DMC-41x3 Integrated Amplifier Installation Manual
Contents
1. Maximum Input Voltage 60VDC Maximum Output Current 32 Amps Figure 5 Label for DMC 41x3 D3540 DMC 41x3 D3240 D3220 Maximum Input Voltage 60VDC Maximum Output Current 60 Amps Figure 6 Label for DMC 41x3 D3240 D3220 DMC 41x3 D3240 D3240 Maximum Input Voltage 60VDC Maximum Output Current 80 Amps Figure 7 Label for DMC 41x3 D3240 D3240 DMC 41x3 D3540 D3520 Maximum Input Voltage 60VDC Maximum Output Current 48 Amps Figure 8 Label for DMC 41x3 D3540 D3520 DMC 41x3 D3540 D3540 Maximum Input Voltage 60VDC Maximum Output Current 64 Amps Figure 9 Label for DMC 41x3 D3540 D3540 DMC 41x3 D3240 D3520 Maximum Input Voltage 60VDC Maximum Output Current 56 Amps Figure 10 Label for DMC 41x3 D3240 D3520 DMC 41x3 D3240 D3540 Maximum Input Voltage 60VDC Maximum Output Current 72 Amps Figure 11 Label for DMC 41x3 D3240 D3540 DMC 41x3 D3540 D3220 Maximum Input Voltage 60VDC Maximum Output Current 52 Amps Figure 12 Label for DMC 41x3 D3540 D3220 DMC 41x3 D3540 D3240 Maximum Input Voltage 60VDC Maximum Output Current 72 Amps Figure 13 Label for DMC 41x3 D3540 D3240 oft ETL LISTED DIR CONFORMS TO CSI Bus UL STD 61010 1 3137106 GERTIFIED TO CAN CSA STD C22 2 NO 61010 1 Figure 14 ETL Mark Installation Mounting the Controller The DMC 41x3 motion controller must be mounted to a flat surface with 4 10 pan head screws through each mounting hole2. 24 ALSG HIGH POWER OPTION 19MCMD MENBL 4HALC SOURCE DOJ 8 1 OP A 12 24VDC 500mA OP0B GND GND 20 80VDC SOURCE DO 16 9 OP1A 12 24VDC 500mA OP1B GND iring wi DMC 41x3 wi Figure 16 Communication Connection Connect the serial cable or the Ethernet cable from your PC to the DMC 41x3 motion controller The Ethernet cable may be connected through a hub or switch or directly to the PC If the controller is connected to a DHCP enabled network the IP address will automatically be assigned to the controller Powering the Controller Once the connections have been made from the DC power supply to the DMC 41x3 motion controller the controller and internal amplifiers may be powered up At this time the Power LED should be illuminated Additional Wiring Additional wiring to the Analog and Digital 1 0 encoders limit switches and other connections found on the D Subs on the DMC 41x3 motion controller will be required to complete your applications The pinout for the connectors are shown below for additional information regarding these connections see the DMC 41x3 User Manual JS I O A D 44 pin HD D Sub Connector Female Pin 1 2 3 4 5 6 7 8 9 11 me m Mm AININ Label ERR DII DI4 DI7 ELO DO3 FSV Description Pin Label Description Pin Label Description J ON D I N LA P Digital Input 7 Electronic Lock Out 2 ABRT Abor
3. A2 Environmental Specifications Description Units Specification Storage Temperature C 40 to 125 Operating Temperature C 0 to 40 Operating Altitude feet 10 000 Humidity RH 20 95 non condensing A3 Mechanical Specifications DMC 4183 DMC 4183 Description Units Weight Ib Length in Width in Height in DMC 4183 D3240 D3240 Included Components Quantiy DMC 4183 l AMP 43240 2 DMC 4183 D3540 D3540 Included Components Quantiy DMC 4183 l AMP 43540 2 Specification 4 25 DMC 4183 D3240 D3240 11 50 T23 1 50 Description Main Controller Board Servo Amplifier Board Description Main Controller Board Servo Amplifier Board 90A09 07t ON 9 vu ISH 94 INOONT 1 OND LE OWOONT ZI P1 Hide SIde SIG 8 SLIG EE Z PLIG 61 91d 6l O0AEZ SL VidO 6 91 Jog 30WNOS Td K 0135 Ate OND SE DINEZ ONE 8090 VU S WO9S19 e 381498 Be OOAv2 2k V dO I gloa 20008 3WOH 38513 Z ON l JWOH8 ASTHEZ ogra ge SEN OTVHI ONON 61 NOILdO 3MOd HOTH 18N3 LL AG 8 OSTE te 9514 va Nav Z 18N3 02 2 MSI Zwang EHS ONS oy IER arae TZ via aNoys IN OGAP2 S aldo vus vidoe Wd0 sot KE elle sun Se tee BIS OND VIdO 6 91 ANIS oaze XOJE zoaz oaa STE PAVE E Siet Sg JGAv2 S 80d0 yup noaei Sioges SOAs See ye et D EIYE Step ON9 Y0dO I gloa ANIS AG GL AS 0 AS 0 Ad 4 angs 460 VW 92 aNDV I GNDV 6 SLAdLNO H 3 O I a y O I SIXV 907VNV aN9 gtdO VO D pp DD nnmn QWOONT ISN LYaV ANY
4. Om L n ONG HO 20AECE WAONI GND HO O0Ar2 S WODST H 3 O I a y O I 9SvECcHI EEGEN 9S7ECcI IGPbPEC I EEGEN 9S7ECcI 9S7EcI EEGEN mn Eer Ern Cen EE FEER FEE E D n D nj D njn D njn ujo D B ojo n ala njo 5 jo ojo ojo n o ojn njn 5 nojn a jn njn gia u 4 L 4 4 4 umo yoria LOW NIT E IWIWAS XNV 13NH3H13 O 13S3H JOHS NAVI YSN NI 3GVW ooo OND 3 g g y OSI OHS N3VH Bes SA ee Yy ae Di d d Ad YNS N3V1 TOYLNOOD NOILOW 1V9 D O AS NS NAVH H3MOd OAH3S H3Idd3LS 9 eg L v O N qd H3MOd H 9 HHHHH eo HHHHH m ml OO LL OG LL A4 Mechanical Specifications DMC 4143 Description Units Specification Weight Ib 2 7 DMC 4143 D3240 Length in 8 05 Width in 7 25 Height in 1 50 POWER D M C 4 1 43 STEPPER SERVO GALIL MOTION CONTROL Ar ES D A ES Cc MADE IN USA 2 RESET O ETHERNET LINK ACT ERROR Power ir a ee SE ee 6 75 7 25 123456 123456 123456 123456 AUX SERIAL 1 0 A D 1 ANALOG ENCODER 1 AGND 18 GND OUTPUTS 9 AGND gt ary 26 MA 17 MB SINK DO 8 1 OPOA GND 10 AI2 3 AI3 25MB ew 4mA OPOB 5 24VDC HIGH POWER OPTION HP C 5 Hov DE SC SOURCE DO 8 1 OPOA 12 24VDC a i 500mA OP B GND ony Di T GND 20 60VDC S M D 1 ERR
5. found on the controller base as shown in Figure 15 If the controller is mounted on a wall the controller should be mounted so that the bottom of the controller is horizontal to the floor as shown in Figure 15 The enclosure must meet or exceed any fire ratings that are required of the system as a whole If the AMP 43xx0 internal amplifiers are being used it should be determined at this time whether or not an additional heat sink will be required This is determined based upon the continuous current requirements of the system as defined in the Additional Mounting Consideration when using the AMP 43xx0 section above The Motor Sizer tool found on our website can be used to determine this value http www galilmc com learning motorsizer php 10 PAN HEAD SCREW e 4 PLACES Figure 15 Mounting the DMC 41x3 Powering the Controller The DMC 41x3 is powered via the DC supply connections All connectors share a common ground The DMC 41x3 is grounded through the metal enclosure and should be installed on an unpainted metal surface The Earth lugs should be used for additional electrical contact Wiring the Controller with internal AMP 43xx0 The basic wiring for a DMC 41x3 motion controller with included AMP 43xx0 servo amplifiers is shown in Figure 16 The disconnect switch or circuit breaker for AC power must be installed in a location that meets the following requirements e Placed in close proximity to the equipment
6. DMC 41x3 Installation Manual ETL DMC 41x3 Integrated Amplifier Installation Manual Manual Rev 1 0a3 By Galil Motion Control Inc Galil Motion Control Inc 270 Technology Way Rocklin California 95765 Phone 916 626 0101 Fax 916 626 0102 E mail Address support galilmc com URL www galilmc com Rev 02 29 12 Using This Manual This manual provides information for the wiring installation powering up and basic communication to the DMC 41x3 motion controller with the Galil mternal amplifiers AMP 435x0 and AMP 432x0 The following list of part numbers are examples of configurations of the DMC 41x3 motion controller that are covered in this manual DMC 41x3 DMC 41x3 D3220 DMC 41x3 D3240 DMC 41x3 D3520 DMC 41x3 D3540 DMC 41x3 D3240 D3220 DMC 41x3 D3240 D3240 DMC 41x3 D3540 D3520 DMC 41x3 D3540 D3540 DMC 41x3 D3240 D3520 DMC 41x3 D3240 D3540 DMC 41x3 D3540 D3220 DMC 41x3 D3540 D3240 This manual covers the basic installation of the controller and amplifier modules For full operational information including specific I O installation detailed programming examples and additional internal driver information see the DMC 41x3 User Manual WARNING Machinery in motion can be dangerous It is the responsibility of the user to design effective error handling and safety protection as part of the machinery Galil shall not be liable or responsible for any incidental or consequential damages If the DMC 41x3
7. e devices when handling the controller 1 Verify that the following components have been shipped along the motion controller e Connectors and mating pins for motor power and amplifier power o Qty 4 4 pin molex connectors for EACH internal amplifier o Qty 1 6 pin molex connector for EAH internal amplifier e Galil Software Installation CD Note Connectors and or software installation CD may not be shipped to existing OEM customers 2 Check that no visible damage has occurred to the controller or internal amplifiers If any damage has occurred to the controller or the components shipped with the controller contact Galil Motion Control immediately Contact information can be found in the beginning of this manual 3 Verify the controller that has been shipped to you is in fact the controller that you have ordered from Galil or your authorized Galil distributor To do this check the labeling on the controller and compare it to the part number that was ordered DMC 41x3 Maximum Input Voltage 60VDC Maximum Input Current 1 Amp Figure 1 Label for DMC 41x3 DMC 41x3 D3220 Maximum Input Voltage 60VDC Maximum Output Current 20 Amps Figure 2 Label for DMC 41x3 D3220 DMC 41x3 D3240 Maximum Input Voltage 60VDC Maximum Output Current 40 Amps Figure 3 Label for DMC 41x3 D3240 DMC 41x3 D3520 Maximum Input Voltage 60VDC Maximum Output Current 16 Amps Figure 4 Label for DMC 41x3 D3520 DMC 41x3 D3540
8. h H Reverse Limit Switch H DO11 Digital Output 11 DO10 Digital Output 10 DO12 DO14 Digital Output 14 DO13 Digital Output 13 DOI5 OPIB Output PWRIGND po Digital Output 16 5V 5V 30 5V 5V Description Digital Ground Digital Input 10 F latch Digital Input 13 Digital Input 16 Digital Ground Forward Limit Switch E Forward Limit Switch F Forward Limit Switch G Forward Limit Switch H Digital Ground Digital Output 9 Digital Output 12 Digital Output 15 Output Compare E H ABRT RST and ELO use INCOMO Jni Encoder 26 pin HD D Sub Connector Female Label Description Pin Label Description PWM Step A Main Encoder Input Rete UM IG UCI SV GA IA NTR oO Hu LA LSCOMn on JAI JB1 JC1 and JD1 is common to LSCOMO on J5 LSCOMnh on JET JF1 JG1 and JH1 is common to LSCOM1 on J8 J4 Analog 15 pin D sub Connector Male Pin Label Description 1 AGND Analog Ground 2 Analog Input 1 3 A13 Analog Input 3 4 Analog Input 5 5 Analog Input 7 6 AGND Analog Ground 8 IV 5V 9 AGND Analog Ground 10 Analog Input 2 11 Al4 Analog Input 4 12 Al6 Analog Input 6 13 Analog Input 8 14 N C No Connect 15 12V 12V Communication with Galil Software To communicate with the controller the GalilTools communications software must first be installed A free version of GalilTools GalilTools Lite may also be used These software applications can be fou
9. hru four axes controllers and the DMC 4153 4163 4173 4183 are five thru eight axes controllers All eight axes have the ability to use Galil s integrated amplifiers or drivers and connections for integrating external devices Commands are sent in ASCII Additional software is available for automatic tuning trajectory viewing on a PC screen and program development using many environments such as Visual Basic C C etc Drivers for Windows XP Vista and 7 32 amp 64 bit as well as Linux are available AMP 43220 43240 Servo Amplifier D3220 D3240 The AMP 43240 and AMP 43220 amplifiers reside inside the DMC 41x3 enclosure The AMP 43240 contains four transconductance PWM amplifiers for driving brushless or brush type servo motors the AMP 43240 contains 2 amplifiers 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 The switching frequency is 24 kHz The drive operates in a Chopper Mode The amplifier offers protection for over voltage under voltage over current short circuit and over temperature Two AMP 43240s or AMP 43220 s can be used in 5 thru 8 axis controllers AMP 43520 43540 Servo Amplifier D3520 D3540 The AMP 43540 and AMP 43520 amplifies reside inside the DMC 41x3 enclosure The AMP 43540 contains four sinusoidally commutated PWM amplifiers for driving brushless servo
10. motion controller and included amplifiers or stepper drivers are not used ina manner specified by Galil Motion Control the protection provided by the controller amplifiers and drivers may be impaired Caution CAUTION HOT The DMC 41x3 controller with internal servo amplifiers contain hot surfaces Chapter 1 Overview Introduction DMC 41x3 Motion Controller The DMC 41x3 Series are Galil s Econo motion controller that 1s a scaled down version of the DMC 40x0 Acclerra series controller The controller series offers many enhanced features compared to prior generation Econo series controllers including high speed communications non volatile program memory faster encoder speeds and improved cabling for EMI reduction Each DMC 41x3 provides two communication channels a high speed 100BaseT Ethernet connection and a USB programming port There is an auxiliary RS 232 port that can be used to communicate to external devices such as HMI s The controllers allow for high speed servo control up to 15 million encoder counts sec and step motor control up to 3 million steps per second Sample rates as low as 62 usec per axis are available A Flash EEPROM provides non volatile memory for storing application programs parameters arrays and firmware New firmware revisions are easily upgraded m 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 t
11. motors the AMP 43520 contains 2 amplifiers Each amplifier drives motors operating at up to 8 Amps continuous 15 Amps peak 20 60 VDC The gain settings of the amplifier are user programmable at 0 4 Amp Volt 0 8 Amp Volt and 1 6 Amp Volt The switching frequency is 33 kHz The amplifier offers protection for over voltage under voltage over current short circuit and over temperature Two AMP 43540s or AMP 43520 s can be used for 5 thru 8 axis controllers Chapter 2 Installation Pre Installation Operating Environment The location for use of the DMC 41x3 AMP 432x0 and AMP 435x0 must meet the following requirements Description Units Specification Ambient Temperature C 0 to 40 Altitude feet 10 000 Humidity RH 20 95 non condensing Mounting Location The DMC 41x3 motion controller must be mounted on a flat surface using the 4 mounting holes found on the metal base plate The grating found on the side of the metal must not be obstructed in order provide proper air flow for adequate heat dissipation The dimensions for a 1 4 axis controller are smaller than that of a 4 8 axis controller these dimensions and the mounting hole locations are found in Appendices A3 and A4 Additional Mounting Consideration when using the AMP 43xx0 When operating a DMC 41x3 D3xx0 D3xx0 or a DMC 41x3 D3xx0 special mounting considerations must be made if the total continuous current output for the controller is greater than 15A for a 1 4 axis co
12. nd on the software installation CD shipped with the controller or online at http www galilmc com support software downloads php Installation instructions for your operating system can be found in the GalilTools user manual http www galilmc com support manuals galiltools introduction html Once the software has been installed run GalilTools or GalilTools Lite and choose your controller USB connection If you are using a USB connection connect the DMC 41x3 USB port to your computer via a Male Type A Male Type B USB cable The port will be identified as a new Serial port The USB port is designed for basic communication to the controller and the standard baud rate of the DMC 41x3 motion controller is 115200 Ethernet connection If you are connected to the controller via an Ethernet connection and your network is DHCP enabled then the controller will automatically have an IP addressed assigned to it If your network is not DHCP enabled or the connection is only between the PC and the controller then the controller be found with the software as no IP address assigned The GalilTools software will allow you to assign the controller with an IP address See the GalilTools documentation for detailed information on using the software to assign the controller IP address Appendix Specifications Al Electrical Specifications DMC 4183 D3240 D3240 Description Units Specification Maximum Input Voltage VDC 60 Minimum I
13. nput Voltage VDC 20 Maximum Input Power W 2400 Maximum Output Current Amps 80 DMC 4183 D3540 D3540 Description Units Specification Maximum Input Voltage VDC 60 Minimum Input Voltage VDC 20 Maximum Input Power W 1920 Maximum Output Current Amps 64 AMP 43240 Description Units Specification Supply Voltage VDC 20 60 Maximum Input Power W 1200 Continuous Output Current per axis Amps 10 Peak Output Current per axis Amps 20 Amplifier Gain A V 0 5 1 0 default 2 0 Switching Frequency kHz 24 Brushless Motor Commutation angle S 120 i 60 option available Supply Voltage Fuse Amps 30 AMP 43540 Description Units Specification Supply Voltage VDC 20 60 Maximum Input Power W 960 Continuous Output Current per axis Amps 8 Peak Output Current per axis Amps 15 Amplifier Gain A V 0 4 0 8 default 1 6 Switching Frequency kHz 33 Brushless Motor Commutation angle 2 120 Supply Voltage Fuse Amps 30 Fault Information The AMP 43240 and AMP 43540 are protected from the following fault conditions Fault Condition AMP 43540 AMP 43240 Over Current Protection yes yes Under Voltage Protection yes yes Over Temperature Protection yes yes Over Voltage Protection yes yes Hall Error Detection yes yes The Over Current protection circuit is shown in Figure 17 For further specifics on fault conditions see the DMC 41x3 User Manual 3 3V VIN_AB 51V EZEN OC_N ZN ZENER 5V AMP DRIVE OVERCURRENT Figure 17 Overcurrent Circuit
14. ntroller and greater than 30A for a 5 8 axis controller In this case the controller base must be mounted to an addition heat sink When the application requires that the DMC 41x3 D3xx0 D3xx0 be mounted to a heat sink the heat sink must be sized such that the base of the DMC 41x3 be kept at a temperature of 65 C or below This works out to a thermal resistance of 0 2 C W at full continuous power Full continuous power is defined as a 100 duty cycle with all 8 axis running 10Amps continuous current 80 Amps total with a 60VDC bus Elements Needed for Installation 1 Isolated DC power supply a Ratings found in Appendix Al 2 Power Supply Cable a Cable from DC power supply to power input for AMP 43xx0 b DMC 4183 controller requires 2 cables PC or laptop with Ethernet and or USB ports 4 GalilTools or GalilTools Lite software package 5 Ethernet Cable a Recommended shielded Cat 5 STP cable Straight through or Cross over 6 Male Type A Male Type B USB cable 7 Molex pin Crimp Tool 8 Additional cables may be required for connection to motors external amplifiers digital or analog I O and other devices See the full DMC 41x3 User Manual for further information 9 Disconnect switch or circuit breaker for AC power to DC Power Supply Unpacking the Controller Caution The DMC 41x3 motion controller and included internal amplifier include electrostatic sensitive components Observe standard precautions for handling ESD sensitiv
15. t Input GN n v LA IA lra Iole KO K HU 5V 3 5V 5V Digital Ground Digital Input 1 A latch 1 INCOMO Input Common DI 1 8 32 DI2 Digital Input 2 B latch g p Digital Input 4 D latch DI3 Digital Input 3 C latch DIS Digital Input 5 DI6 Digital Input 6 DI8 Digital Input 8 Digital Ground LSCOMO Limit Switch Com A D NIC FLSA Forward Limit Switch A HOMA Home Switch A Reverse Limit Switch A FLSB HOMB Home Switch B Reverse Limit Switch B FLSC HOMC Home Switch C Reverse Limit Switeh C FLSD HOMD Home Switch D Reverse Limit Switch D GN OPOA Output GND PWR NIC DOI Digital Output 1 Digital Output 3 DO Digital Output 2 DO4 Digital Output 4 Dos Digital Output 6 DOS Digital Output 5 DO7 Digital Output 7 OPOB Output PWR GND DO8 Digital Output 8 CM Forward Limit Switch B Forward Limit Switch C Forward Limit Switch D Digital Ground Output Compare A D J8 I O E H 44 pin HD D Sub Connector Female For DMC 4153 thru DMC 4183 controllers only Pin O Iloon uy IN INJ Label Description Pin Label Description Pin Label Digital Input 9 E latch INCOMI Input Common DI 9 16 DI10 DI12 Digital Input 12 H latch DI11 Digital Input 11 G latch DI13 DI15 a Input 15 ES DI14 Digital Input 14 DI16 HOME Home Switch E EN Reverse Limit Switch E KC FLSF HOMF Home Switch F Reverse Limit Switch F FLSG HOMG Home Switch G Reverse Limit Switch G FLSH HOMH Home Switc
16. within easy reach of the operator and must not block the installation of the controller e Marked as the disconnect device for the equipment Connectors for AMP 43xx0 On Board Connector Terminal Pins POWER 6 pin MATE N LOK MOLEX 39 31 0060 MOLEX 44476 3 112 A B C D 4 pin Motor 4 pin MATE N LOK Power Connectors MOLEX 39 31 0040 MOLEX 44476 3112 For mating connectors see http www molex com Power Connector Motor Connector Power Connector Pin Number Connection 1 2 3 DC Power Supply Ground 4 5 6 VS DC Power Motor Connector AMP 432x0 l Phase C N C for Bushed Motors 2 Phase B 3 No Connect 4 Phase A Motor Connector AMP 435x0 l Phase C 2 Phase B N C for Bushed Motors 3 No Connect 4 Phase A 20 60 VDC BREAKER OR RELAY T i L E N d IF Gr th AMP 43xx0 G H POWER DMC 41 83 STEPPER SERVO HAEN SN GALIL MOTION CONTROL ir SN MADE IN USA LAEN SR w z D x E w OLINK ACT O ERROR AUX SERIAL O Power Ed SEE Ed SEE SEE SEEST SEE EE 123456 123456 123456 123456 123456 123456 123456 123456 I O A D I O E H INPUTS LSCOM 5 24VDC OR GND INCOM 5 24VDC OR GND RST ELO AND ABRT USE INCOMO I O E H OUTPUTS Au Cup 3045V SINK DO 8 1 OP A GND a A 290016 4mA OPOB 5 24VDC 37 KE SINK D0 16 9 OPIA GND 26 OPIA 4mA OPIB 5 24VDC 2iHALA 39005 3DIR 25 ALSH 15 12V 20 ENBL 2 AEN
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