor Smoothing Constant for the 'm' axis _MTm Contains the motor type value for the 'm' axis Table 6.16: List of operands related to Stepper motor operation Chapter 6 Programming Motion ▫ 92 DMC-41x3 User Manual...
  • Page 98 Under SPM mode, the motor will not be OEm=1 disabled by position error. is set to 2, which causes the automatic subroutine labeled to be executed. #POSERR Chapter 6 Programming Motion ▫ 93 DMC-41x3 User Manual...
  • Page 99 'save current speed setting #return,(_YSA<>2); 'return to thread zero if invalid error 'set slow speed setting for correction "ERROR= ",_QSA YRA=_QSA; 'use QS for correction 'wait for motion to complete Chapter 6 Programming Motion ▫ 94 DMC-41x3 User Manual...
  • Page 100 'stabilize #end,(@ABS[_QSA]<10); 'end correction if error is within defined tolerance YRA=_QSA; 'correction move 100; 'stabilize #loop; 'keep correcting until error is within tolerance #end; 'end #CORRECT subroutine, returning to code SPA=spa Chapter 6 Programming Motion ▫ 95 DMC-41x3 User Manual...

  • Page 101: Dual Loop (Auxiliary Encoder)

    Dual Loop (Auxiliary Encoder) The DMC-41x3 provides an interface for a second encoder for each axis except for axes configured for stepper motor operation and axis used in circular compare. When used, the second encoder is typically mounted on the motor or the load, but may be mounted in any position.
  • Page 102 'find linear encoder error v2=-_TEA/4+v1; 'compensate for motor error #end,(@ABS[v2]<error); 'exit if error is small v2*4; 'correction move 'start correction #correct; 'repeat correction move #end;EN; 'end program Chapter 6 Programming Motion ▫ 97 DMC-41x3 User Manual...

  • Page 103: Motion Smoothing

    Motion Smoothing The DMC-41x3 controller allows the smoothing of the velocity profile to reduce the mechanical vibration of the system. Trapezoidal velocity profiles have acceleration rates which change abruptly from zero to maximum value. The discontinuous acceleration results in jerk which causes vibration. The smoothing of the acceleration profile leads to a continuous acceleration profile and reduces the mechanical shock and vibration.

  • Page 104: Homing

    The motor traverses forward at HV counts/sec until the encoder index pulse is detected. The motor then decelerates to a stop and goes back to the index. The DMC-41x3 defines the home position as the position at which the index was detected and sets the encoder reading at this point to zero.
  • Page 105 BEGINS IN FORWARD DIRECTION POSITION VELOCITY MOTION CHANGES DIRECTION POSITION VELOCITY MOTION IN FORWARD DIRECTION TOWARD INDEX POSITION INDEX PULSES POSITION Figure 6.22: Homing Sequence for Normally Closed Switch and CN,-1 Chapter 6 Programming Motion ▫ 100 DMC-41x3 User Manual...
  • Page 106 Contains the state of the Home Input for the 'm' axis _SCm Contains stop code for the 'm' axis _TSm Contains status of switches and inputs for the 'm' axis Table 6.20: List of operands related to Homing Chapter 6 Programming Motion ▫ 101 DMC-41x3 User Manual...

  • Page 107: High Speed Position Capture (The Latch Function)

    The latch must be re-armed after each latching event. See the Command Reference for more details on these commands. Chapter 6 Programming Motion ▫ 102 DMC-41x3 User Manual...

  • Page 108: Chapter 7 Application Programming

    Each DMC-41x3 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.

  • Page 109: Special Labels

    Using Labels in Programs All DMC-41x3 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.

  • Page 110: Commenting Programs

    The DMC-41x3 provides a command, NO, for commenting programs or single apostrophe. This command allows the user to include up to 78 characters on a single line after the command and can be used to include...

  • Page 111: Executing Programs - Multitasking

    Executing Programs - Multitasking The DMC-41x3 can run up to 8 independent programs simultaneously. These programs are called threads and are numbered 0 through 7, where 0 is the main thread. Multitasking is useful for executing independent operations such as PLC functions that occur independently of motion.

  • Page 112: Debugging Programs

    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-41x3 has several useful commands. The command, DM?, will return the number of array elements currently available. The command, DA?, will return the number of arrays which can be currently defined.
  • Page 113 'position relative move of 5000 counts 'end program From Terminal :XQ #a :?4 PR 5000 7 Command not valid while running Change line 4 of BGA;AMA and re-download the program. :XQ #a Chapter 7 Application Programming ▫ 108 DMC-41x3 User Manual...

  • Page 114: Program Flow Commands

    The DMC-41x3 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.
  • Page 115 #input; 'program label 'wait for input 1 to be active 'enable A axis 10000; 'position relative command 'begin motion 'wait for motion to finish 'disable A axis 'end program Chapter 7 Application Programming ▫ 110 DMC-41x3 User Manual...
  • Page 116 'wait for motion to finish 200; wait 200 ms -10000; 'define new position move 30000; 'set new speed 150000; 'set new acceleration 'begin motion 'wait for motion to finish 'disable A axis 'end program Chapter 7 Application Programming ▫ 111 DMC-41x3 User Manual...

  • Page 117: Conditional Jumps

    Conditional jumps are useful for testing events in real-time. They allow the controller to make decisions without a host computer. For example, the DMC-41x3 can decide between two motion profiles based on the state of an input line.

  • Page 118: Conditional Statements

    _TPA=0 _TVA>500 v1>@AN[2] @IN[1]=0 Multiple Conditional Statements The DMC-41x3 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.
  • Page 119 This technique is known as 'nesting' and the DMC-41x3 allows up to 255 conditional statements to be nested. This is a very powerful technique allowing the user to specify a variety of different cases for branching.
  • Page 120 'begin motion on A axis only 'wait for motion to finish on A axis only 'begin motion on B axis only 'wait for motion to finish on B axis only 'end subroutine Chapter 7 Application Programming ▫ 115 DMC-41x3 User Manual...

  • Page 121: Stack Manipulation

    #LIMSWI Auto-Start Routine The DMC-41x3 has a special label for automatic program execution. A program which has been saved into the controller's non-volatile memory can be automatically executed upon power up or reset by beginning the program with the label #AUTO. The program must be saved into non-volatile memory using the command BP.
  • Page 122 This program prints a message upon the occurrence of a limit switch. For the routine to function, the #LIMSWI DMC-41x3 must be executing an applications program from memory. This can be a very simple program that does nothing but loop on a statement, such as #LOOP;EN. Motion commands, such as can still be #LOOP;JP...
  • Page 123 #done,(_TC<>6); 'check if out of range for JG command "SPEED TOO HIGH"; 'send message "TRY AGAIN"; speed=_JGA; 'keep current jog speed #done; 'zero stack #loop; 'return to main loop 'end program Chapter 7 Application Programming ▫ 118 DMC-41x3 User Manual...
  • Page 124 'wait for motion to be complete PAA=0; 'move to absolute position 0 'begin motion on a axis 'wait for motion to be complete #loop; 'continually loop to make back and forth motion 'end main program Chapter 7 Application Programming ▫ 119 DMC-41x3 User Manual...
  • Page 125 #var; 'label for main program value=5; 'value to be passed by reference global=8; 'global variable #SUM 'first argument passed by reference (&value,1,2,3,4,5,6,7); value; 'message value after subroutine _JS; 'message returned value Chapter 7 Application Programming ▫ 120 DMC-41x3 User Manual...
  • Page 126 #pwrhlpr; 'label for loop for calculations ^c=^c*^a; 'multiply through ^b=^b-1; 'decrement index #pwrhlpr,(^b>0); 'loop while index is above 0 (^d=1); 'if exponent is negative ^c=(1/^c); 'invert value ENDIF; EN,,^c; 'return value Chapter 7 Application Programming ▫ 121 DMC-41x3 User Manual...
  • Page 127 The key to having a deterministic loop time is to have a trippoint that will wait a specified time independent of the time it took to execute the loop code. In this definition, the command is a perfect fit. Chapter 7 Application Programming ▫ 122 DMC-41x3 User Manual...

  • Page 128: Mathematical And Functional Expressions

    Mathematical and Functional Expressions Mathematical Operators For manipulation of data, the DMC-41x3 provides the use of the following mathematical operators: OPERATOR DESCRIPTION Addition Subtraction Multiplication Division Modulo Division & Logical And (Bit-wise) Logical Or (Bit-wise) Parenthesis Table 7.7: List of mathematical operators Mathematical operations are executed from left to right.

  • Page 129: Bit-Wise Operators

    & & Logical Or. These operators allow for bit-wise operations on any valid DMC-41x3 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.
  • Page 130 'set v2 equal to five * sine of the variable pos v3=@IN[1]; 'set v3 equal to value of Digital Input 1 v4=2*(5+@AN[5]); 'set v4 equal to value of Analog Input 5 plus 5, then multiplied by 2 Chapter 7 Application Programming ▫ 125 DMC-41x3 User Manual...

  • Page 131: Variables

    Programmable Variables The DMC-41x3 allows the user to create up to 510 variables. Each variable is defined by a name which can be up to eight characters. The name must start with an alphabetic character; however, numbers are permitted in the rest of the name.
  • Page 132 'read joystick Y and calculate speed vA,vB; 'jog at calculated speeds vA and vB -20; 'wait 20ms from last time reference, creates a deterministic loop time #loop; 'jump back to loop label 'end program Chapter 7 Application Programming ▫ 127 DMC-41x3 User Manual...

  • Page 133: Operands

    Operands can be used in an expression and assigned to a programmable variable, but they cannot be assigned a value. For example: is invalid. _KDA=2 Special Operands The DMC-41x3 provides a few additional operands which give access to internal variables that are not accessible by standard DMC-41x3 commands. OPERAND DESCRIPTION _BGm...

  • Page 134: Arrays

    Arrays For storing and collecting numerical data, the DMC-41x3 provides array space for 24000 elements. The arrays are one dimensional and up to 30 different arrays may be defined. Each array element has a numeric range of 4 bytes of integer (2 ) followed by two bytes of fraction (±2,147,483,647.9999).
  • Page 135 Automatic Data Capture into Arrays The DMC-41x3 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 eight types of data can be captured and stored in eight arrays.
  • Page 136 'send message of recorded position errors ,erA[i],erB[i]; i=i+1; 'increment counter #message,(i<300); 'loop while counting through elements in arrays 'end program De-allocating Array Space Array space may be de-allocated using the command followed by the array name. Chapter 7 Application Programming ▫ 131 DMC-41x3 User Manual...

  • Page 137: Input Of Data (Numeric And String)

    Sending Data from a Host The DMC-41x3 can accept ASCII strings from a host. This is the most common way to send data to the controller such as setting variables to numbers or strings. Any variable can be stored in a string format up to 6 characters by simply specifying defining that variable to the string value with quotes.
  • Page 138 Example – Communication Interrupts A DMC-41x3 is used to jog the A and B axis. This program automatically begins upon power-up and allows the user to input values from the main USB port terminal. The speed of either axis may be changed during motion by specifying the axis letter followed by the new speed value.

  • Page 139: Output Of Data (Numeric And String)

    The DMC-41x3, stores all variables as 6 bytes of information. When a variable is specified as a number, the value of the variable is represented as 4 bytes of integer and 2 bytes of fraction. When a variable is specified as a string, the variable can hold up to 6 characters (each ASCII character is 1 byte).
  • Page 140 'wait for motion to finish 'disable A axis v1=_TPA; 'set variable to A axis motor position posA[1]=_RPA; 'assign array element to A axis reference position v1=?; 'print v1 posA[1]=; 'print posA[1] 'end program Chapter 7 Application Programming ▫ 135 DMC-41x3 User Manual...
  • Page 141 Interrogation Commands The DMC-41x3 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.
  • Page 142 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-41x3 position parameters such as PR, PA, and have units of quadrature counts. Speed parameters such as SP, JG, and have units of counts/sec.

  • Page 143: Hardware I/O

    'end program Hardware I/O Digital Outputs The DMC-41x3 has an 8-bit uncommitted output port, the DMC-4153 through DMC-4183 has an additional 8 outputs. Each bit on the output port may be set and cleared with the software instructions (Set Bit) and (Clear Bit), or (define output bit).
  • Page 144 The inputs have been configured to accept TTL level signals. To connect TTL signals, simply connect the signal to the + input and leave the - input disconnected. For other signal levels, the - input should be connected to a Chapter 7 Application Programming ▫ 139 DMC-41x3 User Manual...
  • Page 145 @IN[82]. NOTE: The auxiliary encoder inputs are not available for any axis that is configured for stepper motor. Input Interrupt Function The DMC-41x3 provides an input interrupt function which causes the program to automatically execute the instructions following the #ININT label.
  • Page 146 Analog Inputs The DMC-41x3 provides eight analog inputs. See the Integrated Components section for more details. The value of these inputs in volts may be read using the function where n is the analog input 1 through 8. The @AN[n] resolution of the Analog-to-Digital conversion is 12 bits (16-bit ADC is available as an option).
  • Page 147 'increase k2 for more filtering 'set initial time reference #loop; 'label for loop an1=(k1*@AN[1])+(k2*an1); 'calculate filtered input -2,1; 'wait 2 samples from last reference #loop; 'jump back to loop label 'end program Chapter 7 Application Programming ▫ 142 DMC-41x3 User Manual...

  • Page 148: Example Applications

    'wait 80 ms #loop; 'jump to loop label 'end program 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 Chapter 7 Application Programming ▫ 143 DMC-41x3 User Manual...
  • Page 149 Further assume that the Z must move 2" at a linear speed of 2" per second. The X-Y motion is tied to A and B axes while the Z motor is connected to C axis. Figure 7.2: Motor Velocity and the Associated Input/Output signals Chapter 7 Application Programming ▫ 144 DMC-41x3 User Manual...
  • Page 150 'move to return A and B axes to initial position 'end vector sequence 200000; 'set vector speed 'begin vector motion 'wait for motion to finish ABC; 'disable A, B, and C axes 'end program Chapter 7 Application Programming ▫ 145 DMC-41x3 User Manual...
  • Page 151 In those cases, it may be easier to use the sampled dual loop method described below. Chapter 7 Application Programming ▫ 146 DMC-41x3 User Manual...
  • Page 152 'jump to end label if error is within acceptable margin 'command correction move 'begin motion #loop; 'jump to loop label to repeat the process #end; 'label to end program 'end program Chapter 7 Application Programming ▫ 147 DMC-41x3 User Manual...

  • Page 153: Using The Dmc Editor To Enter Programs (Advanced)

    The GDK software package provides an editor and utilities that allow the upload and download of DMC programs to the motion controller. In most instances the user will use Galil software or a host application to download programs to the Galil controller rather than using the command. Chapter 7 Application Programming ▫ 148 DMC-41x3 User Manual...

  • Page 154: Chapter 8 Hardware & Software Protection

    These features help protect the various system components from damage. 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-41x3 is an integral part of the WARNING machine, the engineer should design his overall system with protection against a possible component failure on the DMC-41x3.
  • Page 155 The command can also be configured so that the axis will be disabled upon the activation of a limit switch. Chapter 8 Hardware & Software Protection ▫ 150 DMC-41x3 User Manual...

  • Page 156: Software Protection

    Software Protection The DMC-41x3 provides a programmable error limit as well as encoder failure detection. It is recommended that both the position error and encoder failure detection be used when running servo motors with the DMC-41x3. Along with position error and encoder failure detection, then DMC-41x3 has the ability to have programmable software limit.
  • Page 157 'begin motion, all axes will stop after 3 seconds 'end program Off-On-Error The DMC-41x3 controller has a built in function which can turn off the motors under certain error conditions. This function is known as Off-On-Error and is enabled with the command. When this function is enabled, the...
  • Page 158 Limit Switch Routine The DMC-41x3 provides forward and reverse limit switches which inhibit motion in the respective direction. There is also a special label for automatic execution of a limit switch subroutine. The label specifies the start of #LIMSWI the limit switch subroutine. This label causes the statements following to be automatically executed if any limit switch is activated and that axis motor is moving in that direction.

  • Page 159: Chapter 9 Troubleshooting

    Significant noise can be seen on 1. Noise Shield encoder cables MA+ and / or MB+ encoder signals Avoid placing power cables near encoder cables Avoid Ground Loops Use differential encoders Use ±12V encoders Chapter 9 Troubleshooting ▫ 154 DMC-41x3 User Manual...
  • Page 160 Master Reset jumper. If performing a Master Reset does not get rid of the error light, the controller may need to be sent back to the factory to be repaired. Contact Galil for more information. Chapter 9 Troubleshooting ▫ 155 DMC-41x3 User Manual...

  • Page 161: Chapter 10 Theory Of Operation

    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. Chapter 10 Theory of Operation ▫ 156 DMC-41x3 User Manual...
  • Page 162 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. X VELOCITY Y VELOCITY X POSITION Y POSITION TIME Figure 10.2: Velocity and Position Profiles Chapter 10 Theory of Operation ▫ 157 DMC-41x3 User Manual...

  • Page 163: Operation Of Closed-Loop Systems

    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. Chapter 10 Theory of Operation ▫ 158 DMC-41x3 User Manual...

  • Page 164: System Modeling

    = 14.16 oz - in/A = 0.1 Nm/A R = 2 Ω J = 0.0283 oz-in-s = 2 * 10 kg . m L = 0.004H Chapter 10 Theory of Operation ▫ 159 DMC-41x3 User Manual...

  • Page 165: Velocity Loop

    +1)] where the velocity time constant, T , equals = J/K This leads to the transfer function P/V = 1/[K s(sT +1)]  Kt/Js Figure 10.4: Elements of velocity loops Chapter 10 Theory of Operation ▫ 160 DMC-41x3 User Manual...

  • Page 166: Digital Filter

    The digital filter has three element in series: PID, low-pass and a notch filter. The transfer function of the filter. The transfer function of the filter elements are:   D(z) =  Low-pass L(z) =   Notch N(z) =   Chapter 10 Theory of Operation ▫ 161 DMC-41x3 User Manual...
  • Page 167      where T is the sampling period, and B is the pole setting For example, if the filter parameters of the DMC-41x3 are 0.75 (or 0.001 s) 1000 the digital filter coefficients are K = 160 A = 0.9...

  • Page 168: 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-41x3 controller and the following parameters: = 0.1...
  • Page 169 As long as PM is positive, the system is stable. However, for a well damped system, PM should be between 30° and 45°. The phase margin of 70° given above indicated over-damped response. Next, we discuss the design of control systems. Chapter 10 Theory of Operation ▫ 164 DMC-41x3 User Manual...

  • Page 170: System Design And Compensation

    System Design and Compensation The closed-loop control system can be stabilized by a digital filter, which is preprogrammed in the DMC-41x3 controller. The filter parameters can be selected by the user for the best compensation. The following discussion presents an analytical design method.
  • Page 171 KD = D/T Assuming a sampling period of T=1ms, the parameters of the digital filter are: KP = 82.4 KD = 274 The DMC-41x3 can be programmed with the instruction: KP 82.4;KD Chapter 10 Theory of Operation ▫ 166 DMC-41x3 User Manual...
  • Page 172 In a similar manner, other filters can be programmed. The procedure is simplified by the following table, which summarizes the relationship between the various filters. Equivalent Filter Form - DMC-41x3 Digital D(z) =[K(z-A/z) + Cz/(z-1)]· (1-B)/(Z-B) KP, KD, KI, PLK = (KP + KD)

  • Page 173: Appendices

    Maximum A, B edge rate: 15 MHz Minimum IDX pulse width: 39 nsec Stepper Control STPn (Step) TTL (0-5 volts) level at 50% duty cycle. 3,000,000 pulses/sec maximum frequency DIRn (Direction) TTL (0-5 volts) Appendices ▫ 168 DMC-41x3 User Manual...

  • Page 174: Power Requirements

    *The number of auxiliary inputs is dependent on the number of axes ordered Power Requirements 20-80 V 10 W at 25° C +5, ±12V Power Output Specifications Output Voltage Tolerance Max Current Output ± 1.1A +12V ± 40mA -12V ± 40mA Appendices ▫ 169 DMC-41x3 User Manual...

  • Page 175: Performance Specifications

    2 counts/sec Motor Command Resolution 16 bit or 0.0003 V Variable Range ±2 billion Variable Resolution 1 x 10 Number of Variables Array Size 24000 elements, 30 arrays Program Size 4000 lines x 80 characters Appendices ▫ 170 DMC-41x3 User Manual...

  • Page 176: Ordering Options

    BOX4, BOX8 The BOX4 or BOX8 option on the DMC-41x3 provides a metal enclosure for the controller. BOX4 is the box for the 1-4 axis controllers, the BOX8 is for 5-8 axis controllers. The BOXn option is required when using Galil internal amplifiers and is recommended for any application that requires CE certification.
  • Page 177 DMC-4113-CARD(4-20mA) TRES – Encoder Termination Resistors The TRES option provides termination resistors on all of the main and auxiliary encoder inputs on the DMC-41x3 motion controller. The termination resistors are 120 Ω, and are placed between the positive and negative differential inputs on the Main A, B, Index channels as well as the Auxiliary A and B channels as in Figure A.1.
  • Page 178 LSNK – 25mA Sinking Outputs The LSNK option modifies the digital outputs on the DMC-41x3 to be capable of sinking up to 25mA per output. For detailed information see the 25mA Sinking Optoisolated Outputs (LSNK) section in Chapter 3 Connecting Hardware.
  • Page 179 Shut Regulator, see Application Note #5448: “Shunt Regulator Operation” linked below: http://galil.com/download/application-note/note5448.pdf The SR-49000 is installed inside the box of the DMC-41x3 controller, so it does not effect the form of the unit. As a functional example, -SR90 shunt regulator activates when the voltage supplied to the amplifier rises above 90V.
  • Page 180 The HALLF option will place a capacitor between the hall input and digital GND to filter unwanted noise. This results in cleaner, more reliable hall sensor reads. The HALLF option is only available for Galil's internal PWM amplifiers. Part number ordering example: DMC-4143-BOX4-D3040(HALLF) Appendices ▫ 175 DMC-41x3 User Manual...

  • Page 181: Power Connector Part Numbers

    Galil amplifier or driver, refer to the specific amplifier/driver in the Integrated Components section. Molex Part Numbers There are 3 different Molex connectors used with the DMC-41x3. The type of connectors on any given controller will be determined be the Amplifiers/Drivers that were ordered. Below are tables indicating the type of Molex Connectors used and the specific part numbers used on each Amplifier or Driver.

  • Page 182: Cable Shielding

    The following diagrams illustrate the best means of achieving this with the DMC-41x3, with the expectation that the controller's baseplate is mounted to something with a secure connection to Earth Ground.

  • Page 183: Input Current Limitations

    (Vs). To determine if an additional resistor (R) is required, follow Equation A1 below for guidance. 1 mA< <11 mA R+2200 Ω Equation A1: Current limitation requirements for each input. Appendices ▫ 178 DMC-41x3 User Manual...

  • Page 184: Pin-Outs

    Digital Output 12 DO14 Digital Output 14 DO13 Digital Output 13 DO15 Digital Output 15 OP1B Output PWR/GND (Bank 1) DO16 Digital Output 16 Output Compare (E-H) * ABRT, RST and ELO use INCOM0 Appendices ▫ 179 DMC-41x3 User Manual...
  • Page 185 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 +12V Appendices ▫ 180 DMC-41x3 User Manual...
  • Page 186 The Ethernet connection is Auto MDIX, 100bT/10bT. The USB port on the DMC-41x3 is a Female Type B USB port. The standard cable when communicating to a PC will be a Male Type A – Male Type B USB cable.
  • Page 187 RS-422-Auxiliary Port (Non-Standard Option) Standard connector and cable when DMC-41x3 is ordered with RS-422 Option. For detailed information on the RS- 422 option see RS-422 – Auxiliary Serial Port Serial Communication in the Appendices. Pin # Signal Direction Signal Name...

  • Page 188: Signal Descriptions

    Input 1 is latch A, Input 2 is latch B, Input 3 is latch C and Input 4 is latch D. Input 9 is latch E, input 10 is latch F, input 11 is latch G, input 12 is latch H. Appendices ▫ 183 DMC-41x3 User Manual...
  • Page 189 The (DMC-4153 through 4183) output lines are toggled by Set Bit, SB, and Clear Bit, CB, instructions. The instruction is used to define the state of all the bits of the Output port. Appendices ▫ 184 DMC-41x3 User Manual...

  • Page 190: List Of Other Publications

    “hands-on” seminar and students can test their application on actual hardware and review it with Galil specialists. Attendees must have a current application and recently purchased a Galil controller to attend this course. TIME: Two days (8:30-4:30pm) http://galil.com/learn/classes Appendices ▫ 185 DMC-41x3 User Manual...

  • Page 191: Contacting Us

    18 months after shipment. Motors, and Power supplies are warranted for 1 year. Extended warranties are available. In the event of any defects in materials or workmanship, Galil Motion Control will, at its sole option, repair or replace the defective product covered by this warranty without charge. To obtain warranty service, the defective product must be returned within 30 days of the expiration of the applicable warranty period to Galil Motion Control, properly packaged and with transportation and insurance prepaid.

  • Page 192: Integrated Components

    The AMP-43240 (4-axis) is a trapezoidally commutated transconductance, PWM amplifier for driving brushless or brush-type servo motors. It is capable of providing 750 watts of continuous power per axis. The AMP-43240 Brushless drive modules are enclosed in the metal enclosure of the DMC-41x3. The standard amplifier accepts DC supply voltages from 20-80 VDC.
  • Page 193 The AMP-43740 (4-axis) is a sinusoidally commutated, 16 bit PWM amplifier for driving brushless and brush-type servo motors. It is capable of providing 1200 watts of continuous power per axis. The AMP-43740 drive modules are enclosed in the metal enclosure of the DMC-41x3. The standard amplifier accepts DC supply voltages from 20- 80 VDC.

  • Page 194: A1 - Amp-430X0 (-D3040,-D3020)

    A1 – AMP-430x0 (-D3040,-D3020) Description The AMP-43040 resides inside the DMC-41x3 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, 20–80 VDC. The gain settings of the amplifier are user- programmable at 0.4 Amp/Volt, 0.7 Amp/Volt and 1 Amp/Volt.

  • Page 195: Electrical Specifications

    +VS (DC Power) Motor Connector Pin Number 3-phase brushless Brushed Phase C No Connect Phase B Phase A- No Connect No Connect Phase A Phase A+ Table A1.3: Power and Motor Connector Pin-outs A1 – AMP-430x0 (-D3040,-D3020) ▫ 190 DMC-41x3 User Manual...

  • Page 196: Servo Motor Operation

    Use D-Sub connectors on the top face of the controller to access necessary signals to run external amplifiers. For more information on connecting external amplifiers, see Step 2b. Connecting External Amplifiers and Motors in Chapter 2. A1 – AMP-430x0 (-D3040,-D3020) ▫ 191 DMC-41x3 User Manual...
  • Page 197 When configuring the amplifier gain, the axis must be in a motor off (MO) state prior to execution of the command. For more information on the command, refer to the command reference for the DMC-41x3. AG setting Gain Value n = 0 0.4 A/V...
  • Page 198 'set continuous torque limit of 5V TKA=9.9982; 'set max peak torque limit to 9.9982V SHA; 'enable A axis OFA=9.9982; 'command torque signal to 9.9982V 'end program Figure A1.2: Peak Current Operation A1 – AMP-430x0 (-D3040,-D3020) ▫ 193 DMC-41x3 User Manual...

  • Page 199: Error Monitoring And Protection

    If this error occurs, it is indicative of a problem at the system level. An Over-Voltage error is usually WARNING due to regeneration from the motor and load. Consider using a shunt regulator if this occurs during normal operation. A1 – AMP-430x0 (-D3040,-D3020) ▫ 194 DMC-41x3 User Manual...

  • Page 200: Over Temperature Protection

    ELO is used in an application. See the Optoisolated Input Electrical Information section in Chapter 3 Connecting Hardware for information on connecting the ELO input. A1 – AMP-430x0 (-D3040,-D3020) ▫ 195 DMC-41x3 User Manual...

  • Page 201: A2 - Amp-43140 (-D3140)

    A2 – AMP-43140 (-D3140) Description The AMP-43140 resides inside the DMC-41x3 enclosure and contains four linear drives for operating small, brush- type servo motors. The AMP-43140 requires a ± 12-30 VDC input. Output power is 20 W per amplifier or 60 W total.

  • Page 202: Electrical Specifications

    Pin Number Connection 1, 2 DC Power Supply Ground -VS (-DC Power) +VS (DC Power) Motor Connector Pin Number Brushed Phase A- Phase A+ Table A2.3: Power and Motor Connector Pin-outs A2 – AMP-43140 (-D3140) ▫ 197 DMC-41x3 User Manual...

  • Page 203: Servo Motor Operation

    This relay disconnects the amplifier power from the motor power leads when the controller is placed in the motor- off state. If the MO jumper is installed, or the command is burned into memory, the addition of the –SSR option will eliminate any jump due to the power supply. A2 – AMP-43140 (-D3140) ▫ 198 DMC-41x3 User Manual...

  • Page 204: Error Monitoring And Protection

    This relay disconnects the amplifier power from the motor power leads when the controller is placed in the motor- off state. If the MO jumper is installed, or the command is burned into memory, the addition of the –SSR option will eliminate any jump due to the power supply. A2 – AMP-43140 (-D3140) ▫ 199 DMC-41x3 User Manual...

  • Page 205: A3 - Amp-43240 (-D3240)

    A3 – AMP-43240 (-D3240) Description The AMP-43240 resides inside the DMC-41x3 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, 20–80 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 206: Electrical Specifications

    +VS (DC Power) Motor Connector Pin Number 3-phase brushless Brushed Phase C No Connect Phase B Phase A- No Connect No Connect Phase A Phase A+ Table A3.3: Power and Motor Connector Pin-outs A3 – AMP-43240 (-D3240) ▫ 201 DMC-41x3 User Manual...

  • Page 207: Servo Motor Operation

    Use D-Sub connectors on the top face of the controller to access necessary signals to run external amplifiers. For more information on connecting external amplifiers, see Step 2b. Connecting External Amplifiers and Motors in Chapter 2. A3 – AMP-43240 (-D3240) ▫ 202 DMC-41x3 User Manual...
  • Page 208 When configuring the amplifier gain, the axis must be in a motor off (MO) state prior to execution of the command. For more information on the command, refer to the command reference for the DMC-41x3 AG setting Gain Value n = 0 0.5 A/V...
  • Page 209 'set continuous torque limit of 5V TKA=9.9982; 'set max peak torque limit to 9.9982V SHA; 'enable A axis OFA=9.9982; 'command torque signal to 9.9982V 'end program Figure A3.2: Peak Current Operation A3 – AMP-43240 (-D3240) ▫ 204 DMC-41x3 User Manual...

  • Page 210: Error Monitoring And Protection

    If this error occurs, it is indicative of a problem at the system level. An Over-Voltage error is usually WARNING due to regeneration from the motor and load. Consider using a shunt regulator if this occurs during normal operation. A3 – AMP-43240 (-D3240) ▫ 205 DMC-41x3 User Manual...
  • Page 211 ELO is used in an application. See the Optoisolated Input Electrical Information section in Chapter 3 Connecting Hardware for information on connecting the ELO input. A3 – AMP-43240 (-D3240) ▫ 206 DMC-41x3 User Manual...

  • Page 212: A4 - Amp-43540 (-D3540, -D3520)

    Galil recommends powering the controller and amplifier down before changing the connector, and breaking the AC side of the power supply connection in order to power down the amplifier. A4 – AMP-43540 (-D3540, -D3520) ▫ 207 DMC-41x3 User Manual...

  • Page 213: Electrical Specifications

    Motor Connector Pin Number 3-phase brushless Brushed Phase C Phase A- Phase B No Connect No Connect No Connect Phase A Phase A+ Table A4.3: Power and Motor Connector Pin-outs A4 – AMP-43540 (-D3540, -D3520) ▫ 208 DMC-41x3 User Manual...

  • Page 214: Servo Motor Operation

    Use D-Sub connectors on the top face of the controller to access necessary signals to run external amplifiers. For more information on connecting external amplifiers, see Step 2b. Connecting External Amplifiers and Motors in Chapter 2. A4 – AMP-43540 (-D3540, -D3520) ▫ 209 DMC-41x3 User Manual...
  • Page 215 When configuring the amplifier gain, the axis must be in a motor off (MO) state prior to execution of the command. For more information on the command, refer to the command reference for the DMC-41x3. AG setting Gain Value n = 0 0.4 A/V...
  • Page 216 'set continuous torque limit of 5V TKA=9.9982; 'set max peak torque limit to 9.9982V SHA; 'enable A axis OFA=9.9982; 'command torque signal to 9.9982V 'end program Figure A4.2: Peak Current Operation A4 – AMP-43540 (-D3540, -D3520) ▫ 211 DMC-41x3 User Manual...

  • Page 217: Error Monitoring And Protection

    An Over-Temperature error is usually due to insufficient heat dissipation from the amplifier. Heat WARNING must be drawn away from the base of the controller with forced air flow or a heat sink. A4 – AMP-43540 (-D3540, -D3520) ▫ 212 DMC-41x3 User Manual...
  • Page 218 Command Reference for more information and examples. NOTE: Enhanced Error Clearing is supported on the DMC-41x3 as of firmware revision 1.3e and amplifier hardware revision 4. A4 – AMP-43540 (-D3540, -D3520) ▫ 213 DMC-41x3 User Manual...

  • Page 219: A5 - Amp-43547 (-D3547, -D3527)

    Galil recommends powering the controller and amplifier down before changing the connector, and breaking the AC side of the power supply connection in order to power down the amplifier. A5 – AMP-43547 (-D3547, -D3527) ▫ 214 DMC-41x3 User Manual...

  • Page 220: Electrical Specifications

    Phase C Phase A- Phase B- Phase B No Connect Phase B+ No Connect No Connect Phase A- Phase A Phase A+ Phase A+ Table A5.3: Power and Motor Connector Pin-outs A5 – AMP-43547 (-D3547, -D3527) ▫ 215 DMC-41x3 User Manual...

  • Page 221: Servo Motor Operation

    Contact a Galil Applications Engineer to review minimum encoder resolution requirements. Brushed Motor Operation For brushed motor operation, set for the axis. A5 – AMP-43547 (-D3547, -D3527) ▫ 216 DMC-41x3 User Manual...
  • Page 222 When configuring the amplifier gain, the axis must be in a motor off (MO) state prior to execution of the command. For more information on the command, refer to the command reference for the DMC-41x3. AG setting Gain Value n = 0 0.4 A/V...
  • Page 223 'set continuous torque limit of 5V TKA=9.9982; 'set max peak torque limit to 9.9982V SHA; 'enable A axis OFA=9.9982; 'command torque signal to 9.9982V 'end program Figure A5.2: Peak Current Operation A5 – AMP-43547 (-D3547, -D3527) ▫ 218 DMC-41x3 User Manual...

  • Page 224: Stepper Motor Operation

    When configuring the amplifier gain, the axis must be in a motor off (MO) state prior to execution of the command. For more information on the command, refer to the command reference for the DMC-41x3. AG setting Gain Value n = 0 0.75 A/Phase...

  • Page 225: Error Monitoring And Protection

    An Over-Temperature error is usually due to insufficient heat dissipation from the amplifier. Heat WARNING must be drawn away from the base of the controller with forced air flow or a heat sink. A5 – AMP-43547 (-D3547, -D3527) ▫ 220 DMC-41x3 User Manual...
  • Page 226 See the label and command in the Command Reference for more information and #AMPERR examples. NOTE: Enhanced Error Clearing is supported on the DMC-41x3 as of firmware revision 1.3e and later. A5 – AMP-43547 (-D3547, -D3527) ▫ 221 DMC-41x3 User Manual...

  • Page 227: A6 - Amp-43640 (-D3640)

    WARNING occur. Galil recommends powering the controller and amplifier down before changing the connector, and breaking the AC side of the power supply connection in order to power down the amplifier. A6 – AMP-43640 (-D3640) ▫ 222 DMC-41x3 User Manual...

  • Page 228: Electrical Specifications

    Pin Number Connection 1,2,3 DC Power Supply Ground 4,5,6 +VS (DC Power) Motor Connector Pin Number Brushless Phase C Phase B No Connect Phase A Table A6.3: Power and Motor Connector Pin-outs A6 – AMP-43640 (-D3640) ▫ 223 DMC-41x3 User Manual...
  • Page 229 The more power sent to the motor, the less power will be dissipated by the amplifier as heat. Power Dissipated by the Amplifier for a Given Velocity and Current 1 Amp .5 Amp Velocity (kRPM) Figure A6.2: Power Dissipation for Velocity and Current A6 – AMP-43640 (-D3640) ▫ 224 DMC-41x3 User Manual...

  • Page 230: Servo Motor Operation

    Use D-Sub connectors on the top face of the controller to access necessary signals to run external amplifiers. For more information on connecting external amplifiers, see Step 2b. Connecting External Amplifiers and Motors in Chapter 2. A6 – AMP-43640 (-D3640) ▫ 225 DMC-41x3 User Manual...
  • Page 231 'set continuous torque limit of 5V TKA=9.9982; 'set max peak torque limit to 9.9982V SHA; 'enable A axis OFA=9.9982; 'command torque signal to 9.9982V 'end program Figure A6.3: Peak Current Operation A6 – AMP-43640 (-D3640) ▫ 226 DMC-41x3 User Manual...

  • Page 232: Error Monitoring And Protection

    ELO is used in an application. See the Optoisolated Input Electrical Information section in Chapter 3 Connecting Hardware for information on connecting the ELO input. A6 – AMP-43640 (-D3640) ▫ 227 DMC-41x3 User Manual...

  • Page 233: A7 - Amp-43740 (-D3740)

    WARNING occur. Galil recommends powering the controller and amplifier down before changing the connector, and breaking the AC side of the power supply connection in order to power down the amplifier. A7 - AMP-43740 (-D3740) ▫ 228 DMC-41x3 User Manual...

  • Page 234: Electrical Specifications

    +VS (DC Power) Motor Connector Pin Number Brushless Brushed Phase C Phase A- Phase B No Connect No Connect No Connect Phase A Phase A+ Table A7.3: Power and Motor Connector Pin-outs A7 - AMP-43740 (-D3740) ▫ 229 DMC-41x3 User Manual...

  • Page 235: Servo Motor Operation

    Use D-Sub connectors on the top face of the controller to access necessary signals to run external amplifiers. For more information on connecting external amplifiers, see Step 2b. Connecting External Amplifiers and Motors in Chapter 2. A7 - AMP-43740 (-D3740) ▫ 230 DMC-41x3 User Manual...
  • Page 236 When configuring the amplifier gain, the axis must be in a motor off (MO) state prior to execution of the command. For more information on the command, refer to the command reference for the DMC-41x3. AG setting Gain Value n = 0 0.8 A/V...
  • Page 237 'set continuous torque limit of 5V TKA=9.9982; 'set max peak torque limit to 9.9982V SHA; 'enable A axis OFA=9.9982; 'command torque signal to 9.9982V 'end program Figure A7.2: Peak Current Operation A7 - AMP-43740 (-D3740) ▫ 232 DMC-41x3 User Manual...

  • Page 238: Error Monitoring And Protection

    An Over-Temperature error is usually due to insufficient heat dissipation from the amplifier. Heat WARNING must be drawn away from the base of the controller with forced air flow or a heat sink. A7 - AMP-43740 (-D3740) ▫ 233 DMC-41x3 User Manual...
  • Page 239 To clear latched amplifier errors in a DMC program, use MO;WT2;SH. If an axis is moving, motion must be halted before attempting to clear amplifier errors. A7 - AMP-43740 (-D3740) ▫ 234 DMC-41x3 User Manual...

  • Page 240: A8 - Sdm-44040 (-D4040,-D4020)

    A8 – SDM-44040 (-D4040,-D4020) Description The SDM-44040 resides inside the DMC-41x3 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.

  • Page 241: Electrical Specifications

    Figure A8.1: Power and Motor Connector Diagram Power Connector Pin Number Connection 1,2,3 DC Power Supply Ground 4,5,6 +VS (DC Power) Motor Connector Pin Number Stepper Table A8.3: Power and Motor Connector Pin-outs A8 – SDM-44040 (-D4040,-D4020) ▫ 236 DMC-41x3 User Manual...

  • Page 242: Stepper Motor Operation

    When configuring the amplifier gain, the axis must be in a motor off (MO) state prior to execution of the command. For more information on the command, refer to the command reference for the DMC-41x3. AG setting Gain Value n = 0 0.5 A/V...

  • Page 243: Error Monitoring And Protection

    It is recommended that be used for all axes when the ELO is used in an application. See the Optoisolated Input Electrical Information section for information on connecting the ELO input. A8 – SDM-44040 (-D4040,-D4020) ▫ 238 DMC-41x3 User Manual...

  • Page 244: A9 - Sdm-44140 (-D4140)

    A9 – SDM-44140 (-D4140) Description The SDM-44140 resides inside the DMC-41x3 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.

  • Page 245: Electrical Specifications

    Figure A9.1: Power and Motor Connector Diagram Power Connector Pin Number Connection 1,2,3 DC Power Supply Ground 4,5,6 +VS (DC Power) Motor Connector Pin Number Stepper Table A9.3: Power and Motor Connector Pin-outs A9 – SDM-44140 (-D4140) ▫ 240 DMC-41x3 User Manual...

  • Page 246: Stepper Motor Operation

    When configuring the amplifier gain, the axis must be in a motor off (MO) state prior to execution of the command. For more information on the command, refer to the command reference for the DMC-41x3. AG setting Gain Value n = 0 0.5 A/V...

  • Page 247: Error Monitoring And Protection

    It is recommended that be used for all axes when the ELO is used in an application. See the Optoisolated Input Electrical Information section for information on connecting the ELO input. A9 – SDM-44140 (-D4140) ▫ 242 DMC-41x3 User Manual...