Galil Home Security System DMC 3425 User Manual

USER MANUAL  
DMC-3425  
Manual Rev. 1.1b  
By Galil Motion Control, Inc.  
Galil Motion Control, Inc.  
3750 Atherton Road  
Rocklin, California 95765  
Phone: (916) 626-0101  
Fax: (916) 626-0102  
Internet Address: [email protected]  
URL: www.galilmc.com  
Rev 6/06  
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Contents  
Contents  
i
Chapter 1 Overview  
1
Introduction ...............................................................................................................................1  
Overview of Motor Types..........................................................................................................2  
Standard Servo Motors with +/- 10 Volt Command Signal.........................................2  
Stepper Motor with Step and Direction Signals ..........................................................2  
Brushless Servo Motor with Sinusoidal Commutation................................................2  
DMC-3425 Functional Elements...............................................................................................4  
Microcomputer Section ...............................................................................................4  
Motor Interface............................................................................................................4  
Communication ...........................................................................................................4  
General I/O..................................................................................................................5  
System Elements .........................................................................................................5  
Motor...........................................................................................................................5  
Amplifier (Driver) .......................................................................................................5  
Encoder........................................................................................................................6  
Watch Dog Timer........................................................................................................6  
Chapter 2 Getting Started  
7
The DMC-3425 Motion Controller............................................................................................7  
Elements You Need...................................................................................................................8  
Installing the DMC-3425 Controller..........................................................................................8  
Step 1. Determine Overall Motor Configuration........................................................9  
Step 2. Configuring Jumpers on the DMC-3425.........................................................9  
Step 3. Connecting AC or DC power and the Serial Cable to the DMC-3425..........11  
Step 4. Installing the Communications Software.......................................................12  
Step 5. Establishing Communication between the DMC-3425 and the host PC .......12  
Step 6. Set-up axis for sinusoidal commutation (optional).......................................17  
Step 7. Make connections to amplifier and encoder..................................................17  
Step 8a. Connect Standard Servo Motor...................................................................19  
Step 8b. Connect brushless motor for sinusoidal commutation................................23  
Step 8c. Connect Step Motors ...................................................................................26  
Step 9. Tune the Servo System..................................................................................27  
Step 10. Configure the Distributed Control System ..................................................28  
Design Examples .....................................................................................................................32  
Example 1 - System Set-up .......................................................................................32  
Example 2 - Profiled Move .......................................................................................32  
Example 3 - Position Interrogation............................................................................32  
Example 4 - Absolute Position..................................................................................32  
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Example 5 - Velocity Control (Jogging) ...................................................................33  
Example 6 - Operation Under Torque Limit .............................................................33  
Example 7 - Interrogation..........................................................................................33  
Example 8 - Operation in the Buffer Mode...............................................................33  
Example 9 - Motion Programs...................................................................................34  
Example 10 - Motion Programs with Loops..............................................................34  
Example 11- Motion Programs with Trippoints........................................................34  
Example 12 - Control Variables ................................................................................35  
Example 13 - Control Variables and Offset ..............................................................35  
Chapter 3 Connecting Hardware  
37  
Overview .................................................................................................................................37  
Using Inputs.............................................................................................................................37  
Limit Switch Input.....................................................................................................37  
Home Switch Input....................................................................................................38  
Abort Input ................................................................................................................38  
Uncommitted Digital Inputs......................................................................................39  
Amplifier Interface ..................................................................................................................39  
TTL Inputs...............................................................................................................................40  
Analog Inputs ..........................................................................................................................40  
TTL Outputs ............................................................................................................................41  
Chapter 4 Communication  
43  
Introduction .............................................................................................................................43  
RS232 Port...............................................................................................................................43  
RS232 - Port 1 DATATERM ................................................................................43  
RS-232 Configuration ...............................................................................................43  
Ethernet Configuration ............................................................................................................44  
Communication Protocols .........................................................................................44  
Addressing.................................................................................................................44  
Ethernet Handles .......................................................................................................45  
Global vs. Local Operation........................................................................................45  
Operation of Distributed Control...............................................................................47  
Accessing the I/O of the Slaves.................................................................................47  
Handling Communication Errors...............................................................................48  
Multicasting...............................................................................................................48  
Unsolicited Message Handling..................................................................................49  
IOC-7007 Support .....................................................................................................49  
Modbus Support ........................................................................................................50  
Other Communication Options..................................................................................51  
Data Record .............................................................................................................................52  
Data Record Map.......................................................................................................52  
Explanation of Status Information and Axis Switch Information..............................55  
Notes Regarding Velocity and Torque Information ..................................................56  
QZ Command............................................................................................................56  
Using Third Party Software.......................................................................................57  
Chapter 5 Command Basics  
59  
Introduction .............................................................................................................................59  
Command Syntax - ASCII.......................................................................................................59  
Coordinated Motion with more than 1 axis...............................................................60  
Command Syntax - Binary ......................................................................................................60  
Binary Command Format..........................................................................................61  
Binary command table...............................................................................................62  
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Controller Response to DATA ................................................................................................63  
Interrogating the Controller .....................................................................................................64  
Interrogation Commands...........................................................................................64  
Summary of Interrogation Commands ......................................................................64  
Interrogating Current Commanded Values................................................................64  
Operands....................................................................................................................64  
Command Summary..................................................................................................65  
Chapter 6 Programming Motion  
67  
Overview .................................................................................................................................67  
Global vs. Local Operation........................................................................................67  
Independent Axis Positioning..................................................................................................69  
Command Summary - Independent Axis ..................................................................70  
Operand Summary - Independent Axis .....................................................................70  
Examples ...................................................................................................................70  
Independent Jogging................................................................................................................72  
Command Summary - Jogging..................................................................................72  
Operand Summary - Independent Axis .....................................................................72  
Examples ...................................................................................................................72  
Linear Interpolation Mode (Local Mode)................................................................................73  
Specifying Linear Segments......................................................................................73  
Additional Commands...............................................................................................74  
Command Summary - Linear Interpolation...............................................................75  
Operand Summary - Linear Interpolation..................................................................75  
Example.....................................................................................................................76  
Example - Linear Move.............................................................................................76  
Example - Multiple Moves........................................................................................77  
Vector Mode: Linear and Circular Interpolation (Local Mode) ..............................................78  
Specifying Vector Segments .....................................................................................78  
Additional commands................................................................................................79  
Command Summary - Coordinated Motion Sequence..............................................80  
Operand Summary - Coordinated Motion Sequence.................................................80  
Electronic Gearing (Local Mode)............................................................................................82  
Command Summary - Electronic Gearing ................................................................82  
Electronic Cam (Local Mode) .................................................................................................83  
Contour Mode (Local Mode)...................................................................................................89  
Specifying Contour Segments ...................................................................................89  
Additional Commands...............................................................................................91  
Command Summary - Contour Mode .......................................................................91  
Operand Summary - Contour Mode ..........................................................................91  
Virtual Axis (Local Mode) ......................................................................................................94  
Ecam Master Example...............................................................................................95  
Sinusoidal Motion Example ......................................................................................95  
Stepper Motor Operation .........................................................................................................95  
Specifying Stepper Motor Operation.........................................................................95  
Stepper Motor Smoothing .........................................................................................96  
Monitoring Generated Pulses vs. Commanded Pulses ..............................................96  
Motion Complete Trippoint.......................................................................................97  
Using an Encoder with Stepper Motors.....................................................................97  
Command Summary - Stepper Motor Operation.......................................................97  
Operand Summary - Stepper Motor Operation..........................................................97  
Dual Loop (Auxiliary Encoder)...............................................................................................98  
Using the CE Command............................................................................................98  
Additional Commands for the Auxiliary Encoder.....................................................98  
Backlash Compensation ............................................................................................98  
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Example.....................................................................................................................99  
Motion Smoothing.................................................................................................................100  
Using the IT and VT Commands:............................................................................100  
Example...................................................................................................................100  
Homing..................................................................................................................................101  
Example...................................................................................................................102  
Command Summary - Homing Operation...............................................................104  
Operand Summary - Homing Operation..................................................................104  
High Speed Position Capture (Latch) ....................................................................................104  
Example...................................................................................................................105  
Chapter 7 Application Programming  
107  
Overview ...............................................................................................................................107  
Global vs. Local Programming................................................................................107  
Entering Programs .................................................................................................................108  
Edit Mode Commands.............................................................................................108  
Example:..................................................................................................................109  
Program Format.....................................................................................................................109  
Using Labels in Programs .......................................................................................109  
Special Labels..........................................................................................................110  
Commenting Programs............................................................................................110  
Executing Programs - Multitasking .......................................................................................111  
Debugging Programs .............................................................................................................112  
Trace Command ......................................................................................................113  
Error Code Command..............................................................................................113  
Stop Code Command...............................................................................................113  
RAM Memory Interrogation Commands ................................................................113  
Operands..................................................................................................................114  
Breakpoints and single stepping..............................................................................114  
EEPROM Memory Interrogation Operands ............................................................114  
Program Flow Commands .....................................................................................................115  
Event Triggers & Trippoints....................................................................................115  
Conditional Jumps...................................................................................................119  
If, Else, and Endif....................................................................................................121  
Subroutines..............................................................................................................123  
Stack Manipulation..................................................................................................123  
Auto-Start and Auto Error Routine .........................................................................123  
Automatic Subroutines for Monitoring Conditions.................................................124  
Mathematical and Functional Expressions ............................................................................127  
Mathematical Operators ..........................................................................................127  
Bit-Wise Operators..................................................................................................128  
Functions .................................................................................................................129  
Variables................................................................................................................................129  
Programmable Variables .........................................................................................130  
Operands................................................................................................................................131  
Special Operands.....................................................................................................131  
Examples .................................................................................................................132  
Arrays ....................................................................................................................................132  
Defining Arrays.......................................................................................................132  
Assignment of Array Entries...................................................................................132  
Uploading and Downloading Arrays to On Board Memory....................................133  
Automatic Data Capture into Arrays.......................................................................133  
Deallocating Array Space........................................................................................135  
Outputting Numbers and Strings ...........................................................................................135  
Sending Messages ...................................................................................................135  
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Displaying Variables and Arrays.............................................................................137  
Interrogation Commands.........................................................................................137  
Formatting Variables and Array Elements ..............................................................139  
Converting to User Units.........................................................................................140  
Hardware I/O .........................................................................................................................140  
Digital Outputs ........................................................................................................140  
Digital Inputs...........................................................................................................141  
Input Interrupt Function ..........................................................................................142  
Analog Inputs ..........................................................................................................142  
Extended I/O of the DMC-3425 Controller...........................................................................143  
Configuring the I/O of the DMC-3425....................................................................143  
Saving the State of the Outputs in Non-Volatile Memory.......................................144  
Accessing Extended I/O ..........................................................................................144  
Interfacing to Grayhill or OPTO-22 G4PB24 .........................................................145  
Example Applications............................................................................................................145  
Wire Cutter..............................................................................................................145  
A-B (X-Y) Table Controller....................................................................................146  
Speed Control by Joystick.......................................................................................148  
Position Control by Joystick....................................................................................149  
Chapter 8 Hardware & Software Protection  
151  
Introduction ...........................................................................................................................151  
Hardware Protection ..............................................................................................................151  
Output Protection Lines...........................................................................................151  
Input Protection Lines .............................................................................................152  
Software Protection ...............................................................................................................152  
Example:..................................................................................................................152  
Programmable Position Limits................................................................................152  
Example:..................................................................................................................153  
Off-On-Error ...........................................................................................................153  
Examples:................................................................................................................153  
Automatic Error Routine.........................................................................................153  
Example:..................................................................................................................153  
Limit Switch Routine ..............................................................................................154  
Chapter 9 Troubleshooting  
155  
Overview ...............................................................................................................................155  
Installation .............................................................................................................................155  
Communication......................................................................................................................156  
Stability..................................................................................................................................156  
Operation ...............................................................................................................................156  
Chapter 10 Theory of Operation  
157  
Overview ...............................................................................................................................157  
Operation of Closed-Loop Systems.......................................................................................159  
System Modeling...................................................................................................................160  
Motor-Amplifier......................................................................................................161  
Encoder....................................................................................................................163  
DAC ........................................................................................................................164  
Digital Filter ............................................................................................................164  
ZOH.........................................................................................................................165  
System Analysis.....................................................................................................................165  
System Design and Compensation.........................................................................................167  
The Analytical Method............................................................................................167  
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Appendices  
171  
Electrical Specifications ........................................................................................................171  
Servo Control ..........................................................................................................171  
Input/Output ............................................................................................................171  
Power Requirements................................................................................................171  
Performance Specifications ...................................................................................................171  
Connectors for DMC-3425....................................................................................................172  
J3 DMC-3425 General I/O; 37- PIN D-type ...........................................................172  
J3 DMC-3425-Stepper General I/O; 37- PIN D-type..............................................173  
J5 POWER; 6 PIN MOLEX....................................................................................173  
J1 RS232 Main port: DB-9 Pin Male: .....................................................................174  
Pin-Out Description...............................................................................................................174  
ICM-1460 Interconnect Module ............................................................................................175  
Opto-Isolation Option for ICM-1460.....................................................................................177  
Opto-isolated inputs: ...............................................................................................177  
Opto-isolated outputs: .............................................................................................178  
64 Extended I/O of the DMC-3425 Controller ......................................................................179  
Configuring the I/O of the DMC-3425 with DB-14064..........................................179  
Connector Description:............................................................................................181  
IOM-1964 Opto-Isolation Module for Extended I/O Controllers..........................................183  
Description: .............................................................................................................183  
Overview .................................................................................................................184  
Configuring Hardware Banks..................................................................................185  
Digital Inputs...........................................................................................................185  
High Power Digital Outputs ....................................................................................187  
Standard Digital Outputs.........................................................................................188  
Electrical Specifications..........................................................................................189  
Relevant DMC Commands......................................................................................190  
Screw Terminal Listing...........................................................................................190  
Coordinated Motion - Mathematical Analysis.......................................................................193  
List of Other Publications......................................................................................................196  
Training Seminars..................................................................................................................196  
Contacting Us ........................................................................................................................197  
WARRANTY ........................................................................................................................198  
Index  
199  
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Chapter 1 Overview  
Introduction  
The DMC-3425 provides a highly versatile, powerful form of distributed control where multiple DMC-  
3425 controllers can be linked together on the Ethernet. One DMC-3425 is designated as a “master”  
that receives all commands from the host computer and passes them to the other “slave” DMC-3425  
controllers. Efficient, quick communications are realized as this approach eliminates the usual,  
multiple communication links between the host computer and each controller.  
Each DMC-3425 precisely controls two servo motors, providing ECAM, gearing and both linear and  
circular interpolation for coordinated motion along the two local axis. A single axis DMC-3415 is also  
available. When acting as the “master,” a DMC-3425 can receive PR, PA and JG commands for up to  
eight axes and distribute them to the appropriate controller. Coordinated motion is commanded locally  
by each DMC-3425 “slave” controller. Performance capability of these controllers includes: 12 MHz  
encoder input frequency, 16-bit motor command output DAC, +/-2 billion counts total travel per move,  
250 μsec minimum sample rate and non-volatile memory for program and parameter storage.  
Designed for maximum flexibility, the DMC-3425 can be interfaced to a variety of motors and drives  
including step motors, brush and brushless servo motors and hydraulics. The DMC-3425 can also be  
configured to provide sinusoidal commutation for brushless motors.  
The controller accepts feedback from a quadrature linear or rotary encoder with input frequencies up to  
12 million quadrature counts per second. Modes of motion include jogging, point-to-point positioning,  
electronic cam, electronic gearing and contouring. Several motion parameters can be specified  
including acceleration and deceleration rates and slew speed. The DMC-3425 also provides motion  
smoothing to eliminate jerk.  
For synchronization with outside events, the DMC-3425 provides uncommitted I/O. The DMC-3425  
provides up to 3 digital inputs, 3 digital outputs and 2 analog inputs. The DMC-3415 provides 7  
digital inputs, 3 digital outputs and 2 analog inputs. Committed digital inputs are provided for forward  
and reverse limits, abort, home, and definable input interrupts. An additional 64 configurable I/O  
points may be added with the optional DB-14064 daughter card. The DMC-3425 distributed system  
may also be linked with multiple IOC-7007 Ethernet I/O modules for complete machine I/O control.  
Event triggers can automatically check for elapsed time, distance and motion complete.  
The DMC-3425 is easy to program. Instructions are represented by two letter commands such as BG  
for Begin and SP for Speed. Conditional instructions, Jump statements and arithmetic functions are  
included for writing self-contained applications programs. An internal editor allows programs to be  
quickly entered and edited, and support software such as the WSDK allows quick system set-up and  
tuning. Commands may also be sent in Binary to decrease processing time.  
To prevent system damage during machine operation, the DMC-3425 provides many error-handling  
features. These include software and hardware limits, automatic shut-off on excessive error, abort  
input and user-definable error and limit routines.  
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The DMC-3425 is designed for stand-alone applications and provides non-volatile storage for  
programs, variables and array elements.  
This manual uses ‘DMC-3425’ to refer to the distributed control E-series from Galil. However, most  
functions described in this manual are available using either the DMC-3425 or the DMC-3415. If a  
function is specific to only one of the controllers, this will be explicitly stated.  
Overview of Motor Types  
The DMC-3425 can provide the following types of motor control:  
1. Standard servo motors with +/- 10 volt command signals  
2. Step motors with step and direction signals  
3. Brushless servo motors with sinusoidal commutation  
4. Other actuators such as hydraulics - For more information, contact Galil.  
The user can configure each axis for any combination of motor types, providing maximum flexibility.  
Standard Servo Motors with +/- 10 Volt Command Signal  
The DMC-3425 achieves superior precision through use of a 16-bit motor command output DAC and a  
sophisticated PID filter that features velocity and acceleration feedforward, an extra notch filter and  
integration limits.  
The controller is configured by the factory for standard servo motor operation. In this configuration,  
the controller provides an analog signal (+/- 10Volt) to connect to a servo amplifier. This connection  
is described in Chapter 2.  
Stepper Motor with Step and Direction Signals  
The DMC-3425 can control 2 stepper motors. In this mode, the controller provides two signals to  
connect to each stepper motor: Step and Direction. For stepper motor operation, the controller does  
not require an encoder and operates the stepper motor in an open loop. Chapter 2 describes the proper  
connection and procedure for using stepper motors.  
NOTE: In order to use two stepper motors on the DMC-3425, the controller must be ordered as a  
DMC-3425-Stepper. In this mode, the Amp Enable and Error outputs are converted to the Step and  
Direction signals for the Y-axis. Contact Galil for other stepper options.  
Brushless Servo Motor with Sinusoidal Commutation  
The DMC-3415 can provide sinusoidal commutation for brushless motors (BLM). In this  
configuration, the controller generates two sinusoidal signals for connection with amplifiers  
specifically designed for this purpose. Please note, for a 2 axis DMC-3425, converting to a brushless  
motor uses up the second axis.  
Note: The task of generating sinusoidal commutation may be accomplished in the brushless motor  
amplifier. If the amplifier generates the sinusoidal commutation signals, only a single command signal  
is required and the controller should be configured for a standard servo motor (described above).  
Sinusoidal commutation in the controller can be used with linear and rotary BLMs. However, the  
motor velocity should be limited such that a magnetic cycle lasts at least 6 milliseconds*. For faster  
motors, please contact the factory.  
The controller provides a one-time, automatic set-up procedure. The parameters determined by this  
procedure can then be saved in non-volatile memory to be used whenever the system is powered on.  
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The DMC-3415 can control BLMs equipped with Hall sensors as well as without Hall sensors. If hall  
sensors are available, once the controller has been setup, the controller will estimate the commutation  
phase upon reset. This allows the motor to function immediately upon power up. The Hall effect  
sensors also provide a method for setting the precise commutation phase. Chapter 2 describes the  
proper connection and procedure for using sinusoidal commutation of brushless motors.  
* 6 Milliseconds per magnetic cycle assumes a servo update of 1 msec (default rate).  
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DMC-3425 Functional Elements  
The DMC-3425 circuitry can be divided into the following functional groups as shown in Figure 1.1  
and discussed below.  
WATCHDOG TIMER  
ISOLATED LIMITS AND  
HOME INPUTS  
MAIN ENCODERS  
68331  
MICROCOMPUTER  
WITH  
HIGH-SPEED  
MOTOR/ENCODER  
INTERFACE  
ETHERNET  
AUXILIARY ENCODERS  
+/- 10 VOLT OUTPUT FOR  
SERVO MOTORS  
1 Meg RAM  
RS-232  
4 Meg FLASH EEPROM  
PULSE/DIRECTION OUTPUT  
FOR STEP MOTORS  
HIGH SPEED ENCODER  
COMPARE OUTPUT  
I/O INTERFACE  
2 UNCOMMITTED  
ANALOG INPUTS  
3 PROGRAMMABLE  
OUTPUTS  
3 PROGRAMMABLE,  
INPUTS  
HIGH-SPEED LATCH FOR EACH AXIS  
Figure 1.1 - DMC-3425 Functional Elements  
Microcomputer Section  
The main processing unit of the DMC-3425 is a specialized 32-bit Motorola 68331 Series  
Microcomputer with 1 Meg RAM and 4 Meg Flash EEPROM. The RAM provides memory for  
variables, array elements and application programs. The flash EEPROM provides non-volatile storage  
of variables, programs, and arrays. It also contains the DMC-3425 firmware.  
Motor Interface  
Galil’s GL-1800 custom, sub-micron gate array performs quadrature decoding of each encoder at up to  
12 MHz. For standard servo operation, the controller generates a +/-10 Volt analog signal (16 Bit  
DAC). For sinusoidal commutation operation, the controller uses two DACs to generate two +/-10Volt  
analog signals. For stepper motor operation, the controller generates a step and direction signal.  
Communication  
The communication interface with the DMC-3425 consists of one RS-232 port (19.2 kbaud) and one  
10base-T Ethernet port.  
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General I/O  
The DMC-3415 provides interface circuitry for 7 TTL inputs and 3 TTL outputs. In addition, the  
controller provides two 12-bit analog inputs. The general inputs can also be used for triggering a high-  
speed positional latch for each axis.  
NOTE: In order to accommodate 2 axes on the DMC-3425, many of the general I/O features become  
dedicated I/O for the second axis. The standard DMC-3425 will have 3 TTL inputs, 3 TTL outputs and  
2 analog inputs. If extra I/O is needed, the DB-14064 I/O daughter card increases general purpose I/O  
by 64 points.  
System Elements  
As shown in Fig. 1.2, the DMC-3425 is part of a motion control system, which includes amplifiers,  
motors and encoders. These elements are described below.  
Power Supply  
Amplifier (Driver)  
Computer  
DMC-3425 Controller  
Encoder  
Motor  
Figure 1.2 - Elements of Servo systems  
Motor  
A motor converts current into torque, which produces motion. Each axis of motion requires a motor  
sized properly to move the load at the required speed and acceleration. (Galil's "Motion Component  
Selector" software can help you with motor sizing). Contact Galil for more information.  
The motor may be a step or servo motor and can be brush-type or brushless, rotary or linear. For step  
motors, the controller is capable of controlling full-step, half-step, or microstep drives. An encoder is  
not required when step motors are used.  
Amplifier (Driver)  
For each axis, the power amplifier converts a +/-10 Volt signal from the controller into current to drive  
the motor. For stepper motors, the amplifier converts step and direction signals into current. The  
amplifier should be sized properly to meet the power requirements of the motor. For brushless motors,  
an amplifier that provides electronic commutation is required or the controller must be configured to  
provide sinusoidal commutation. The amplifiers may be either pulse-width-modulated (PWM) or  
linear. They may also be configured for operation with or without a tachometer. For current  
amplifiers, the amplifier gain should be set such that a 10 Volt command generates the maximum  
required current. For example, if the peak motor current is 10A, the amplifier gain should be 1 A/V.  
For velocity mode amplifiers, 10 Volts should run the motor at the maximum speed.  
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For step motors, the amplifiers should accept step and direction signals.  
Encoder  
An encoder translates motion into electrical pulses that are fed back into the controller. The DMC-3425  
accepts feedback from either a rotary or linear encoder. Typical encoders provide two channels in  
quadrature, known as CHA and CHB. This type of encoder is known as a quadrature encoder.  
Quadrature encoders may be either single-ended (CHA and CHB) or differential (CHA,CHA-,  
CHB,CHB-). The DMC-3425 decodes either type into quadrature states or four times the number of  
cycles. Encoders may also have a third channel (or index) for synchronization. The DMC-3425 can  
also interface to encoders with pulse and direction signals.  
There is no limit on encoder line density; however, the input frequency to the controller must not  
exceed 3,000,000 full encoder cycles/second (12,000,000 quadrature counts/sec). For example, if the  
encoder line density is 10000 cycles per inch, the maximum speed is 300 inches/second. If higher  
encoder frequency is required, please consult the factory.  
The standard voltage level is TTL (zero to five volts), however, voltage levels up to 12 Volts are  
acceptable. (If using differential signals, 12 Volts can be input directly to the DMC-3425. Single-  
ended 12 Volt signals require a bias voltage input to the complementary inputs.)  
The DMC-3425 can accept analog feedback instead of an encoder for any axis. For more information  
see description of analog feedback in the Command Reference under the AF command.  
To interface with other types of position sensors such as resolvers or absolute encoders, Galil can  
customize the controller and command set. Please contact Galil to talk to one of our applications  
engineers about your particular system requirements.  
Watch Dog Timer  
The DMC-3425 provides an internal watch dog timer which checks for proper microprocessor  
operation. The timer toggles the Amplifier Enable Output (AEN), which can be used to switch the  
amplifiers off in the event of a serious DMC-3425 failure. The AEN output is normally high. During  
power-up and if the microprocessor ceases to function properly, the AEN output will go low. The  
error light for each axis will also turn on at this stage. A reset is required to restore the DMC-3425 to  
normal operation. Consult the factory for a Return Materials Authorization (RMA) number if your  
DMC-3425 is damaged.  
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Chapter 2 Getting Started  
The DMC-3425 Motion Controller  
Daughter card connector for  
DB-14064 Extended I/O card  
Stepper motor/Motor off  
configuration jumpers  
+12V/-12V Test  
Points  
RAM  
+5V/Gnd Test  
Points  
JP2  
9-Pin DSub  
RS232 serial port  
J6  
DMC-1415  
REV D  
U4  
GALIL MOTION CONTROL  
MADE IN USA  
Ethernet  
network IC  
U1  
Motorola  
68331  
6 Pin Molex  
Power Connector  
Master reset/baud  
rate jumpers  
J4  
J1  
A8  
GL-1800  
U10  
U2  
A4  
A2  
A1  
J5  
JP1  
Reset switch  
Distributed Control Axis  
configuration jumpers  
SW1  
J2  
JP3  
J3  
D2  
D4  
SD MC  
Step/Direction or  
Motor Command  
configuration jumpers  
RJ-45 10BaseT  
Ethernet connector  
Status/Communications  
LED's  
Main 37-pin DSub  
connector  
Figure 2.1 – Outline of the DMC-3425  
DMC-3425  
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Elements You Need  
Before you start, you must get all the necessary system elements. These include:  
1. (1) DMC-3425 or DMC-3415, (1) 37-pin cable (order Cable -37).  
2. Servo motor(s) with encoders or stepper motors.  
3. Appropriate motor drive - servo amp (Power Amplifier or AMP-1460) or stepper drive.  
4. Power Supply for Amplifier  
5. +5V, ±12V supply for DMC-3425  
6. Communication CD from Galil  
7. WSDK Servo Design Software (not necessary, but strongly recommended)  
8. Interface Module ICM-1460 with screw-type terminals or integrated Interface  
Module/Amplifier, AMP-1460. (Note: An interconnect module is not necessary, but strongly  
recommended.) Also, the AMP-1460 only provides for 1 axis power amplification.  
The motors may be servo (brush or brushless type) or steppers. The driver (amplifier) should be  
suitable for the motor and may be linear or pulse-width-modulated and it may have current feedback or  
voltage feedback.  
For servo motors, the drivers should accept an analog signal in the +/-10 Volt range as a command.  
The amplifier gain should be set so that a +10V command will generate the maximum required current.  
For example, if the motor peak current is 10A, the amplifier gain should be 1 A/V. For velocity mode  
amplifiers, a command signal of 10 Volts should run the motor at the maximum required speed.  
For step motors, the driver should accept step and direction signals. For start-up of a step motor  
system refer to Step 8c “Connecting Step Motors”.  
The WSDK software is highly recommended for first time users of the DMC-3425. It provides step-  
by-step instructions for system connection, tuning and analysis.  
Installing the DMC-3425 Controller  
Installation of a complete, operational DMC-3425 system consists of 9 steps.  
Step 1.  
Step 2.  
Step 3.  
Step 4.  
Step 5.  
Step 6.  
Step 7.  
Step 8a.  
Step 8b.  
Step 8c.  
Step 9.  
Step 10.  
Determine overall motor configuration.  
Configuring jumpers on the DMC-3425.  
Connect the DC power supply and serial cable to the DMC-3425.  
Install the communications software.  
Establish communications between the DMC-3425 and the host PC.  
Set-up axis for sinusoidal commutation.  
Make connections to amplifier and encoder.  
Connect standard servo motor.  
Connect brushless motor for sinusoidal commutation.  
Connect step motor.  
Tune servo system.  
Configure distributed control system.  
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Step 1. Determine Overall Motor Configuration  
Before setting up the motion control system, the user must determine the desired motor configuration.  
The DMC-3425 can control standard brush or brushless servo motors, sinusoidally commutated  
brushless motors or stepper motors. For control of other types of actuators, such as hydraulics, please  
contact Galil. The following configuration information is necessary to determine the proper motor  
configuration:  
Standard Servo Motor Operation:  
The DMC-3425 has been setup by the factory for standard servo motor operation providing an analog  
command signal of +/- 10 volt. The position of the jumpers at JP2/JP3 determines the type of output  
the controllers will provide, analog motor command or PWM output. The installation of these jumpers  
is discussed in the section “Configuring Jumpers on the DMC-3425”. Figure 2.2 shows how the  
jumpers are configured for the standard output mode.  
The DMC-3425 controller will output the analog command signal to either brush or brushless servo  
amplifiers. Please note that if the brushless amplifier provides the sinusoidal commutation, the  
standard servo motor operation from the controller will be used. If the commutation is to be performed  
by the controller, please see below.  
Sinusoidal Commutation:  
Please consult the factory before operating with sinusoidal commutation.  
Sinusoidal commutation is configured through a single software command, BA. This setting causes  
the controller to reconfigure the control axis to output two commutated phases. The DMC-3425  
requires two DAC outputs for a single axis of commutation. Issuing the BA command will enable the  
second DAC for commutation.  
If a DMC-3425 is used for sinusoidal commutation, the second axis will be used for the second DAC  
phase. Please note that if the DMC-3425 is used for sinusoidal commutation, it will still be  
represented by two axes within the distributed system, even though only one axis is truly active. The  
DMC-3415 in brushless mode will take only a single axis within the distributed system.  
Further instruction for sinusoidal commutation connections are discussed in Step 6.  
Stepper Motor Operation:  
The DMC-3415 can be configured to operate in stepper mode by installing a hardware jumper and  
issuing a software command. The DMC-3425 can be configured to operate with two stepper motors by  
ordering the DMC-3425-Stepper option from the factory. To configure the DMC-3425 for stepper  
motor operation, the controller requires a jumper for the stepper motors and the command, MT, must  
be given. The installation of the stepper motor jumper is discussed in the following section entitled  
"Configuring Jumpers on the DMC-3425". Further instructions for stepper motor connections are  
discussed in Step 8b.  
Step 2. Configuring Jumpers on the DMC-3425  
Master Reset and Upgrade Jumper  
JP1 contains two jumpers, MRST and UPGD. The MRST jumper is the Master Reset jumper. When  
MRST is connected, the controller will perform a master reset upon PC power up or upon the reset  
input going low. Whenever the controller has a master reset, all programs, arrays, variables, and  
motion control parameters stored in EEPROM will be ERASED.  
The UPGD jumper enables the user to unconditionally update the controller’s firmware. This jumper  
is not necessary for firmware updates when the controller is operating normally, but may be necessary  
in cases of corrupted EEPROM. EEPROM corruption should never occur, however, it is possible if  
DMC-3425  
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there is a power fault during a firmware update. If EEPROM corruption occurs, your controller may  
not operate properly. In this case, install the UPGD Jumper and use the update firmware function on  
the Galil Smart Terminal or WSDK to re-load the system firmware.  
Setting the Baud Rate on the DMC-3425  
The jumpers labeled “9600” and “1200” at JP1 allow the user to select the serial communication baud  
rate. The baud rate can be set using the following table:  
JUMPER SETTINGS  
BAUD RATE  
9600  
OFF  
ON  
1200  
OFF  
OFF  
ON  
--  
19200  
9600  
1200  
OFF  
The default baud rate for the controller is 19.2k.  
Selecting MO as default on the DMC-3425  
The default condition for the motor on the DMC-3425 is the servo on (SH) state. This will enable the  
amplifiers upon power up of the controller. This state can be changed to the motor off (MO) default by  
placing a jumper at JP2 across the MO terminals. This will power up the controller with the amplifiers  
disabled and the motor command off. The SH command must then be given in order for the servos or  
steppers to operate.  
Stepper Motor Jumpers  
The DMC-3415 is user configurable to control either a servo motor or a stepper motor. The DMC-  
3425 is factory default to servo control, but may also control two steppers if ordered from the factory  
as a DMC-3425-Stepper.  
To configure the DMC-3415 for stepper output, two jumpers must be placed on the controller. First,  
the SMX jumper at location JP2 must be installed. This configures the board for step/direction output.  
Second, the jumpers at location JP3 must be moved from the MC position to the SD position as shown  
in Figure 2.2. This configures the output pins on the controller to output step and direction instead of  
the analog motor command.  
The configuration for two stepper motors on the DMC-3425-Stepper is handled at the factory. The  
same procedure is used, placing jumpers on SMX and SMY at location JP2, and moving the SD/MC  
jumpers at location JP3. A board modification is also required, which should only be handled by Galil  
technicians.  
JP3  
JP3  
SD  
MC  
SD MC  
Setting for step/direction output  
Setting for analog motor command  
Figure 2.2 - Jumper settings for motor command output  
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Axis Configuration Jumpers  
When using the HC automatic configuration, jumpers must be set to indicate which controller is the  
master and which controllers are slaves. Depending on the configuration of the jumpers, a controller  
will be set up as either the A (B) master or any of the axes slaves.  
The 8-pin jumper, found at location J4 next to the Molex power connector, is used to select axes  
configurations. Jumpers at this location are labeled A1, A2, A4 and A8, which represent the binary  
value for each of the 8 axes within a system. The following chart shows proper jumper selection for  
each of the DMC-3415 or DMC-3425’s in a system.  
Master A (B) axis  
Slave Axis B  
Slave Axes C  
Slave Axis D  
Slave Axes E  
Slave Axis F  
Slave Axes G  
Slave Axis H  
No Jumpers  
A1 On A2 Off A4 Off A8 Off  
A1 Off A2 On A4 Off A8 Off  
A1 On A2 On A4 Off A8 Off  
A1 Off A2 Off A4 On A8 Off  
A1 On A2 Off A4 On A8 Off  
A1 Off A2 On A4 On A8 Off  
A1 On A2 On A4 On A8 Off  
Jumpers on a card are used to denote the first axis it represents in a system. Therefore, a DMC-3415  
takes up a single jumper setting. A DMC-3425 is selected with a single jumper setting but represents  
two axes.  
For example, the jumper settings for a system with a DMC-3415 master A axis, a DMC-3425 slave BC  
axis and a DMC-3415 slave D axis, the following jumper settings would be used.  
Master A – No Jumpers  
Slave Axis BC – A1 On A2 Off A4 Off A8 Off  
Slave Axis D – A1 On  
A2 On A4 Off A8 Off  
A1 A2  
A4  
A8  
Fig. 2.3 – Example jumper settings for DMC-3425 E, F axis configuration.  
Step 3. Connecting AC or DC power and the Serial Cable to the  
DMC-3425  
1. Insert 37-pin cable to J3. Connect the other end of the cable to the ICM-1460.  
2. If using serial communications, use the 9-pin RS232 ribbon cable to connect the SERIAL port  
of the DMC-3425 to your computer or terminal communications port. The DMC-3425 serial  
DMC-3425  
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port is configured as DATASET. Your computer or terminal must be configured as a  
DATATERM for full duplex, no parity, 8 bits data, one start bit and one stop bit.  
Your computer needs to be configured as a "dumb" terminal that sends ASCII characters as  
they are typed to the DMC-3425.  
Connections to the controller for Ethernet communication are covered in Step 5.  
3. If using the card level version, apply ±12V and +5V power to the J5 connector. If using the  
box level version, connect the AC cord to a power outlet. AC power requirements for the  
controller are single phase, 50 or 60 Hz at 90 to 260 VAC.  
4. Applying power will turn on the green LED power indicator.  
Step 4. Installing the Communications Software  
After applying power to the computer, you should install the Galil software that enables  
communication between the controller and PC.  
Using DOS:  
Using the Galil Software CD-ROM, go to the directory, DMCDOS. Type "INSTALL" at the DOS  
prompt and follow the directions.  
Using Windows 3.x (16 bit versions):  
Using the Galil Software CD ROM, go to the directory, DMCWIN16. Run DMCWIN16.exe at the  
Command prompt and follow the directions.  
Using Windows 95, NT or 98 (32 bit versions):  
The Galil Software CD-ROM will automatically begin the installation procedure when the CD-ROM is  
installed. After installing the Galil CD-ROM software on your computer, you can easily install other  
software components as desired. To install the basic communications software, run the Galil Software  
CD-ROM and choose “DMC Smart Terminal”. This will install the Galil Terminal that can be used  
for communication.  
Step 5. Establishing Communication between the DMC-3425 and the  
host PC  
Note: This section will show how to communicate with a single DMC-3425 or DMC-3415 controller.  
If the controllers will be configured in a multi-axis, distributed control system, only the master axis  
needs an IP address actively configured.  
Communicating through the RS-232 Serial Communications Port  
Connect the DMC-3425 serial port to your computer via the Galil CABLE-9PIN-D (RS-232 Cable).  
Using Galil Software for DOS  
To communicate with the DMC-3425, type TALK2DMC at the prompt. Once you have established  
communication, the terminal display should show a colon, :. If you do not receive a colon, press the  
carriage return. If a colon prompt is not returned, there is most likely an incorrect setting of the serial  
communications port. The user must ensure that the correct communication port and baud rate are  
specified when attempting to communicate with the controller. Please note that the serial port on the  
controller must be set for handshake mode for proper communication with Galil software. The user  
must also insure that the proper serial cable is being used. See appendix for pin-out of serial port.  
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Using Galil Software for Windows  
In order for the Windows software to communicate with a Galil controller, the controller must be  
registered in the Windows Registry. To register a controller, you must specify the model of the  
controller, the communication parameters, and other information. The registry is accessed through the  
Galil software, such as WSDK or DMCSmartTerm.  
The registry window is equipped with a button to Add a New Controller, change the Properties of an  
existing controller, Delete a controller, or Find an Ethernet controller.  
Use the New Controller button to add a new entry to the Registry. Use the Properties button to  
change the properties of a current controller. For a new registration, you will need to supply the Galil  
Controller type. The controller model number must be entered. If you are changing an existing  
controller, this field will already have an entry. Pressing the down arrow to the right of this field will  
reveal a menu of valid controller types. Once the DMC-3425 has been selected, there is a choice for  
either Serial or Ethernet communication, as shown below. Select Serial communication.  
DMC-3425  
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After selecting Next, the registry information will show a default Comm Port of 1 and a default Comm  
Speed of 19200 appears. This information should be changed as necessary to reflect the computers  
Comm Port and the baud rate set by the controller's baud rate jumpers.  
Once you have set the appropriate Registry information for your controller, Select Finish and close the  
registry window. You will now be able to communicate with the DMC-3425. Within WSDK, select  
File and Connect to Controller. Within DMCSmartTerm, select Tools and Select Controller. Once  
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the entry has been selected, click on the OK button. If the software has successfully established  
communications with the controller, the registry entry will be displayed at the top of the screen.  
If you are not properly communicating with the controller, the program will pause for 3-15 seconds.  
The top of the screen will display the message “Status: not connected with Galil motion controller” and  
the following error will appear: “STOP - Unable to establish communication with the Galil controller.  
A time-out occurred while waiting for a response from the Galil controller.” If this message appears,  
you must click OK. In this case, there is most likely an incorrect setting of the serial communications  
port. The user must ensure that the correct communication port and baud rate are specified when  
attempting to communicate with the controller. Please note that the serial port on the controller must  
be set for handshake mode for proper communication with Galil software. The user must also insure  
that the proper straight-through serial cable is being used (no Null modem). See appendix for the  
correct pin-outs for the serial cable.  
Once you establish communications, click on the menu for terminal and you will receive a colon  
prompt. Communicating with the controller is described in later sections.  
Using Non-Galil Communication Software  
The DMC-3425 serial port is configured as DATASET. Your computer or terminal must be  
configured as a DATATERM for full duplex, no parity, 8 data bits, one start bit and one stop bit.  
Check to insure that the baud rate switches have been set to the desired baud rate as described above.  
Your computer needs to be configured as a "dumb" terminal that sends ASCII characters as they are  
typed to the DMC-3425. Use the EO command to specify if the characters should be echoed back  
from the controller.  
Sending Test Commands to the Terminal:  
After you connect your terminal, press <carriage return> or the <enter> key on your keyboard. In  
response to carriage return (CR), the controller responds with a colon, :  
Now type  
TPA (CR)  
This command directs the controller to return the current position of the A axis. The controller should  
respond with a number such as  
0000000  
Communicating through the Ethernet  
For Ethernet communication, connect the DMC-3425 to your computer or to a hub. If connecting  
through a switch or a hub, a standard RJ45 Ethernet cable is used. If connecting directly to the PC, a  
cross-over RJ45 Ethernet cable must be used.  
Using Galil Software for Windows  
The controller must be registered in the Galil Windows registry for the host computer to communicate  
with it. The registry may be accessed via Galil software, such as WSDK or DMCSmartTerm.  
From WSDK, the registry is accessed under the FILE menu. From DMCSmartTerm it is accessed  
under the Tools and Controller Registration menu. In the Galil Registry, the DMC-3425 can either  
be added manually with the New Controller button or the software can automatically try to find the  
controller with the Find Ethernet Controller button.  
The first registry option is to use the New Controller button. The DMC-3425 should be selected from  
the models listed, with Ethernet selected as the mode of communication.  
DMC-3425  
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After Next is pressed, the next screen will allow the IP address to be selected and assigned.  
Enter the IP address obtained from your system administrator into the box IP Address. Select the  
button corresponding to the protocol in which you wish to communicate with the controller, UDP or  
TCP. If the IP address has not been already assigned to the controller, click on ASSIGN IP  
ADDRESS.  
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ASSIGN IP ADDRESS will check the controllers that are linked to the network to see which ones do  
not have an IP address. The program will then ask you whether you would like to assign the IP  
address you entered to the controller with the specified serial number. Click on YES to assign it, NO  
to move to next controller, or CANCEL to not save the changes. If there are no controllers on the  
network that do not have an IP address assigned, the program will state this. Once the correct  
controller has been selected, click on Finish.  
If an IP address has already been assigned to the controller through the serial port and the IA  
command, add this address to the IP Address box and then select Finish.  
The second method for registering the controller is by using the option within the registry labeled Find  
Ethernet Controllers. This utility uses the DMCNet software program to search for any controllers  
on the network, both with and without IP addresses. If the DMC-3425 does not have an IP address, the  
utility will listen for the BOOTP packet and then ask for an IP address to be assigned. Once the IP  
address is added, click on Register and the controller will be added to the Galil Registry. If an IP  
address has already been assigned to the controller, the utility will list that controller with its current IP  
address. At this point, click on Register and the controller will be added to the Galil Registry.  
Once you have set the appropriate Registry information for your controller, Select Close to close the  
registry window. You will now be able to communicate with the DMC-3425. Within WSDK, select  
File and Connect to Controller. Within DMCSmartTerm, select Tools and Select Controller. Once  
the appropriate entry has been selected, click on the OK button. If the software has successfully  
established communications with the controller, the registry entry will be displayed at the top of the  
screen.  
See Chapter 4 Communication for additional information on the Ethernet configuration and  
connection.  
Sending Test Commands to the Terminal:  
After you connect your terminal, press <return> or the <enter> key on your keyboard. In response to  
carriage return <return>, the controller responds with a colon, :  
Now type  
TPA <return>  
This command directs the controller to return the current position of the A axis. The controller should  
respond with a number such as  
0000000  
Step 6. Set-up axis for sinusoidal commutation (optional)  
* This step is only required when the controller will be used to control a brushless motor with  
sinusoidal commutation. Please consult the factory before operating with sinusoidal commutation.  
The command BA is used to specify sinusoidal commutation mode for the DMC-3415 or DMC-3425.  
In this mode the controller will output two sinusoidal phases for the DACs. Once specified, follow the  
procedure outlined in Step 8b.  
Step 7. Make connections to amplifier and encoder  
Once you have established communications between the software and the DMC-3425, you are ready to  
connect the rest of the motion control system. The motion control system generally consists of an  
ICM-1460 Interface Module, a servo amplifier, and a motor to transform the current from the servo  
amplifier into torque for motion. Galil also offers the AMP-1460 Interface Module which is an ICM-  
1460 equipped with a servo amplifier for a DC motor.  
DMC-3425  
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A signal breakout board of some type is strongly recommended. If you are using a breakout board  
from a third party, consult the documentation for that board to insure proper system connection.  
If you are using the ICM-1460 or AMP-1460 with the DMC-3425, connect the 37-pin cable between  
the controller and interconnect module.  
Here are the first steps for connecting a motion control system:  
Step A. Connect the motor to the amplifier with no connection to the controller. Consult the  
amplifier documentation for instructions regarding proper connections. Connect and  
turn on the amplifier power supply. If the amplifiers are operating properly, the  
motor should stand still even when the amplifiers are powered up.  
Step B. Connect the amplifier enable signal. Before making any connections from the  
amplifier to the controller, you need to verify that the ground level of the amplifier is  
either floating or at the same potential as earth.  
Note: If you are using a DMC-3425-Stepper, the amplifier enable signal is used for  
the second stepper output.  
WARNING: When the amplifier ground is not isolated from the power line or when it has a different potential  
than that of the computer ground, serious damage may result to the computer controller and amplifier.  
If you are not sure about the potential of the ground levels, connect the two ground  
signals (amplifier ground and earth) by a 10 kΩ resistor and measure the voltage  
across the resistor. Only if the voltage is zero, proceed to connect the two ground  
signals directly.  
The amplifier enable signal is used by the controller to disable the motor. This  
signal is labeled AMPEN on the ICM-1460 and should be connected to the enable  
signal on the amplifier. Note that many amplifiers designate this signal as the  
INHIBIT signal. Use the command, MO, to disable the motor amplifiers - check to  
insure that the motor amplifiers have been disabled (often this is indicated by an  
LED on the amplifier).  
This signal changes under the following conditions: the watchdog timer activates,  
the motor-off command, MO, is given, or the OE1 command (Enable Off-On-Error)  
is given and the position error exceeds the error limit. As shown in Figure 3.1, AEN  
can be used to disable the amplifier for these conditions.  
The standard configuration of the AEN signal is TTL active high. In other words,  
the AEN signal will be high when the controller expects the amplifier to be enabled.  
The polarity and the amplitude can be changed if you are using the ICM-1460  
interface board. To change the polarity from active high (5 volts = enable, zero volts  
= disable) to active low (zero volts = enable, 5 volts = disable), replace the 7407 IC  
with a 7406. Note that many amplifiers designate the enable input as ‘inhibit’.  
To change the voltage level of the AEN signal, note the state of the JP1 jumper on  
the ICM-1460. When the jumper is placed across 5V and AEN, the output voltage is  
0-5V. To change to 12 volts, pull the jumper and rotate it so that +12V is connected  
to AEN. If you remove the jumper, the output signal is an open collector, allowing  
the user to connect an external supply with voltages up to 24V.  
Step C. Connect the encoders  
For stepper motor operation, an encoder is optional.  
For servo motor operation, if you have a preferred definition of the forward and  
reverse directions, make sure that the encoder wiring is consistent with that  
definition.  
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The DMC-3425 accepts single-ended or differential encoder feedback with or  
without an index pulse. If you are not using the AMP-1460 or the ICM-1460, you  
will need to consult the appendix for the encoder pinouts for connection to the  
motion controller. The AMP-1460 and the ICM-1460 can accept encoder feedback  
from a 10-pin ribbon cable or individual signal leads. For a 10-pin ribbon cable  
encoder, connect the cable to the protected header connector labeled JP2. For  
individual wires, simply match the leads from the encoder you are using to the  
encoder feedback inputs on the interconnect board. The signal leads are labeled  
CHA, CHB, and INDEX. These labels represent channel A, channel B, and the  
INDEX pulse, respectively. For differential encoders, the complement signals are  
labeled CHA-, CHB-, and INDEX-.  
Note: When using pulse and direction encoders, the pulse signal is connected to  
CHA and the direction signal is connected to CHB. The controller must be  
configured for pulse and direction with the command CE. See the command  
summary for further information on the command CE.  
Step D. Verify proper encoder operation.  
Once the encoder is connected as described above, turn the motor shaft and  
interrogate the position with the instruction TP <return>. The controller response  
will vary as the motor is turned.  
At this point, if TP does not vary with encoder rotation, there are three possibilities:  
1. The encoder connections are incorrect - check the wiring as necessary.  
2. The encoder has failed - using an oscilloscope, observe the encoder signals.  
Verify that both channels A and B have a peak magnitude between 5 and 12  
volts. Note that if only one encoder channel fails, the position reporting varies  
by one count only. If the encoder failed, replace the encoder. If you cannot  
observe the encoder signals, try a different encoder.  
3. There is a hardware failure in the controller - connect the same encoder to a  
different axis. If the problem disappears, you probably have a hardware failure.  
Consult the factory for help.  
Step E. Connect Hall Sensors if available (sinusoidal commutation only)  
Please consult factory before operating with sinusoidal commutation. Hall sensors  
are only used with sinusoidal commutation on the DMC-3415 or DMC-3425 and are  
not necessary for proper operation. The use of hall sensors allows the controller to  
automatically estimate the commutation phase upon reset and also provides the  
controller the ability to set a more precise commutation phase. Without hall sensors,  
the commutation phase must be determined manually.  
The Hall effect sensors are connected to the digital inputs of the controller. These  
inputs can be used with the general-purpose inputs (bits 1 - 7). If you are using the  
DMC-3425, only the first 3 inputs are available for general purpose.  
Each set of inputs must use inputs that are in consecutive order. The input lines are  
specified with the command, BI. For example, if the Hall sensors are connected to  
inputs 1, 2 and 3, use the instruction:  
BI1 <CR>  
Step 8a. Connect Standard Servo Motor  
The following discussion applies to connecting the DMC-3425 controller to standard servo motor  
amplifiers:  
DMC-3425  
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The motor and the amplifier may be configured in the torque or the velocity mode. In the torque  
mode, the amplifier gain should be such that a 10 Volt signal generates the maximum required current.  
In the velocity mode, a command signal of 10 Volts should run the motor at the maximum required  
speed.  
Step by step directions on servo system setup are also included on the WSDK (Windows Servo Design  
Kit) software offered by Galil. See section on WSDK for more details.  
Check the Polarity of the Feedback Loop  
It is assumed that the motor and amplifier are connected together and that the encoder is operating  
correctly (Step D). Before connecting the motor amplifiers to the controller, read the following  
discussion on setting Error Limits and Torque Limits.  
Step A. Set the Error Limit as a Safety Precaution  
Usually, there is uncertainty about the correct polarity of the feedback. The wrong  
polarity causes the motor to run away from the starting position. Using a terminal  
program, such as DMCSmartTerm, the following parameters can be given to avoid  
system damage:  
Input the commands:  
ER 2000,2000 <CR>  
OE 1,1 <CR>  
Sets error limit to be 2000 counts  
Disables amplifier when excess error exists  
If the motor runs away and creates a position error of 2000 counts, the motor  
amplifier will be disabled.  
Note: This function requires the AEN signal to be connected from the controller to  
the amplifier.  
Step B. Setting Torque Limit as a Safety Precaution  
To limit the maximum voltage signal to your amplifier, the DMC-3425 controller has  
a torque limit command, TL. This command sets the maximum voltage output of the  
controller and can be used to avoid excessive torque or speed when initially setting  
up a servo system.  
When operating an amplifier in torque mode, the voltage output of the controller will  
be directly related to the torque output of the motor. The user is responsible for  
determining this relationship using the documentation of the motor and amplifier.  
The torque limit can be set to a value that will limit the motors output torque.  
When operating an amplifier in velocity or voltage mode, the voltage output of the  
controller will be directly related to the velocity of the motor. The user is responsible  
for determining this relationship using the documentation of the motor and amplifier.  
The torque limit can be set to a value that will limit the speed of the motor.  
For example, the following command will limit the output of the controller to 1 volt:  
TL 1 <CR>  
Sets torque limit to 1 Volt on A axis  
Note: Once the correct polarity of the feedback loop has been determined, the torque  
limit should, in general, be increased to the default value of 9.99. The servo will not  
operate properly if the torque limit is below the normal operating range. See  
description of TL in the command reference.  
Step C. Disable motor  
Issue the motor off command to disable the motor.  
MO <CR>  
Turns motor off  
Step D. Connecting the Motor  
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Once the parameters have been set, connect the analog motor command signal  
(ACMD) to the amplifier input.  
Issue the servo here command to turn the motors on. To test the polarity of the  
feedback, command a move with the instruction:  
SH <CR>  
Servo Here to turn motors on  
Position relative 1000 counts  
Begin motion  
PR 1000 <CR>  
BG <CR>  
When the polarity of the feedback is wrong, the motor will attempt to run away. The  
controller should disable the motor when the position error exceeds 2000 counts. In  
this case, the polarity of the loop must be inverted.  
Inverting the Loop Polarity  
When the polarity of the feedback is incorrect, the user must invert the loop polarity and this may be  
accomplished by several methods. If you are driving a brush-type DC motor, the simplest way is to  
invert the two motor wires (typically red and black). For example, switch the M1 and M2 connections  
going from your amplifier to the motor. When driving a brushless motor, the polarity reversal may be  
done with the encoder. If you are using a single-ended encoder, interchange the signal CHA and CHB.  
If, on the other hand, you are using a differential encoder, interchange only CHA+ and CHA-. The  
loop polarity and encoder polarity can also be affected through software with the MT, and CE  
commands. For more details on the MT command or the CE command, see the Command Reference  
section.  
Sometimes the feedback polarity is correct (the motor does not attempt to run away) but the direction  
of motion is reversed with respect to the commanded motion. If this is the case, reverse the motor  
leads AND the encoder signals.  
If the motor moves in the required direction but stops short of the target, it is most likely due to  
insufficient torque output from the motor command signal ACMD. This can be alleviated by reducing  
system friction on the motors. The instruction:  
TT <CR>  
Tell torque  
reports the level of the output signal. It will show a non-zero value that is below the friction level.  
Once you have established that you have closed the loop with the correct polarity, you can move on to  
the compensation phase (servo system tuning) to adjust the PID filter parameters, KP, KD and KI. It is  
necessary to accurately tune your servo system to ensure fidelity of position and minimize motion  
oscillation as described in the next section.  
DMC-3425  
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J2  
ICM-1460  
Encoder lines  
VAMP+  
Motor 1  
Power Supply  
AMPGND  
Motor  
Motor 2  
Figure 2.3 - System Connections with the AMP-1460 Amplifier  
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ICM-1460  
Description  
Connection  
Channel A+  
Channel B+  
Channel A-  
Channel B-  
Index -  
MA+  
MB+  
MA-  
MB-  
I-  
Index +  
I+  
Gnd  
+5V  
GND  
5V  
Red Connector  
Red Wire  
Black Wire  
Black Connector  
11 INHIBIT  
4 +REF IN  
2 SIGNALGND  
Figure 2.4 - System Connections with a separate amplifier (MSA 12-80). This diagram shows the  
connections for a standard DC Servo Motor and encoder.  
Step 8b. Connect brushless motor for sinusoidal commutation  
Please consult the factory before operating with sinusoidal commutation. Any controller within  
the distributed system may be configured for sinusoidal commutation. If a DMC-3415 is used, the  
second DAC is simply initiated with the BA command. If a DMC-3425 is used, it will control only a  
single brushless motor, but will take up two axes in configuration. When using sinusoidal  
commutation, the parameters for the commutation must be determined and saved in the controller’s  
non-volatile memory. The servo can then be tuned as described in Step 9.  
Step A. Disable the motor amplifier  
Use the command, MO, to disable the motor amplifiers.  
Step B. Connect the motor amplifier to the controller.  
The sinusoidal commutation amplifier requires 2 signals, usually denoted as Phase A  
and Phase B. These inputs should be connected to the two sinusoidal signals  
DMC-3425  
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generated by the controller. The first signal is the main controller motor output,  
ACMD. The second signal utilizes the second DAC on the controller and is brought  
out on the ICM-1460 at pin 38 (ACMD2).  
It is not necessary to be concerned with cross-wiring the 1st and 2nd signals. If this  
wiring is incorrect, the setup procedure will alert the user (Step D).  
Step C. Specify the Size of the Magnetic Cycle.  
Use the command, BM, to specify the size of the brushless motors magnetic cycle in  
encoder counts. For example, if you are using a linear motor where the magnetic  
cycle length is 62 mm, and the encoder resolution is 1 micron, the cycle equals  
62,000 counts. This can be commanded with the command:  
BM 62000 <CR>  
On the other hand, if you are using a rotary motor with 4000 counts per revolution  
and 3 magnetic cycles per revolution (three pole pairs) the command is:  
BM 1333.333 <CR>  
Step D. Test the Polarity of the DACs and Hall Sensor Configuration.  
Use the brushless motor setup command, BS, to test the polarity of the output DACs.  
This command applies a certain voltage, V, to each phase for some time T, and  
checks to see if the motion is in the correct direction.  
The user must specify the value for V and T. For example, the command:  
BS 2,700 <CR>  
will test the brushless axis with a voltage of 2 volts, applying it for 700 milliseconds  
for each phase. In response, this test indicates whether the DAC wiring is correct and  
will indicate an approximate value of BM. If the wiring is correct, the approximate  
value for BM will agree with the value used in the previous step.  
Note: In order to properly conduct the brushless setup, the motor must be allowed to  
move a minimum of one magnetic cycle in both directions.  
Note: When using Galil Windows software, the timeout must be set to a minimum of  
10 seconds (time-out = 10000) when executing the BS command. This allows the  
software to retrieve all messages returned from the controller.  
If Hall Sensors are Available:  
Since the Hall sensors are connected randomly, it is very likely that they are wired in  
the incorrect order. The brushless setup command indicates the correct wiring of the  
Hall sensors. The hall sensor wires should be re-configured to reflect the results of  
this test.  
The setup command also reports the position offset of the hall transition point and the  
zero phase of the motor commutation. The zero transition of the Hall sensors  
typically occurs at 0°, 30° or 90° of the phase commutation. It is necessary to  
inform the controller about the offset of the Hall sensor and this is done with the  
instruction, BB.  
Step E. Save Brushless Motor Configuration  
It is very important to save the brushless motor configuration in non-volatile  
memory. After the motor wiring and setup parameters have been properly  
configured, the burn command, BN, should be given.  
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If Hall Sensors are Not Available:  
Without hall sensors, the controller will not be able to estimate the commutation  
phase of the brushless motor. In this case, the controller could become unstable until  
the commutation phase has been set using the BZ command (see next step). It is  
highly recommended that the motor off command be given before executing the BN  
command. In this case, the motor will be disabled upon power up or reset and the  
commutation phase can be set before enabling the motor.  
Step F. Set Zero Commutation Phase  
When an axis has been defined as sinusoidally commutated, the controller must have  
an estimate for commutation phase. When hall sensors are used, the controller  
automatically estimates this value upon reset of the controller. If no hall sensors are  
used, the controller will not be able to make this estimate and the commutation phase  
must be set before enabling the motor.  
If Hall Sensors are Not Available:  
To initialize the commutation without Hall effect sensor use the command, BZ. This  
function drives the motor to a position where the commutation phase is zero, and sets  
the phase to zero.  
The BZ command argument is a real number that represents the voltage to be applied  
to the amplifier during the initialization. When the voltage is specified by a positive  
number, the initialization process will end up in the motor off (MO) state. A  
negative number causes the process to end in the Servo Here (SH) state.  
Warning: This command must move the motor to find the zero commutation phase.  
This movement is instantaneous and will cause the system to jerk. Larger applied  
voltages will cause more severe motor jerk. The applied voltage will typically be  
sufficient for proper operation of the BZ command. For systems with significant  
friction, this voltage may need to be increased and for systems with very small  
motors, this value should be decreased.  
For example,  
BZ -2 <CR>  
will drive the axis to zero, using a 2V signal. The controller will then leave the  
motor enabled. For systems that have external forces working against the motor,  
such as gravity, the BZ argument must provide a torque 10x the external force. If the  
torque is not sufficient, the commutation zero may not be accurate.  
If Hall Sensors are Available:  
The estimated value of the commutation phase is good to within 30°. This estimate  
can be used to drive the motor but a more accurate estimate is needed for efficient  
motor operation. There are 3 possible methods for commutation phase initialization:  
Method 1. Use the BZ command as described above.  
Method 2. Drive the motor close to commutation phase of zero and then use BZ  
command. This method decreases the amount of system jerk by moving the motor  
close to zero commutation phase before executing the BZ command. The controller  
makes an estimate for the number of encoder counts between the current position and  
the position of zero commutation phase. This value is stored in the operand _BZx.  
Using this operand the controller can be commanded to move the motor. The BZ  
command is then issued as described above. For example, to initialize the A axis  
motor upon power or reset, the following commands may be given:  
SH <CR>  
Enable A axis motor  
DMC-3425  
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PRA=-1*(_BZA) <CR> Move A motor close to zero commutation phase  
BGA <CR>  
AMA<CR>  
BZA=-1 <CR>  
Begin motion on A axis  
Wait for motion to complete on A axis  
Drive motor to commutation phase zero and leave motor  
on  
Method 3. Use the command, BC. This command uses the hall transitions to  
determine the commutation phase. Ideally, the hall sensor transitions will be  
separated by exactly 60° and any deviation from 60° will affect the accuracy of this  
method. If the hall sensors are accurate, this method is recommended. The BC  
command monitors the hall sensors during a move and monitors the Hall sensors for  
a transition point. When that occurs, the controller computes the commutation phase  
and sets it. For example, to initialize the motor upon power or reset, the following  
commands may be given:  
SH <CR>  
Enable motor  
BC <CR>  
Enable the brushless calibration command  
Command a relative position movement  
PR 50000 <CR>  
BG <CR>  
Begin motion. When the hall sensors detect a phase  
transition, the commutation phase is re-set.  
Step 8c. Connect Step Motors  
In Stepper Motor operation, the pulse output signal has a 50% duty cycle. Step motors operate open  
loop and do not require encoder feedback. When a stepper is used, the auxiliary encoder for the  
corresponding axis is unavailable for an external connection. If an encoder is used for position  
feedback, connect the encoder to the main encoder input corresponding to that axis. The commanded  
position of the stepper can be interrogated with RP or DE. The encoder position can be interrogated  
with TP. Only the DMC-3415 allows the use of the main encoder input with a stepper motor. The  
DMC-3425 does not have this option.  
The frequency of the step motor pulses can be smoothed with the filter parameter, KS. The KS  
parameter has a range between 0.5 and 8, where 8 implies the largest amount of smoothing. See  
Command Reference regarding KS.  
The DMC-3425 profiler commands the step motor amplifier. All DMC-3425 motion commands apply  
such as PR, PA, VP, CR and JG. The acceleration, deceleration, slew speed and smoothing are also  
used. Since step motors run open-loop, the PID filter does not function and the position error is not  
generated.  
To connect step motors with the DMC-3425 you must follow this procedure:  
Step A. Install SM jumper  
Install the jumper SMX at location JP2 to enable stepper motor operation on the  
DMC-3415. For the DMC-3425-Stepper, the jumpers should be loaded on SMX and  
SMY. For a discussion of SM jumpers, see section “Step 2. Configuring Jumpers on  
the DMC-3425”.  
Step B. Connect step and direction signals from the controller to respective signals on your  
step motor amplifier.  
The DMC-3415 outputs STEPX (step) signals on the ICM-1460 terminal labeled  
ACMD, and outputs DIRX (direction) signals on the ICM-1460 terminal labeled  
ACMD2.  
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The DMC-3425 outputs STEPY signals on the ICM-1460 terminal labeled ERROR,  
and outputs DIRX on the ICM-1460 terminal labeled AMPEN. X-axis connections  
are identical to the DMC-3415.  
Consult the documentation for your step motor amplifier for proper connections.  
Step C. Configure DMC-3425 for motor type using MT command. You can configure the  
DMC-3425 for active high or active low pulses. Use the command MT 2 for active  
high step motor pulses and MT -2 for active low step motor pulses. See description  
of the MT command in the Command Reference.  
Note: The DMC-3425 must be ordered as a DMC-3425-Stepper to drive two axes of stepper motors.  
Step 9. Tune the Servo System  
The system compensation provides fast and accurate response by adjusting the filter parameters. The  
following presentation suggests a simple and easy way for compensation. More advanced design  
methods are available with software design tools from Galil, such as the Windows Servo Design Kit  
(WSDK software).  
If the torque limit was set as a safety precaution in the previous step, you may want to increase this  
value. See Step B of the above section “Setting Torque Limit as a Safety Precaution”  
The filter has three parameters: the damping, KD; the proportional gain, KP; and the integrator, KI.  
The parameters should be selected in this order.  
To start, set the integrator to zero with the instruction  
KI 0 <CR>  
Integrator gain  
and set the proportional gain to a low value, such as  
KP 1 <CR>  
Proportional gain  
Derivative gain  
KD 100 <CR>  
For more damping, you can increase KD (maximum is 4095). Increase gradually and stop after the  
motor vibrates. A vibration is noticed by audible sound or by interrogation. If you send the command  
TE <CR>  
Tell error  
a few times, and get varying responses, especially with reversing polarity, it indicates system vibration.  
When this happens, simply reduce KD.  
Next you need to increase the value of KP gradually (maximum allowed is 1023). You can monitor the  
improvement in the response with the Tell Error instruction  
KP 10 <CR>  
TE <CR>  
Proportion gain  
Tell error  
As the proportional gain is increased, the error decreases.  
Again, the system may vibrate if the gain is too high. In this case, reduce KP. Typically, KP should  
not be greater than KD/4.  
Finally, to select KI, start with zero value and increase it gradually. The integrator eliminates the  
position error, resulting in improved accuracy. Therefore, the response to the instruction  
TE <CR>  
becomes zero. As KI is increased, its effect is amplified and it may lead to vibrations. If this occurs,  
simply reduce KI.  
For a more detailed description of the operation of the PID filter and/or servo system theory, see  
Chapter 10 Theory of Operation.  
DMC-3425  
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Step 10. Configure the Distributed Control System  
The final step in Getting Started with the DMC-3425 distributed control system is to configure the  
individual controllers as their respective axes in the system. For more information on the operation of  
distributed control, please refer to Chapter 4.  
Configuring Operation for Distributed Control  
There are two methods for configuring a distributed control system; an automatic mode or a manual  
mode. The automatic mode uses a single command (HC) to configure all the slaves in a particular  
system. This command uses the BOOTP packets from the slaves, along with configuration jumpers, to  
automatically select IP addresses and set up the system. In the manual mode, slave controllers are  
assigned IP addresses and then configured into axes through various software commands. Both  
methods are outlined below.  
Automatic Configuration of Distributed Control  
The automatic method of assigning a distributed control network uses the HC command to indicate  
number of axes, type of communication and update rate of a system. This command also configures  
the number of IOC extended I/O modules in the system, if any.  
The data update rate specifies the rate at which each slave sends a data packet to the master containing  
current status information. The data records are used by the master controller to make decisions based  
on the status of the slave controllers or IOC-7007 modules. This data record rate may be selected  
manually with the QW command, but will be set automatically by the second field of the HC  
command.  
The data contained in the record is as follows:  
reference position  
encoder position  
position error  
velocity  
torque  
limit and home switches  
axis status (in motion, motor off, at speed, stopcode)  
uncommitted inputs  
uncommitted outputs  
user defined variables (4)  
In order for the HC command to be initiated, an IP address must already be assigned to the master. See  
Step 5 “Establishing Communication between the DMC-3425 and the host PC” for information on  
addressing the master controller. The slaves, in this method, will typically remain without IP  
addresses. If the slaves are to be addressed manually while still using the HC mode, skip to the next  
section Manual Slave IP configuration with HC command.  
Once initiated, the master controller will ARP for slaves with IP address already assigned, and then  
‘listen’ for BOOTP packets from the slave controllers without IP addresses. As it receives these  
packets, the master will configure the slave axes according to jumpers set on each slave controller.  
Once this connection has been established, the master will initiate QW, or data records, to begin from  
each slave for status updates.  
The full procedure for this method is as follows:  
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Step 1. Assign IP address to master controller either through IA command or through  
BOOTP utility in the Galil Software Registry. You may then burn this IP address  
into the master with the BN in order to keep this address during resets.  
Step 2. Place jumpers on each slave controller indicating which slave corresponds to which  
axes in the system. See section “Step 2. Configuring Jumpers on the DMC-3425”.  
Step 3. Determine total number of axes, data update rate, and number of IOC-7007  
controllers in the distributed system.  
Step 4. Issue the command HCn,m,o,p where n is the total number of axes, m is the data  
update rate in milliseconds, o is a 1 for UDP communication or 2 for TCP/IP  
communication and p is the total number of IOC-7007’s in the system. When using  
UDP communication, the HC command will assign one handle for both commands  
and QW records. When using TCP/IP communication, the HC command will assign  
one handle for commands and one handle for QW records. If o is a 3, then TCP/IP is  
used for commands, and UDP is used for QW records.  
Step 5. Poll the operand _HC for success of connection. A response of 1 indicates the  
command is currently executing, a 2 for a successful configuration and a 0 for a  
failed configuration or no HC issued.  
NOTE: The HC command may take up to 20 seconds to complete due to the time involved in waiting  
for the BOOTP packets.  
Manual Slave IP configuration with HC command  
It may be desired to manually assign an IP address to the slaves, while still using the HC command to  
connect to these slaves. This is possible, but you will need to take into account the addressing scheme  
the HC command is using, and you must install axis configuration jumpers according to “Step 2.  
Configuring jumpers on the DMC-3425”.  
When the HC command is initiated, the master will ARP addresses where it expects slave controllers  
to reside. If no controllers respond to the ARPs, the master will then ‘listen’ for the BOOTP packets  
from un-assigned slave controllers.  
For addressing the slaves manually, the IP address MUST be assigned as follows. This will insure that  
the HC command will properly configure these controllers based on the master IP address.  
Assume Master IP address = m.n.o.p where m, n, o and p is a valid Ethernet IP address.  
First Slave IP address (Axis B or C) = m.n.o.p+2  
Next slave is assigned +2 if previous slave was a single axis (DMC-3415).  
Next slave is assigned +4 if previous slave was a dual axis (DMC-3425).  
Slave axes are always assigned addresses based on their first axis.  
IOC-7007 controllers are addressed as follows:  
IOC 1 = m.n.o.p+16  
IOC 2 = m.n.o.p+20  
For example, in a 5 axis/1 IOC-7007 system with a DMC-3415 A axis Master, a DMC-3415  
B axis, a DMC-3425 CD axis and a DMC-3415 E axis the following IP addresses would  
be set:  
Assume Master IP address – 10.10.50.10  
B Axis DMC-3415 – 10.10.50.12  
CD Axis DMC-3425 – 10.10.50.14  
E Axis DMC-3415 – 10.10.50.18  
DMC-3425  
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IOC-7007 (1) – 10.10.50.26  
Automatic Configuration Example  
The example below shows a typical setup file for the DMC-3425 distributed control system using the  
automatic configuration. This example is for a UDP system, with one handle used per slave. The IP  
addresses of the slaves are unassigned, as this is the simplest way for the slave controllers to be  
configured. The IP address of the master needs to have been assigned as described in Step 5  
“Establishing Communication between the DMC-3425 and the host PC”. The HC command will  
automatically assign those IP addresses based on the axis jumper settings described in Chapter 2.  
Instruction  
#SETUP  
Interpretation  
Begin Program  
HC=6,20,1,0  
Automatic configuration for a 6 axis UDP system with 20 msec  
update rate. The final 0 indicates no IOC-7007 Ethernet I/O  
modules in the system.  
#LOOP; JP#LOOP,_HC=1  
Wait while automatic configuration operates. This could take  
up to 10+ seconds.  
IF (_HC=0)  
Test for HC success. 0 = failed while 2 = success.  
MG”CONFIGURATION FAILED”  
ELSE  
MG”CONFIG SUCCESS”  
ENDIF  
EN  
Manual Configuration of Distributed Control  
For the manual configuration of distributed control, each 3425 must be assigned an IP address. This  
can be done with the BOOTP procedure in the Galil software or the IA command can be used to assign  
the IP address through the serial port. Once the IP address has been assigned, a BN command should  
be issued to save this value in the controller’s non-volatile memory. Since all configuration is done  
manually in this method, there is no limit for the IP address of each slave in the system.  
Upon power-up or reset, the master 3425 must establish each slave connection. The following steps  
must be taken while connected to the master 3425:  
1. Using the IH command, open handles for each slave. For a TCP/IP connection, each  
slave controller must have 2 open handles, one for commands from the master, the other  
for data returned from the slave (QW). The second internet handle for each slave  
controller must contain a specific port value. The value must be an even number greater  
than 502. For a UDP connection, a slave controller can use a single handle for both  
commands from the master as well as data returned from the slave. The command for  
opening the communication handle is:  
IHh=ip0,ip1,ip2,ip3<p>n h is the handle. ip is the slave IP address. <p specifies  
port number. >n specifies connection type, 1 for UDP or 2 for TCP/IP.  
2. Set the total number of axes in the system with the NA command. For example, assume  
there are 2 DMC-3425 slave cards, therefore there will be 6 axes (2 in the master and 4 in  
the slaves) and the command would be NA6.  
3. Connect each slave handle to the master. This is accomplished with the CH command.  
The format of this command is:  
CHa=h1,h2  
where a is the first axis designator of the slave controller, h1 is the  
handle for commands and h2 is the handle for slave status. h1 may equal h2 in a  
UDP setup.  
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Note that only one of the 2 axes (per DMC-3425) needs to be assigned with the CH command.  
4. In order for the Master controller to be able to make decisions based on the status of the  
slave/server controllers, it is necessary for the slaves to generate data records giving their  
current status. The record is sent at a rate set by the QW command. The QW command  
must be executed by the master before the slave can issue a record under any method.  
The format of the command is  
QWh=n where h is the handle. n is a number between 4 and 16000.  
n sets the number of samples (msec with default TM1000).  
n equal to 0 disables the mode.  
The data contained in the record is as follows:  
reference position  
encoder position  
position error  
velocity  
torque  
limit and home switches  
axis status (in motion, motor off, at speed, stopcode)  
uncommitted inputs  
uncommitted outputs  
user defined variables (4)  
Manual Configuration Example  
The example below shows a typical setup file for the DMC-3425 distributed control system in manual  
mode. This example is for a TCP/IP system, with two handles used per slave. The IP address of the  
first slave (Axes C and D) is 160.50.10.1, while the address of the second slave (Axes E and F) is  
160.50.10.2. Note that in the two axis setup, different port numbers are used for the second handle to  
the same IP address.  
Instruction  
#SETUP  
Interpretation  
Begin Program  
IHD=160,50,10,1>2  
IHE=160,50,10,1<510>2  
IHF=160,50,10,2>2  
IHG=160,50,10,2<512>2  
NA6  
Set handle D (for commands) to slave 1's IP  
Open handle E for slave 1's data record  
Set handle F (for commands) to slave 2’s IP  
Open handle G for slave 2's data record  
6 axis total  
CHC=D,E  
Axis C & D assigned to slave 1 (Handle D,E)  
Axis E & F assigned to slave 2 (Handle F,G)  
Handle E sends data record every 20 msec  
Handle G sends data record every 20 msec  
CHE=F,G  
QWE=20  
QWG=20  
EN  
Note: This program is the minimum necessary for manually setting up the controller. An actual  
application program should make use of error and status checking. An example would be testing the  
operand _IHh2 for successful handle connections. See Command Reference for more details.  
DMC-3425  
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Design Examples  
Here are a few examples for tuning and using your controller. These examples are shown for a single axis system  
only, but can be modified to test up to 8 axes within a distributed control network. See Chapter 6  
Programming Motion for more examples of multi-axis programming.  
Example 1 - System Set-up  
This example assigns the system filter parameters, error limits and enables the automatic error shut-off.  
Instruction  
KP 10  
Interpretation  
Set proportional gain  
Set damping  
KD 100  
KI 1  
Set integral  
OE 1  
Set error off  
ER 1000  
Set error limit  
Example 2 - Profiled Move  
Objective: Rotate a distance of 10,000 counts at a slew speed of 20,000 counts/sec and an acceleration  
and deceleration rates of 100,000 counts/s2.  
Instruction  
PR 10000  
SP 20000  
DC 100000  
AC 100000  
BGA  
Interpretation  
Distance  
Speed  
Deceleration  
Acceleration  
Start Motion  
In response, the motor turns and stops.  
Example 3 - Position Interrogation  
The position of the A axis may be interrogated with the instruction  
TPA  
Tell position  
which returns the position of the main encoder.  
The position error, which is the difference between the commanded position and the actual position  
can be interrogated by the instructions  
TEA  
Tell error  
Example 4 - Absolute Position  
Objective: Command motion by specifying the absolute position.  
Instruction  
DP 0  
Interpretation  
Define the current position as 0  
Sets the desired absolute position  
Start motion on A axis  
PA 7000  
BGA  
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Example 5 - Velocity Control (Jogging)  
Objective: Drive the motor at specified speeds.  
Instruction  
JG 10000  
AC 100000  
DC 50000  
BGA  
Interpretation  
Set Jog Speed  
Set acceleration  
Set deceleration  
Start motion on A axis  
after a few seconds, command:  
JG –40000  
New speed and Direction  
TVA  
Returns speed  
This causes velocity changes including direction reversal. The motion can be stopped with the  
instruction  
STA  
Stop  
Example 6 - Operation Under Torque Limit  
The magnitude of the motor command may be limited independently by the instruction TL. The  
following program illustrates that effect.  
Instruction  
TL 0.2  
Interpretation  
Set output limit to 0.2 volts  
Set speed  
JG 10000  
BGA  
Start motion on A axis  
The motor will probably not move as the output signal is not sufficient to overcome the friction. If the  
motion starts, it can be stopped easily by a touch of a finger.  
Increase the torque level gradually by instructions such as  
TL 1.0  
Increase torque limit to 1 volt.  
TL 9.98  
Increase torque limit to maximum, 9.98 Volts.  
The maximum level of 10 volts provides the full output torque.  
Example 7 - Interrogation  
The values of the parameters may be interrogated using a ?. For example, the instruction  
KP ?  
Return gain  
The same procedure applies to other parameters such as KI, KD, FA, etc.  
Example 8 - Operation in the Buffer Mode  
The instructions may be buffered before execution as shown below.  
Instruction  
PR 600000  
SP 10000  
WT 10000  
BGA  
Interpretation  
Distance  
Speed  
Wait 10000 milliseconds before reading the next instruction  
Start the motion  
DMC-3425  
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Example 9 - Motion Programs  
Motion programs may be edited and stored in the memory. They may be executed at a later time.  
The instruction  
ED  
Edit mode  
moves the operation to the editor mode where the program may be written and edited. For example, in  
response to the first ED command, the Galil Windows software will open a simple editor window.  
From this window, the user can type in the following program:  
#A  
Define label  
PR 700  
SP 2000  
BGA  
EN  
Distance  
Speed  
Start motion  
End program  
This program can be downloaded to the controller by selecting the File menu option download. Once  
this is done, close the editor.  
Now the program may be executed with the command  
XQ #A  
Start the program running  
Example 10 - Motion Programs with Loops  
Motion programs may include conditional jumps as shown below.  
Instruction  
#A  
Interpretation  
Label  
DP 0  
Define current position as zero  
Set initial value of V1  
Label for loop  
V1=1000  
#Loop  
PA V1  
Move motor V1 counts  
Start motion  
BGA  
AMA  
After motion is complete  
Wait 500 ms  
WT 500  
TPA  
Tell position  
V1=V1+1000  
JP #Loop,V1<10001  
EN  
Increase the value of V1  
Repeat if V1<10001  
End  
After the above program is entered, download the program from the File menu and exit the Editor. To  
start the motion, command:  
XQ #A  
Execute Program #A  
Example 11- Motion Programs with Trippoints  
The motion programs may include trippoints as shown below.  
Instruction  
#B  
Interpretation  
Label  
DP0  
Define initial position  
Set target  
PR 30000  
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SP 5000  
BGA  
Set speed  
Start motion  
AD 4000  
TPA  
Wait until A moved 4000  
Tell position  
EN  
End program  
To start the program, command:  
XQ #B  
Execute Program #B  
Example 12 - Control Variables  
Objective: To show how control variables may be utilized.  
Instruction  
#A;DP0  
PR 4000  
SP 2000  
BGA  
Interpretation  
Label; Define current position as zero  
Initial position  
Set speed  
Move  
AMA  
Wait until move is complete  
Wait 500 ms  
WT 500  
#B  
V1 = _TP  
PR –V1/2  
BGA  
Determine distance to zero  
Command move 1/2 the distance  
Start motion  
AMA  
After motion  
WT 500  
V1=  
Wait 500 ms  
Report the value of V1  
Exit if position=0  
Repeat otherwise  
End  
JP #C, V1=0  
JP #B  
#C;EN  
To start the program, command  
XQ #A  
Execute Program #A  
This program moves the motor to an initial position of 4000 and returns it to zero on increments of half  
the distance. Note, _TP is an internal variable that returns the value of the position. Internal variables  
may be created by preceding a DMC-3425 instruction with an underscore, _.  
Example 13 - Control Variables and Offset  
Objective: Illustrate the use of variables in iterative loops and use of multiple instructions on one line.  
Instruction  
#A  
Interpretation  
Set initial values  
KI0  
DP0  
V1=8; V2=0  
#B  
Initializing variables to be used by program  
Program label #B  
OF V1  
WT 200  
Set offset value  
Wait 200 msec  
DMC-3425  
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V2=_TP  
Set variable V2 to the current position  
Exit if error small  
JP#C,@ABS[V2]<2  
MG V2  
Report value of V2  
Decrease Offset  
V1=V1-1  
JP #B  
Return to top of program  
End  
#C;EN  
This program starts with a large offset and gradually decreases its value, resulting in decreasing error.  
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Chapter 3 Connecting Hardware  
Overview  
The DMC-3425 provides digital inputs for A and B forward limit, A and B reverse limit, A and B  
home input and abort input. The controller also has 3 uncommitted, TTL inputs, 3 TTL outputs  
and 2 analog inputs (12-bit).  
The DMC-3415 provides a forward and reverse limit, home input and abort input. The controller also  
has 7 uncommitted, TTL inputs, 3 TTL outputs and 2 analog inputs (12-bit).  
This chapter describes the inputs and outputs and their proper connection.  
Using Inputs  
Limit Switch Input  
The forward limit switch (FLSx) inhibits motion in the forward direction immediately upon activation  
of the switch. The reverse limit switch (RLSx) inhibits motion in the reverse direction immediately  
upon activation of the switch. If a limit switch is activated during motion, the controller will make a  
decelerated stop using the deceleration rate previously set with the DC command. The motor will  
remain on (in a servo state) after the limit switch has been activated and will hold motor position. To  
set the activation state of the limit switches refer to the command CN, configure, in the Command  
Reference.  
When a forward or reverse limit switch is activated, the current application program that is running  
will be interrupted and the controller will automatically jump to the #LIMSWI subroutine if one exists.  
This is a subroutine that the user can include in any motion control program and is useful for executing  
specific instructions upon activation of a limit switch.  
After a limit switch has been activated, further motion in the direction of the limit switch will not be  
possible until the logic state of the switch returns back to an inactive state. This usually involves  
physically opening the tripped switch. Any attempt at further motion before the logic state has been  
reset will result in the following error: “022 - Begin not possible due to limit switch” error.  
The operands, _LFx and _LRx, return the state of the forward and reverse limit switches, respectively  
(x represents the axis, A or B). The value of the operand is either a ‘0’ or ‘1’ corresponding to the  
logic state of the limit switch, active or inactive, respectively. If the limit switches are configured for  
active low, no connection or a 5V input will be read as a ‘0’, while grounding the switch will return a  
‘1’. If the limit switches are configured for active high, the reading will be inverted and no connection  
or a 5V input will be read as a ‘1’, while grounding the switch will return a ‘0’.  
Using a terminal program, the state of a limit switch can be printed to the screen with the command,  
MG _LFx or MG _LRx. This prints the value of the limit switch operands for the 'x' axis. The logic  
DMC-3425  
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state of the limit switches can also be interrogated with the TS command. For more details on TS,  
_LFx, _LRx, or MG see the Command Reference.  
Home Switch Input  
Homing inputs are designed to provide mechanical reference points for a motion control application.  
A transition in the state of a Home input alerts the controller that a particular reference point has been  
reached by a moving part in the motion control system. A reference point can be a point in space or an  
encoder index pulse.  
The Home input detects any transition in the state of the switch and changes between logic states 0 and  
1, corresponding to either 0V or 5V depending on the configuration set by the user (CN command).  
The CN command can be used to customize the homing routine to the user’s application.  
There are three homing routines supported by the DMC-3425: Find Edge (FE), Find Index (FI), and  
Standard Home (HM).  
The Find Edge routine is initiated by the command sequence: FEx <return>, BGx <return> (where x  
could be any axis on the controller, A through H). The Find Edge routine will cause the motor to  
accelerate then slew at constant speed until a transition is detected in the logic state of the Home input.  
The direction of the FE motion is dependent on the state of the home switch. Refer to the CN  
command to set the correspondence between the Home Input voltage and motion direction. The motor  
will decelerate to a stop when a transition is seen on the input. The acceleration rate, deceleration rate  
and slew speed are specified by the user, prior to the movement, using the commands AC, DC, and SP.  
It is recommended that a high deceleration value be used so the motor will decelerate rapidly after  
sensing the Home switch.  
The Find Index routine is initiated by the command sequence: FIx <return>, BGx <return> (where x  
could be any axis on the controller, A through H). Find Index will cause the motor to accelerate to  
the user-defined slew speed (SP) at a rate specified by the user with the AC command and slew until  
the controller senses a change in the index pulse signal from low to high. The motor then decelerates  
to a stop at the rate previously specified by the user with the DC command. Although Find Index is an  
option for homing, it is not dependent upon a transition in the logic state of the Home input, but instead  
is dependent upon a transition in the level of the index pulse signal.  
The Standard Homing routine is initiated by the sequence of commands HMx <return>, BGx <return>  
(where x could be any axis on the controller, A through H). Standard Homing is a combination of  
Find Edge and Find Index homing. Initiating the standard homing routine will cause the motor to slew  
until a transition is detected in the logic state of the Home input. The motor will accelerate at the rate  
specified by the command, AC, up to the slew speed. After detecting the transition in the logic state  
on the Home Input, the motor will decelerate to a stop at the rate specified by the command DC. After  
the motor has decelerated to a stop, it switches direction and approaches the transition point at the  
speed of 256 counts/sec. When the logic state changes again, the motor moves forward (in the  
direction of increasing encoder count) at the same speed, until the controller senses the index pulse.  
After detection, it decelerates to a stop and defines this position as 0. The logic state of the Home input  
can be interrogated with the command MG _HMA. This command returns a 0 or 1 if the logic state is  
low or high (dependent on the CN command). The state of the Home input can also be interrogated  
indirectly with the TS command.  
For examples and further information about Homing, see command HM, FI, FE of the Command  
Reference and the section entitled ‘Homing’ in the Programming Motion Section of this manual.  
Abort Input  
The function of the Abort input is to immediately stop the controller upon transition of the logic state.  
NOTE: The response of the abort input is significantly different from the response of an activated  
limit switch. When the abort input is activated, the controller stops generating motion commands  
immediately, whereas the limit switch response causes the controller to make a decelerated stop.  
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NOTE: The effect of an Abort input is dependent on the state of the off-on-error function for each  
axis. If the Off-On-Error function is enabled for any given axis, the motor for that axis will be turned  
off when the abort signal is generated. This could cause the motor to ‘coast’ to a stop since it is no  
longer under servo control. If the Off-On-Error function is disabled, the motor will decelerate to a stop  
as fast as mechanically possible and the motor will remain in a servo state.  
All motion programs that are currently running are terminated when a transition in the Abort input is  
detected. For information on setting the Off-On-Error function, see the Command Reference, OE.  
Uncommitted Digital Inputs  
The general use inputs are TTL and are accessible through the ICM-1460 or AMP-1460 as IN1 – IN3  
for the DMC-3425 and IN1 – IN7 for the DMC-3415. The inputs can be accessed directly from the 37  
Pin-D cable or connector on the controller, also. For a description of the pinouts, consult the appendix.  
These inputs can be interrogated with the use of the command TI (Tell Inputs), the operand _TI, the  
function @IN[n] and the distributed I/O command TZ. All of these commands may be used locally to  
address individual controllers, or globally through the distributed control network. See Chapter 4 for a  
discussion of Global vs. Local communication as it pertains to I/O of the control system.  
NOTE: For systems using the ICM-1460 or AMP-1460 interconnect module, there is an option to  
provide opto-isolation on the inputs. In this case, the user provides an isolated power supply (+5V to  
+24V and ground). For more information, see the section “Opto-Isolation Option for ICM-1460” in  
the Appendix of this manual, or consult Galil.  
Amplifier Interface  
The DMC-3425 analog command voltage, ACMD, ranges between +/-10V. This signal, along with  
GND, provides the input to the power amplifiers. The power amplifiers must be sized to drive the  
motors and load. For best performance, the amplifiers should be configured for a current mode of  
operation with no additional compensation. The gain should be set such that a 10 Volt input results in  
the maximum required current. If the controller is operating in stepper mode, the pulse and direction  
signals will be input into a stepper drive.  
The DMC-3425 also provides an amplifier enable signal, AEN. This signal is activated under the  
following conditions: the watchdog timer activates, the motor-off command, MO, is given, or the  
OE1command (Enable Off-On-Error) is given and the position error exceeds the error limit. As  
shown in Figure 3.1, AEN can be used to disable the amplifier for these conditions.  
Note: For a controller ordered as a DMC-3425-Stepper, the amplifier enable signal is used for the  
second stepper output.  
The standard configuration of the AEN signal is TTL active high. In this configuration the AEN signal  
will be high when the controller expects the amplifier to be enabled. The polarity and the amplitude  
can be changed if you are using the ICM-1460 interface board. To change the polarity from active  
high (5 volts= enable, zero volts = disable) to active low (zero volts = enable, 5 volts= disable), replace  
the 7407 IC with a 7406. Note that many amplifiers designate the enable input as ‘inhibit’.  
To change the voltage level of the AEN signal, note the state of the jumper on the ICM/AMP-1460.  
When JP1 has a jumper from “AEN” to “5V” (default setting), the output voltage is 0-5V. To change  
to 12 volts, pull the jumper out and rotate it so that it connects the pins marked “AEN” and “+12V”. If  
the jumper is removed entirely, the output is an open collector, allowing the user to connect an external  
supply with voltages up to 24V.  
To connect an external 24V supply, remove the jumper JP1 from the interconnect board. Connect a  
2.2kΩ resistor in series between the +24V of the supply and the amplifier enable terminal on the  
interconnect (AMPEN). Then wire the AMPEN to the enable pin on the amplifier. Connect the -24V  
DMC-3425  
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to the ground, GND, of the interconnect and connect the GND of the interconnect to the GND of the  
amplifier.  
DMC-3425  
ICM-1460  
Connection to +5V or +12V made through  
jumper location JP1. Removing the jumper  
allows the user to connect their own supply to  
the desired voltage level (Up to24V).  
+12V  
+5V  
SERVO  
MOTOR  
AMPEN  
AMPLIFIER  
GND  
37 - 40  
Pin Cable  
ACMD  
7407 Open Collector  
Buffer. The Enable signal  
can be inverted by using  
a 7406.  
Analog Switch  
Figure 3.1 - Connecting AEN to the motor amplifier  
TTL Inputs  
As previously mentioned, the DMC-3425 has 3 uncommitted TTL level inputs while the DMC-3415  
has 7 uncommitted TTL level inputs. The command @IN, TI and TZ will read the state of the inputs.  
For more information on these commands refer to the Command Reference.  
The reset input is also a TTL level, non-isolated signal and is used to locally reset the DMC-3425  
without resetting the PC.  
Analog Inputs  
The DMC-3425 has 2 analog inputs configured for the range between –10V and +10V. The inputs are  
decoded by a 12-bit ADC giving a voltage resolution of approximately .005V. The impedance of these  
inputs is 10Kohms. The analog inputs may be read using the @AN[n] function, where n is the number  
of the analog input to be read.  
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TTL Outputs  
The DMC-3425 provides three general use outputs, an output compare and 4 status LED’s.  
The general use outputs are TTL and are accessible through the ICM-1460 as OUT1 thru OUT3.  
These outputs can be turned On and Off with the commands SB (Set Bit), CB (Clear Bit), OB (Output  
Bit) and OP (Output Port). For more information about these commands, see the Command Reference.  
The value of the outputs can be checked with the operand _OP, the function @OUT[] and the  
distributed control command TZ. Chapter 4 contains more information with regards to I/O in the  
distributed control network.  
The output compare signal is TTL and is available on the ICM-1460 as CMP. Output compare is  
controlled by the position of any of the main encoders on the controller. The output can be  
programmed to produce an active low pulse (1usec) based on an incremental encoder value or to  
activate once when an axis position has been passed. For further information, see the command OC in  
the Command Reference.  
Note: For a controller ordered as a DMC-3425-Stepper, the Error output is taken for the second  
stepper motor output.  
There are four status LEDs on the controller, which indicate operating and error conditions on the  
controller. Below is a list of those LEDs and their functions.  
Green Power LED - The green status LED indicates that the +5V power has been applied properly to  
the controller.  
Red Status/Error LED - The red error LED will flash on initially at power up, and stay lit for  
approximately 1 – 8 seconds. After this initial power up condition, the LED will illuminate  
for the following reasons:  
1. At least one axis has a position error greater than the error limit. The error limit is set by  
using the command ER.  
2. The reset line on the controller is held low or is being affected by noise.  
3. There is a failure on the controller and the processor is resetting itself.  
4. There is a failure with the output IC which drives the error signal.  
Green Link LED – The second green LED is lit when there is an Ethernet connection to the  
controller. This LED tests only for the physical connection, not for an active or enabled link.  
Yellow Activity LED – The yellow LED indicates traffic across the Ethernet connection. This LED  
will show both transmit and receive activity across the connection. If there is no Ethernet  
connection or IP address assigned, the LED will flash at regular intervals to show that the  
BOOTP packets are being broadcast.  
Note: For systems using the ICM-1460 or AMP-1460 interconnect module, there is an option to  
provide opto-isolation for the outputs. In this case, the user provides an isolated power supply  
(+5V to +24V and ground). For more information, see the section “Opto-Isolation Option for  
ICM-1460” in the Appendix of this manual, or contact Galil.  
DMC-3425  
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Chapter 4 Communication  
Introduction  
The DMC-3425 has one RS232 port and one Ethernet port. The RS-232 port is the data set. The  
Ethernet port is a 10Base-T link. The RS-232 is a standard serial link with communication baud rates  
up to 19.2kbaud.  
For initial setup, Galil recommends starting with the RS-232 interface. The RS-232 provides a  
simplified interface that minimizes the potential problems for first time setup. Once the configuration  
parameters have been properly set and saved on the controller, the Ethernet communication should be  
established.  
RS232 Port  
The DMC-3425 has a single RS232 connection for sending and receiving commands from a PC or  
other terminal. The pin-outs for the RS232 connection are as follows.  
RS232 - Port 1 DATATERM  
1 CTS – output  
6 CTS – output  
2 Transmit Data - output  
3 Receive Data - input  
4 RTS – input  
7 RTS – input  
8 CTS – output  
9 No connect (Can connect to +5V or sample clock)  
5 Ground  
RS-232 Configuration  
Configure your PC for 8-bit data, one start-bit, one stop-bit, full duplex and no parity. The baud rate  
for the RS232 communication can be selected by selecting the proper jumper configuration on the  
DMC-3425 according to the table below.  
Baud Rate Selection  
JUMPER SETTINGS  
BAUD RATE  
96  
OFF  
ON  
12  
--  
OFF  
OFF  
19200  
9600  
DMC-3425  
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OFF  
ON  
1200  
Handshaking Modes  
The RS232 port is configured for hardware handshaking. In this mode, the RTS and CTS lines are  
used. The CTS line will go high whenever the DMC-3425 is not ready to receive additional  
characters. The RTS line will inhibit the DMC-3425 from sending additional characters. Note: The  
RTS line goes high for inhibit. This handshake procedure ensures proper communication especially at  
higher baud rates.  
Ethernet Configuration  
Communication Protocols  
The Ethernet is a local area network through which information is transferred in units known as  
packets. Communication protocols are necessary to dictate how these packets are sent and received.  
The DMC-3425 supports two industry standard protocols, TCP/IP and UDP/IP. The controller will  
automatically respond in the format in which it is contacted.  
TCP/IP is a "connection" protocol. The master must be connected to the slave in order to begin  
communicating. Each packet sent is acknowledged when received. If no acknowledgement is  
received, the information is assumed lost and is resent.  
Unlike TCP/IP, UDP does not require a "connection". This protocol is similar to communicating via  
RS232. If information is lost, the controller does not return a colon or question mark. Because the  
protocol does not provide for lost information, the sender must re-send the packet.  
Ethernet communication transfers information in ‘packets’. The packets must be limited to 470 data  
bytes or less. Larger packets could cause the controller to lose communication.  
NOTE: In order not to lose information in transit, Galil recommends that the user wait for an  
acknowledgement of receipt of a packet before sending the next packet.  
Addressing  
There are three levels of addresses that define Ethernet devices. The first is the Ethernet or hardware  
address. This is a unique and permanent 6 byte number. No other device will have the same Ethernet  
address. The DMC-3425 Ethernet address is set by the factory and the last two bytes of the address are  
the serial number of the controller.  
The second level of addressing is the IP address. This is a 32-bit (or 4 byte) number. The IP address is  
constrained by each local network and must be assigned locally. Assigning an IP address to the  
controller can be done in a number of ways.  
The first method is to use the BOOT-P utility via the Ethernet connection (the DMC-3425 must be  
connected to network and powered). For a brief explanation of BOOT-P, see the section: Third Party  
Software. Either a BOOT-P server on the internal network or the Galil terminal software may be used.  
To use the Galil BOOT-P utility, select the registry in the terminal emulator. Next, select the DMC-  
3425 controller communicating via Ethernet from the software registry. Once the controller has been  
selected, the next screen shows options for the actual connection. Enter the IP address at the prompt  
and select either TCP/IP or UDP/IP as the protocol. When done, click on the ASSIGN IP ADDRESS.  
The Galil Terminal Software will respond with a list of all controllers on the network that do not  
currently have IP addresses. The user selects the controller and the software will assign the controller  
the specified IP address. Then enter the terminal and type in BN to save the IP address to the  
controller's non-volatile memory. A full description of addressing the card may be found in Chapter 2  
Getting Started.  
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CAUTION: Be sure that there is only one BOOT-P server running. If your network has DHCP or BOOT-P  
running, it may automatically assign an IP address to the controller upon linking it to the network. In order to  
ensure that the IP address is correct, please contact your system administrator before connecting the controller  
to the Ethernet network.  
The second method for setting an IP address is to send the IA command through the DMC-3425 main  
RS-232 port. The IP address you want to assign may be entered as a 4 byte number delimited by  
commas (industry standard uses periods) or a signed 32 bit number. (Ex. IA 124,51,29,31 or IA  
2083724575) Type in BN to save the IP address to the controller's non-volatile memory.  
NOTE: Galil strongly recommends that the IP address selected is not one that can be accessed across  
the Gateway. The Gateway is an application that controls communication between an internal network  
and the outside world.  
The third level of Ethernet addressing is the UDP or TCP port number. The Galil controller does not  
require a specific port number. The port number is established by the client or master each time it  
connects to the controller.  
Ethernet Handles  
An Ethernet handle is a communication resource within a device. The DMC-3425 can have a  
maximum of 8 Ethernet handles open at any time. When using TCP/IP, each connection to a device,  
such as the host computer, requires an individual Ethernet handle. In UDP/IP, one handle may be used  
for all the masters, but each slave uses one. (Pings and ARP's do not occupy handles.) If all 8 handles  
are in use and a 9th master tries to connect, it will be sent a "reset packet" that generates the appropriate  
error in its windows application.  
The TH command may be used to indicate which handles are currently connected to and which are  
currently free.  
Global vs. Local Operation  
Each DMC-3425 controls two axes of motion, referred to as A and B. The host computer can  
communicate directly with any DMC-3425 using an Ethernet or RS-232 connection. When the host  
computer is directly communicating with any DMC-3425, all commands refer to the first two axes as  
A and B. Direct communication with the DMC-3425 is known as LOCAL OPERATION.  
The concept of Local and Global Operation also applies to application programming. See Chapter 7:  
Global vs. Local Programming.  
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LOCAL OPERATION  
Host Computer  
RS-232  
or  
Ethernet  
DMC-3425  
A and B  
Axes  
DMC-3425  
A and B  
Axes  
DMC-3425  
A and B  
Axes  
DMC-3425  
A and B  
Axes  
The DMC-3425 supports Galil’s Distributed Control System. This allows up to 4 DMC-3425s to be  
connected together as a single virtual 8-axis controller. In this system, one of the controllers is  
designated as the master. The master can receive commands from the host computer that apply to all  
of the axes in the system.  
A simple way to view Local and Global Operation: When the host communicates with a slave  
controller, it considers the slave as a 2-axis controller. When the host communicates with a master, it  
considers the master as a multi-axis controller. Similarly, an application program residing in a slave  
controller deals only with 2 motors as A & B. An application program in a master deals with all  
motors referenced as A through H.  
GLOBAL OPERATION  
Host Computer  
RS-232  
or  
Ethernet  
DMC-3425  
A and B  
Axes  
Ethernet  
DMC-3425  
C and D  
Axes  
DMC-3425  
E and F  
Axes  
DMC-3425  
G and H  
Axes  
The controllers may operate under both Local and/or Global Mode. In general, operating in Global  
Mode simplifies controlling the entire system. However, Local Mode operation is necessary in some  
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situations; using Local Mode for setup and testing is useful since this isolates the controller. Specific  
modes of motion require operation in Local Mode. Also, each controller can have a program,  
including the slave controllers. When a slave controller has a program, this program would always  
operate in Local Mode.  
Operation of Distributed Control  
For most commands it is not necessary to be conscious of whether an axis is local or remote. For  
instance to set the KP value for the A and C axes, the command to the master would be  
KP 10,,20  
Similarly, the interrogation commands can also be issued. For example, the position error for all axes  
would be TE. The position operand for the F axis would be_TPF.  
Some commands inherently are sent to all controllers. These include commands such as AB (abort),  
CN and TM. In addition, the * may be used to send commands to all controllers. For example  
SP*=1000  
will send a speed of 1000 cts/sec to all axes. This syntax may be used with any configuration or  
parameter commands.  
Certain commands need to be launched specifically. For this purpose there is the SA command. In its  
simplest form the SA command is  
SAh= "command string"  
Here "command string" will be sent to handle h. For example, the SA command is the means for  
sending an XQ command to a slave/server. A more flexible form of the command is  
SAh= field1,field2,field3,field4 ... field8  
where each field can be a string in quotes or a variable.  
For example, to send the command KI,,5,10; Assume var1=5 and var2=10 and send the command:  
SAF= "KI",var1,var2  
When the Master/client sends an SA command to a Slave/server, it is possible for the master to  
determine the status of the command. The response _IHh4 will return the number 1 to 4. One means  
waiting for the acknowledgement from the slave. Two means a colon (command accepted) has been  
received. Three means a question mark (command rejected) has been received. Four means the  
command timed out.  
If a command generates responses (such as the TE command), the values will be stored in _SAh0 thru  
_SAh7. If a field is unused its _SA value will be -2^31.  
Accessing the I/O of the Slaves  
The I/O of the server/slaves is settable and readable from the master. The bit numbers are adjusted by  
the handle number of the slave controller. Each handle adds 100 to the bit number. Handle A is 100  
and handle H is 800. In a TCP/IP control setup with two handles per slave, Galil recommends using  
the value of the first handle for simplicity. In a UDP system, the single handle per slave is used to  
address the I/O.  
The command TZ can be used to display all of the digital I/O contained in a distributed control system.  
Any IOC-7007’s configured using the HC command will also be displayed with the TZ command. See  
the Command Reference for more information on the TZ command.  
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Digital Outputs  
For outputs, the SB and CB commands are used to command individual output ports, while the OP  
command is used for setting bytes of data. The SB and CB commands may be set globally through the  
master, while the OP command must be sent to the slave using the SA command.  
Outputs may be set globally according to the following numbering scheme: Bitnum = (Slave Handle *  
100) + Output Bit. For example:  
Set Bit 2 on a UDP distributed slave using the E handle for communication. The E handle would have  
a numerical value of 500, plus the bit number of 2. The command would therefore become SB502.  
Specific outputs in a distributed system may be read by using the @OUT[n] function, where n is the  
corresponding bit number as defined above.  
Output bits on an IOC-7007 may also be set through the master controller in a distributed network.  
Please refer to the IOC-7007 Manual for information on setting and reading these I/O points.  
Digital Inputs  
Digital inputs may be addressed individually using the @IN[n] function, or in blocks using the TI  
command. Both of these commands may be sent globally to the controller. The ‘n’ in the @IN[n]  
function operates identically to the SB/CB syntax. This means that a specific input bit is referenced as  
the slave handle number * 100 plus the input bit. For example:  
Read input bit 4 on a TCP/IP distributed slave using the C handle for communication. The C handle in  
this case would give a value of 300. Therefore, to read bit 4, the command would be MG@IN[304].  
The MG in this case simply displays this data to the terminal.  
The TI command may be used to read all inputs on a slave in blocks of 8. This is helpful if the slave  
controller in question has a DB-14064 expanded I/O daughter card. The TI command uses the slave  
handle number * 100 plus the block number to be read. The block number is only used if the  
controller has the DB-14064 expansion option.  
Inputs on an IOC-7007 may also be read through the master controller in a distributed network. Please  
refer to the IOC-7007 Manual for information on setting and reading these points.  
Analog Inputs  
Each DMC-3425 controller has two 12-bit analog inputs. These inputs are read with the command  
@AN[n], where n is the input to be read. The master controller has n = 1 and 2, the first slave  
controller uses n = 3 and 4, etc.  
Handling Communication Errors  
A new automatic subroutine which is identified by the label #TCPERR, has been added. If a controller  
has an application program running and the TCP or UDP communication is lost, the #TCPERR routine  
will automatically execute. The #TCPERR routine should be ended with a RE command. In the UDP  
configuration, the QW commands must be active in order for the #TCPERR routine on the master to  
operate properly.  
Multicasting  
A multicast may only be used in UDP and is similar to a broadcast, (where everyone on the network  
gets the information) but specific to a group. In other words, all devices within a specified group will  
receive the information that is sent in a multicast. There can be many multicast groups on a network  
and are differentiated by their multicast IP address. To communicate with all the devices in a specific  
multicast group, the information can be sent to the multicast IP address rather than to each individual  
device IP address. All Galil controllers belong to a default multicast address of 239.255.19.56. The  
controller's multicast IP address can be changed by using the IA> u command.  
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The Galil Registry has an option to disable the opening of the multicast handle on the DMC-3425. By  
default this multicast handle will be opened.  
Unsolicited Message Handling  
Anytime a controller generates an internal response from a program, generates an internal error or  
sends a message from a program using the MG command, this is termed an unsolicited message.  
There are two software commands that will configure how the controller handles these messages; the  
CW and the CF command.  
The DMC-3425 has 8 Ethernet handles as well as 1 serial port where unsolicited messages may be  
sent. The CF command is used to configure the controller to send these messages to specific ports. In  
addition, the Galil Registry has various options for sending this CF command. For more information,  
see the CF command in the DMC-3425 Command Reference. The MG can also send the message to a  
specific handle using the MG{Eh} syntax, where h is the handle. See the MG command in the  
Command Reference for more information.  
The CW command has two data fields that affect unsolicited messages. The first field configures the  
most significant bit (MSB) of the message. A value of 1 will set the MSB of unsolicited messages,  
while a value of 2 suppresses the MSB. The majority of software programs use a setting of CW2,  
although the Galil Smart Terminal and WSDK will set this to CW1 for internal usage. If you have  
difficulty receiving characters from the controller, or receive garbage characters instead of messages,  
check the status of the CW command for a setting of CW2.  
IOC-7007 Support  
The IOC-7007 is an Intelligent Ethernet I/O controller that can be programmed in standard Galil  
language. This module allows various configurations of TTL inputs, opto-isolated inputs, high power  
outputs and relay switches to be used in the Galil distributed motion system. Each IOC-7007 may be  
populated by up to seven IOM I/O modules.  
The IOC-7007 Ethernet I/O controller may be used in a distributed system and commanded by the  
master controller. The HC command is used to specify total number of IOC-7007 controllers within  
that distributed system. Once configured, the I/O of that IOC-7007 becomes incorporated in the  
distributed system, much the same as board level I/O of the DMC-3425 slaves.  
Inputs of the IOC-7007 are read using the standard @IN[n] and TI commands as follows:  
@IN[n] where n is the IOC-7007 input bit to be read. n is calculated with the equation n =  
(HandleNum * 1000) + BitNum. HandleNum is the numeric value of the IOC-7007 handle (1 – 8)  
while BitNum is the specific bit number on the IOC to be read.  
TIn where n is the IOC-7007 input slot to be read. n is calculated with the equation n =  
(HandleNum * 1000) + SlotNum. Again, HandleNum is the numeric value of the IOC-7007 handle (1  
– 8). SlotNum corresponds to the location of the IOM input module in the 7 slots of the IOC-7007 (0 –  
6). This will return either an 8 bit or 16 bit decimal value depending on which IOM input module is  
being used.  
Outputs of the IOC-7007 are set and cleared using the standard SB and CB commands, as well as with  
the OQ and OB commands. Outputs can be read with the @OUT[n] command. These commands  
operate as follows:  
SBn or CBn where n is the IOC-7007 output to be set or cleared. n is calculated identically to  
the @IN[n] configuration, with n = (HandleNum * 1000) + BitNum.  
@OUT[n] where n is the IOC-7007 output to be read. This uses the same n configuration as  
SB and CB.  
OQn,m where n is the IOC-7007 output location and m is the data to be written. Specifically,  
n = (HandleNum * 1000) + SlotNum where HandleNum is the numeric value of the IOC-7007 handle  
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(1 – 8) and SlotNum is the slot number of the IOM output module to be written to (0 – 6). m is the  
decimal representation of the data written to the 4 (0 – 15) or 8 (0 – 255) output points of the IOM  
module.  
Please refer to the IOC-7007 manual for complete information on how to configure, read and write  
information to the IOC-7007 Ethernet I/O module.  
Modbus Support  
The Modbus protocol supports communication between masters and slaves. The masters may be  
multiple PC's that send commands to the controller. The slaves are typically peripheral I/O devices  
that receive commands from the controller.  
When the Galil controller acts as the master, the IH command is used to assign handles and connect to  
its slaves. The IP address may be entered as a 4 byte number separated with commas (industry  
standard uses periods) or as a signed 32 bit number. A port number may also be specified, and should  
be set to 502, which is the Modbus defined port number. The protocol (TCP/IP or UDP/IP) to use  
must also be designated at this time. Otherwise, the controller will not connect to the slave. (Ex.  
IHB=151,25,255,9<502>2 - This will open handle #2 and connect to the IP address 151.25.255.9, port  
502, using TCP/IP)  
An additional protocol layer is available for speaking to I/O devices. Modbus is an RS-485 protocol  
that packages information in binary packets that are sent as part of a TCP/IP packet. In this protocol,  
each slave has a 1 byte slave address. The DMC-3425 can use a specific slave address or default to the  
handle number.  
The Modbus protocol has a set of commands called function codes. The DMC-3425 supports the 10  
major function codes:  
Function Code  
01  
Definition  
Read Coil Status (Read Bits)  
02  
03  
04  
05  
06  
07  
15  
16  
17  
Read Input Status (Read Bits)  
Read Holding Registers (Read Words)  
Read Input Registers (Read Words)  
Force Single Coil (Write One Bit)  
Preset Single Register (Write One Word)  
Read Exception Status (Read Error Code)  
Force Multiple Coils (Write Multiple Bits)  
Preset Multiple Registers (Write Words)  
Report Slave ID  
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The DMC-3425 provides three levels of Modbus communication. The first level allows the user to  
create a raw packet and receive raw data. It uses the MBh command with a function code of –1. The  
format of the command is  
MBh = -1,len,array[]  
where len is the number of bytes  
array[] is the array with the data  
The second level incorporates the Modbus structure. This is necessary for sending configuration and  
special commands to an I/O device. The formats vary depending on the function code that is called.  
For more information refer to the Command Reference.  
The third level of Modbus communication uses standard Galil commands. Once the slave has been  
configured, the commands that may be used are @IN[], @AN[], SB, CB, OB, and AO. For example,  
AO 2020,8.2 would tell I/O number 2020 to output 8.2 volts.  
If a specific slave address is not necessary, the I/O number to be used can be calculated with the  
following:  
I/O Number = (HandleNum*1000) +((Module-1)*4) + (BitNum-1)  
Where HandleNum is the handle number from 1 (A) to 8 (H). Module is the position of the module in  
the rack from 1 to 16. BitNum is the I/O point in the module from 1 to 4.  
If an explicit slave address is to be used, the equation becomes:  
I/O Number = (SlaveAddress*10000) + (HandleNum*1000) +((Module-1)*4) + (Bitnum-1)  
To view an example procedure for communicating with an OPTO-22 rack, refer to the appendix.  
Other Communication Options  
User Defined Ethernet Variables  
It may be necessary within a distributed system to share information that is not contained as position,  
torque, velocity or other control data. The DMC-3425 provides 2 user defined variables that are  
passed as part of the QW record shared among the distributed system. In this way, it is not necessary  
for a single controller to write variable data directly to all the other controllers in the system.  
ZA and ZB are two user defined variables which are passed with the QW record at each update. Data  
that is written to these variables is then seen by the master DMC-3425 in the system.  
Handle Switching  
By default, when initiating a communication session with a DMC-3425 controller, the first available  
handle is used. If no handles have been assigned to the controller, the A handle is chosen. The  
command HS allows the user to switch this connection to another handle, freeing up the initial handle  
or trading with another currently used handle. Or, once handles have been defined, the HS command  
may be used to switch handles to prioritize slave locations and I/O locations.  
Handle Restore on Communication Failure  
There are instances within an Ethernet system, whether UDP or TCP/IP, when a handle may become  
disconnected without closing properly. An example of this would be a simple cable failure, where the  
Ethernet cable of a certain slave becomes detached.  
The command HR is used to enable a mode in which the master controller, upon seeing a failure on a  
handle, will attempt to restore that handle. This is helpful when a distributed system is already fully  
configured and a slave is lost. The #TCPERR routine can be used to flag the error, while the handle  
restore will attempt to reconnect to the slave until the problem is fixed. This makes it unnecessary to  
re-run the setup for the entire distributed system.  
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Note: This function is only available if the system has been configured using the automatic handle  
configuration command, HC.  
Waiting on Handle Responses  
The operation of the distributed network has commands being sent to the master controller, which then  
distributes these commands to the slave axes in the system. For example, the command  
PR10,10,10,10,10,10,10,10 sent to the master becomes packets of PR10,10 sent by the master to each  
of the slaves in the system. When the slave receives this command from the master, a colon or  
question mark is generated and sent back to the master to acknowledge the command.  
The HW command allows the user to select whether or not the master will wait on this colon response  
from the slave. If the HW is set to 0, the master will not wait for these responses. This results in faster  
command execution but could cause problems if any slave errors are generated. The setting HW1, on  
the other hand, insures that the master knows of any slave errors but does result in a slightly increased  
command execution time as it waits for these responses.  
Data Record  
The DMC-3425 can provide a block of status information with the use of a single command, QR. This  
command, along with the QZ command can be very useful for accessing complete controller status.  
The QR command will return 4 bytes of header information and specific blocks of information as  
specified by the command arguments: QR ABCDEFGHS  
Each argument corresponds to a block of information according to the Data Record Map below. If no  
argument is given, the entire data record map will be returned. Note that the data record size will  
depend on the number of axes.  
NOTE: A, B, C, & D can be interchanged with X, Y, Z, & W respectively.  
Data Record Map  
DATA TYPE  
ITEM  
1st byte of header  
2nd byte of header  
3rd byte of header  
BLOCK  
Header  
Header  
Header  
Header  
I block  
I block  
I block  
I block  
I block  
I block  
I block  
I block  
I block  
I block  
I block  
I block  
I block  
UB  
UB  
UB  
UB  
UW  
UB  
UB  
UB  
UB  
UB  
UB  
UB  
UB  
UB  
UB  
UB  
UB  
4rth byte of header  
sample number  
general input bank 0 (Inputs 1-7)  
general input bank 1 (Always 0)  
general input bank 2 (DB-14064)  
general input bank 3 (DB-14064)  
general input bank 4 (DB-14064)  
general input bank 5 (DB-14064)  
general input bank 6 (DB-14064)  
general input bank 7 (DB-14064)  
general input bank 8 (DB-14064)  
general input bank 9 (DB-14064)  
general output bank 0 (Outputs 1 – 3)  
general output bank 1 (Always 0)  
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UB  
UB  
UB  
UB  
UB  
UB  
UB  
UB  
UB  
UB  
UW  
UW  
SL  
general output bank 2 (DB-14064)  
general output bank 3 (DB-14064)  
general output bank 4 (DB-14064)  
general output bank 5 (DB-14064)  
general output bank 6 (DB-14064)  
general output bank 7 (DB-14064)  
general output bank 8 (DB-14064)  
general output bank 9 (DB-14064)  
error code  
I block  
I block  
I block  
I block  
I block  
I block  
I block  
I block  
I block  
I block  
S block  
S block  
S block  
T block  
T block  
T block  
A block  
A block  
A block  
A block  
A block  
A block  
A block  
A block  
A block  
A block  
B block  
B block  
B block  
B block  
B block  
B block  
B block  
B block  
B block  
B block  
C block  
C block  
C block  
C block  
C block  
C block  
C block  
C block  
C block  
general status  
segment count of coordinated move for S plane  
coordinated move status for S plane  
distance traveled in coordinated move for S plane  
0
UW  
UW  
SL  
0
0
UW  
UB  
UB  
SL  
A axis status  
A axis switches  
A axis stopcode  
A axis reference position  
A axis motor position  
A axis position error  
A axis auxiliary position  
A axis velocity  
SL  
SL  
SL  
SL  
SW  
SW  
UW  
UB  
UB  
SL  
A axis torque  
Analog Input 1  
B axis status  
B axis switches  
B axis stopcode  
B axis reference position  
B axis motor position  
B axis position error  
B axis auxiliary position  
B axis velocity  
SL  
SL  
SL  
SL  
SW  
SW  
UW  
UB  
UB  
SL  
B axis torque  
Analog Input 2  
C axis status  
C axis switches  
C axis stopcode  
C axis reference position  
C axis motor position  
C axis position error  
C axis auxiliary position  
C axis velocity  
SL  
SL  
SL  
SL  
SW  
C axis torque  
DMC-3425  
Chapter 4 Communication53  
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SW  
UW  
UB  
UB  
SL  
C axis analog input  
D axis status  
C block  
D block  
D block  
D block  
D block  
D block  
D block  
D block  
D block  
D block  
D block  
E block  
E block  
E block  
E block  
E block  
E block  
E block  
E block  
E block  
E block  
F block  
F block  
F block  
F block  
F block  
F block  
F block  
F block  
F block  
F block  
G block  
G block  
G block  
G block  
G block  
G block  
G block  
G block  
G block  
G block  
H block  
H block  
H block  
H block  
D axis switches  
D axis stopcode  
D axis reference position  
D axis motor position  
D axis position error  
D axis auxiliary position  
D axis velocity  
SL  
SL  
SL  
SL  
SW  
SW  
UW  
UB  
UB  
SL  
D axis torque  
D axis analog input  
E axis status  
E axis switches  
E axis stopcode  
E axis reference position  
E axis motor position  
E axis position error  
E axis auxiliary position  
E axis velocity  
SL  
SL  
SL  
SL  
SW  
SW  
UW  
UB  
UB  
SL  
E axis torque  
E axis analog input  
F axis status  
F axis switches  
F axis stopcode  
F axis reference position  
F axis motor position  
F axis position error  
F axis auxiliary position  
F axis velocity  
SL  
SL  
SL  
SL  
SW  
SW  
UW  
UB  
UB  
SL  
F axis torque  
F axis analog input  
G axis status  
G axis switches  
G axis stopcode  
G axis reference position  
G axis motor position  
G axis position error  
G axis auxiliary position  
G axis velocity  
SL  
SL  
SL  
SL  
SW  
SW  
UW  
UB  
UB  
SL  
G axis torque  
G axis analog input  
H axis status  
H axis switches  
H axis stopcode  
H axis reference position  
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SL  
SL  
SL  
SL  
SW  
SW  
H axis motor position  
H axis position error  
H axis auxiliary position  
H axis velocity  
H block  
H block  
H block  
H block  
H block  
H block  
H axis torque  
H axis analog input  
NOTE: UB = Unsigned Byte, UW = Unsigned Word, SW = Signed Word, SL = Signed Long Word  
Explanation of Status Information and Axis Switch Information  
Header Information - Byte 0, 1 of Header:  
BIT 15  
BIT 14  
BIT 13  
BIT 12  
BIT 11  
BIT 10  
BIT 9  
BIT 8  
1
N/A  
N/A  
N/A  
N/A  
I Block  
Present  
in Data  
Record  
T Block  
Present  
in Data  
Record  
S Block  
Present  
in Data  
Record  
BIT 7  
BIT 6  
BIT 5  
BIT 4  
BIT 3  
BIT 2  
BIT 1  
BIT 0  
H Block  
Present  
in Data  
Record  
G Block  
Present  
in Data  
Record  
F Block  
Present  
in Data  
Record  
E Block  
Present  
in Data  
Record  
D Block  
Present  
in Data  
Record  
C Block  
Present  
in Data  
Record  
B Block  
Present  
in Data  
Record  
A Block  
Present  
in Data  
Record  
Bytes 2, 3 of Header:  
Bytes 2 and 3 make a word that represents the Number of bytes in the data record, including the  
header. Byte 2 is the low byte and byte 3 is the high byte  
NOTE: The header information of the data records is formatted in little endian.  
General Status Information (1 Byte)  
BIT 7  
BIT 6  
BIT  
5
BIT  
4
BIT  
3
BIT 2  
BIT 1  
BIT 0  
Program N/A  
Running  
N/A  
N/A  
N/A  
Waiting for  
input from IN  
command  
Trace On Echo On  
Axis Switch Information (1 Byte)  
BIT 7  
BIT 6  
BIT 5  
BIT 4  
N/A  
BIT 3  
BIT 2  
BIT 1  
BIT 0  
Latch  
Occurred Latch  
Input  
State of  
N/A  
State of  
Forward  
Limit  
State of  
Reverse  
Limit  
State of  
Home  
Input  
SM  
Jumper  
Installed  
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Axis Status Information (2 Byte)  
BIT 15  
BIT 14  
BIT 13  
BIT 12  
BIT 11  
BIT 10  
BIT 9  
BIT 8  
2nd Phase  
of HM  
complete  
or FI  
command Motion  
issued  
Move in  
Progress Motion  
Mode of Mode of (FE)  
Home  
(HM) in  
Progress complete  
1st Phase  
of HM  
Mode of  
Motion  
Motion  
Find  
Edge in  
Progress  
PA or  
PR  
PA only  
Coord.  
BIT 7  
BIT 6  
BIT 5  
BIT 4  
BIT 3  
BIT 2  
BIT 1  
BIT 0  
Motion is  
stopping  
due to ST  
or Limit  
Switch  
Motion is  
making  
final  
Negative Mode of Motion  
Latch is  
armed  
Off-On-  
Error  
occurred  
Motor  
Off  
Direction Motion  
is  
Move  
slewing  
Contour  
decel.  
Coordinated Motion Status Information for plane (2 Byte)  
BIT 15  
BIT  
14  
BIT 13  
BIT 12  
BIT 11  
BIT  
10  
BIT 9  
BIT 8  
Move in  
Progress  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
N/A  
BIT 7  
BIT 6  
BIT 5  
BIT 4  
BIT 3  
BIT 2  
BIT 1  
BIT 0  
N/A  
N/A  
Motion is Motion is  
slewing  
Motion is N/A  
stopping due making  
N/A  
N/A  
to ST or  
Limit  
final  
decel.  
Switch  
Notes Regarding Velocity and Torque Information  
The velocity information that is returned in the data record is 64 times larger than the value returned  
when using the command TV (Tell Velocity). See command reference for more information about  
TV.  
The Torque information is represented as a number in the range of +/-32767. Maximum negative  
torque is -32767. Maximum positive torque is 32767. Zero torque is 0.  
QZ Command  
The QZ command can be very useful when using the QR command, since it provides information  
about the controller and the data record. The QZ command returns the following 4 bytes of  
information.  
BYTE # INFORMATION  
0
1
2
3
Number of axes present  
Number of bytes in general block of data record  
Number of bytes in coordinate plane block of data record  
Number of Bytes in each axis block of data record  
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Using Third Party Software  
Galil supports ARP, BOOT-P, and Ping, which are utilities for establishing Ethernet connections. ARP  
is an application that determines the Ethernet (hardware) address of a device at a specific IP address.  
BOOT-P is an application that determines which devices on the network do not have an IP address and  
assigns the IP address you have chosen to it. Ping is used to check the communication between the  
device at a specific IP address and the host computer.  
The DMC-3425 can communicate with a host computer through any application that can send TCP/IP  
or UDP/IP packets. A good example of this is Telnet, a utility that comes with most Windows  
systems. In the absence of the Galil Windows Terminal software, the Telnet terminal may be used for  
communication with the DMC-3425 Ethernet controller. The Windows Hyperterminal may also be  
used for communication.  
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Chapter 5 Command Basics  
Introduction  
The DMC-3425 provides over 100 commands for specifying motion and machine parameters.  
Commands are included to initiate action, interrogate status and configure the digital filter. These  
commands can be sent in ASCII or binary.  
In ASCII, the DMC-3425 instruction set is BASIC-like and easy to use. Instructions consist of two  
uppercase letters that correspond phonetically with the appropriate function. For example, the  
instruction BG begins motion, and ST stops the motion. In binary, commands are represented by a  
binary code ranging from 80 to FF.  
ASCII commands can be sent "live" over the bus for immediate execution by the DMC-3425, or an  
entire group of commands can be downloaded into the DMC-3425 memory for execution at a later  
time. Combining commands into groups for later execution is referred to as Applications  
Programming and is discussed in the following chapter. Binary commands cannot be used in  
Applications programming.  
This section describes the DMC-3425 instruction set and syntax. A summary of commands as well as  
a complete listing of all DMC-3425 instructions is included in the Command Reference chapter.  
Command Syntax - ASCII  
DMC-3425 instructions are represented by two ASCII upper case characters followed by applicable  
arguments. A space may be inserted between the instruction and arguments. A semicolon or <return>  
is used to terminate the instruction for processing by the DMC-3425 command interpreter.  
NOTE: If you are using a Galil terminal program, commands will not be processed until a <return>  
command is given. This allows the user to separate many commands on a single line and not begin  
execution until the user gives the <return> command.  
IMPORTANT: All DMC-3425 commands are sent in upper case.  
For example, the command  
PR 4000 <return>  
Position relative  
DMC-3425  
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PR is the two character instruction for position relative. 4000 is the argument which represents the  
required position value in counts. The <return> terminates the instruction. The space between PR and  
4000 is optional.  
For specifying data for the A,B,C and D axes, commas are used to separate the axes. If no data is  
specified for an axis, a comma is still needed as shown in the examples below. If no data is specified  
for an axis, the previous value is maintained.  
To view the current values for each command, type the command followed by a ? for each axis  
requested.  
PR 1000  
Specify A only as 1000  
Specify B only as 2000  
Specify C only as 3000  
Specify D only as 4000  
Specify A B C and D  
Specify B and D only  
Request A,B,C,D values  
Request B value only  
PR ,2000  
PR ,,3000  
PR ,,,4000  
PR 2000, 4000,6000, 8000  
PR ,8000,,9000  
PR ?,?,?,?  
PR ,?  
The DMC-3425 provides an alternative method for specifying data. Here data is specified individually  
using a single axis specifier such as A,B,C or D. An equals sign is used to assign data to that axis.  
For example:  
PRA=1000  
Specify a position relative movement for the A axis of 1000  
ACB=200000  
Specify acceleration for the B axis as 200000  
Instead of data, some commands request action to occur on an axis or group of axes. For example, ST  
AB stops motion on both the A and B axes. Commas are not required in this case since the particular  
axis is specified by the appropriate letter A, B, C or D. If no parameters follow the instruction, action  
will take place on all axes. Here are some examples of syntax for requesting action:  
BG A  
Begin A only  
BG B  
Begin N only  
BG ABCD  
BG BD  
BG  
Begin all axes  
Begin B and D only  
Begin all axes  
For controllers with 5 or more axes, the axes are referred to as A,B,C,D,E,F,G,H.  
BG ABCDEFGH  
Begin all axes  
BG D  
Begin D only  
Coordinated Motion with more than 1 axis  
When requesting action for coordinated motion, the letter S is used to specify a coordinated motion  
plane. For example:  
BG S  
Begin coordinated sequence, S  
BG SW  
Begin coordinated sequence, S, and W axis  
Command Syntax - Binary  
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Some commands have an equivalent binary value. Binary communication mode can be executed much  
faster than ASCII commands. Binary format can only be used when commands are sent from the PC  
and cannot be embedded in an application program.  
Binary Command Format  
All binary commands have a 4 byte header and are followed by data fields. The 4 bytes are specified  
in hexadecimal format.  
Header Format:  
Byte 1  
Specifies the command number between 80 to FF. The complete binary command number table is  
listed below.  
Byte 2  
Specifies the # of bytes in each field as 0,1,2,4 or 6 as follows:  
00  
01  
02  
04  
06  
No datafields (i.e. SH or BG)  
One byte per field  
One word (2 bytes per field)  
One long word (4 bytes) per field  
Galil real format (4 bytes integer and 2 bytes fraction)  
Byte 3  
Specifies whether the command applies to a coordinated move as follows:  
00  
01  
No coordinated motion movement  
Coordinated motion movement  
For example, the command STS designates motion to stop on a vector motion. The third byte for the  
equivalent binary command would be 01.  
Byte 4  
Specifies the axis # or data field as follows  
Bit 7 = H axis or 8th data field  
Bit 6 = G axis or 7th data field  
Bit 5 = F axis or 6th data field  
Bit 4 = E axis or 5th data field  
Bit 3 = D axis or 4th data field  
Bit 2 = C axis or 3rd data field  
Bit 1 = B axis or 2nd data field  
Bit 0 = A axis or 1st data field  
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Datafields Format  
Datafields must be consistent with the format byte and the axes byte. For example, the command PR  
1000,, -500 would be  
A7 02 00 05 03 E8 FE 0C  
where A7 is the command number for PR  
02 specifies 2 bytes for each data field  
00 S is not active for PR  
05 specifies bit 0 is active for A axis and bit 2 is active for C axis (20 + 22=5)  
03 E8 represents 1000  
FE OE represents -500  
Example  
The command ST ABCS would be  
A1 00 01 07  
where A1 is the command number for ST  
00 specifies 0 data fields  
01 specifies stop the coordinated axes S  
07 specifies stop A (bit 0), B (bit 1) and C (bit 2) 20+21+23 =7  
Binary command table  
COMMAND  
NO.  
80  
81  
82  
83  
84  
85  
86  
87  
88  
89  
8a  
8b  
8c  
8d  
8e  
8f  
COMMAND  
reserved  
reserved  
reserved  
reserved  
reserved  
LM  
NO.  
ab  
ac  
COMMAND  
No.  
d6  
d7  
d8  
d9  
da  
db  
dc  
dd  
de  
df  
Reserved  
KP  
KI  
reserved  
reserved  
RP  
ad  
ae  
KD  
DV  
AF  
KF  
PL  
TP  
af  
TE  
b0  
b1  
b2  
a3  
b4  
b5  
b6  
b7  
b8  
b9  
ba  
bb  
bc  
bd  
TD  
LI  
TV  
VP  
RL  
ER  
IL  
CR  
TT  
TN  
TS  
TL  
LE, VE  
VT  
TI  
e0  
e1  
e2  
e3  
e4  
e5  
e6  
e7  
e8  
MT  
CE  
OE  
FL  
SC  
VA  
reserved  
reserved  
reserved  
TM  
VD  
VS  
BL  
AC  
DC  
SP  
VR  
90  
91  
92  
reserved  
reserved  
CM  
CN  
LZ  
OP  
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IT  
93  
94  
95  
96  
97  
98  
99  
9a  
9b  
9c  
9d  
9e  
9f  
CD  
be  
bf  
OB  
e9  
ea  
eb  
ec  
ed  
ee  
ef  
f0  
f1  
f2  
f3  
f4  
f5  
f6  
f7  
f8  
f9  
fa  
fb  
fc  
fd  
fe  
ff  
FA  
DT  
SB  
FV  
ET  
c0  
c1  
c2  
c3  
c4  
c5  
c6  
c7  
c8  
c9  
ca  
cb  
cc  
cd  
ce  
cf  
CB  
GR  
EM  
EP  
I I  
DP  
EI  
DE  
EG  
AL  
OF  
EB  
reserved  
reserved  
reserved  
reserved  
reserved  
reserved  
reserved  
reserved  
reserved  
reserved  
reserved  
reserved  
reserved  
reserved  
reserved  
reserved  
reserved  
GM  
EQ  
Reserved  
Reserved  
Reserved  
Reserved  
Reserved  
BG  
EC  
reserved  
AM  
MC  
TW  
MF  
MR  
AD  
AP  
a0  
a1  
a2  
a3  
a4  
a5  
a6  
a7  
a8  
a9  
aa  
ST  
AB  
HM  
FE  
AR  
FI  
AS  
d0  
d1  
d2  
d3  
d4  
d5  
PA  
AI  
PR  
AT  
JG  
WT  
WC  
reserved  
MO  
SH  
Controller Response to DATA  
The DMC-3425 returns a : for valid commands and a ? for invalid commands.  
For example, if the command BG is sent in lower case, the DMC-3425 will return a ?.  
:bg <return>  
invalid command, lower case  
?
DMC-3425 returns a ?  
When the controller receives an invalid command the user can request the error code. The error code  
will specify the reason for the invalid command response. To request the error code, type the  
command: TC1. For example:  
?TC1 <return>  
Tell Code command  
1 Unrecognized  
command  
Returned response  
There are many reasons for receiving an invalid command response. The most common reasons are:  
unrecognized command (such as typographical entry or lower case), command given at improper time  
(such as during motion), or a command out of range (such as exceeding maximum speed). A complete  
listing of all codes is listed in the TC command in the Command Reference section.  
DMC-3425  
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Interrogating the Controller  
Interrogation Commands  
The DMC-3425 has a set of commands that directly interrogate the controller. When the command is  
entered, the requested data is returned in decimal format on the next line followed by a carriage return  
and line feed. The format of the returned data can be changed using the Position Format (PF), Variable  
Format (VF) and Leading Zeros (LZ) command. See Chapter 7 and the Command Reference.  
Summary of Interrogation Commands  
RP  
RL  
R V  
SC  
TB  
TC  
TD  
TE  
TI  
Report Command Position  
Report Latch  
Firmware Revision Information  
Stop Code  
Tell Status  
Tell Error Code  
Tell Dual Encoder  
Tell Error  
Tell Input  
TP  
Tell Position  
TR  
TS  
Trace  
Tell Switches  
Tell Torque  
TT  
TV  
Tell Velocity  
For example, the following example illustrates how to display the current position of the A axis:  
TP A <return>  
Tell position A  
0000000000  
Controllers Response  
Tell position A and B  
Controllers Response  
TP AB <return>  
0000000000,0000000000  
Interrogating Current Commanded Values.  
Most commands can be interrogated by using a question mark (?) as the axis specifier. Type the  
command followed by a ? for each axis requested.  
PR ?,?,?,?  
Request A,B,C,D values  
PR ,?  
Request B value only  
The controller can also be interrogated with operands.  
Operands  
Most DMC-3425 commands have corresponding operands that can be used for interrogation.  
Operands must be used inside of valid DMC expressions. For example, to display the value of an  
operand, the user could use the command:  
MG ‘operand’ where ‘operand’ is a valid DMC operand  
All of the command operands begin with the underscore character (_). For example, the value of the  
current position on the A axis can be assigned to the variable ‘V’ with the command:  
V=_TPA  
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The Command Reference denotes all commands which have an equivalent operand as "Used as an  
Operand". Also, see description of operands in Chapter 7.  
Command Summary  
For a complete command summary, see Command Reference manual.  
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Chapter 6 Programming Motion  
Overview  
The DMC-3425 provides many modes of motion, including independent positioning and jogging,  
coordinated motion, electronic cam motion, and electronic gearing. Each one of these modes is  
discussed in the following sections.  
Global vs. Local Operation  
Each DMC-3425 controls two axes of motion, referred to as A and B. The host computer can  
communicate directly with any DMC-3425 using an Ethernet or RS-232 connection. When the host  
computer is directly communicating with any DMC-3425, all commands refer to the first two axes as  
A and B. Direct communication with the DMC-3425 is known as LOCAL OPERATION.  
LOCAL OPERATION  
Host Computer  
RS-232  
or  
Ethernet  
DMC-3425  
A and B  
Axes  
DMC-3425  
A and B  
Axes  
DMC-3425  
A and B  
Axes  
DMC-3425  
A and B  
Axes  
The DMC-3425 supports Galil’s Distributed Control System. This allows up to eight axes of DMC-  
3425 and DMC-3415 controllers to be connected together as a single virtual axis controller. In this  
system, one of the controllers is designated as the master. The master can receive commands from the  
host computer that apply to all of the axes in the system.  
DMC-3425  
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GLOBAL OPERATION  
Host Computer  
RS-232  
or  
Ethernet  
DMC-3425  
A and B  
Axes  
Ethernet  
DMC-3425  
C and D  
Axes  
DMC-3425  
E and F  
Axes  
DMC-3425  
G and H  
Axes  
The controllers may operate under both Local and/or Global mode. In general, operating in Global  
mode simplifies controlling the entire system. However, Local Mode operation is necessary in some  
situations; Using local mode for setup and testing is useful since this isolates the controller. Specific  
modes of motion require operation in Local Mode. Also, each controller can have a program,  
including the slave controllers. When a slave controller has a program, this program would always  
operate in Local mode.  
The following table describes the modes of motion and whether this mode will work in Global or  
Local Mode:  
Mode of Motion  
Basic description  
Commands  
Global  
LOCAL  
Relative Independent  
Axis Positioning  
Each axis operates independently and motion is  
specified with a relative distance, velocity,  
acceleration and deceleration. The axis follows the  
prescribed velocity profile.  
PR, AC, DC, SP YES  
YES  
Absolute Independent  
Axis Positioning  
Each axis operates independently and motion is  
specified with an absolute position, velocity,  
acceleration and deceleration. The axis follows the  
prescribed velocity profile.  
PA, AC, DC, SP YES  
YES  
YES  
Independent Jogging  
Linear Interpolation  
Each axis operates independently and the axis  
follows a prescribed velocity profile with no final  
endpoint. The motion is specified with velocity,  
acceleration and deceleration. Motion stops on Stop  
command.  
JG  
YES  
NO  
AC, DC  
ST  
2 thru 8 axes of coordinated motion. The path is  
described by linear incremental segments and vector  
velocity, vector acceleration and vector  
deceleration. The vector motion follows the  
prescribed velocity profile.  
LM  
YES  
LI, LE  
VS, VA, VD  
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Vector Motion  
2-D motion path consisting of arc segments and  
linear segments, such as engraving or quilting.  
Vector velocity, vector acceleration and vector  
deceleration are specified. The vector motion  
follows the prescribed velocity profile.  
VM  
NO  
YES  
VP, CR  
VS, VA, VD  
Electronic Gearing  
Contour Mode  
Motion in which one axis must follow another axis  
such as conveyer speed. Once setup, the slave axis  
will follow the master position.  
GA  
GR  
NO  
NO  
YES  
YES  
1 – 8 axes of motion along arbitrary profiles or  
mathematically prescribed profiles such as sine or  
cosine trajectories. The path is described by linear  
incremental segments and the time between  
segments  
CM  
CD  
DT  
Electronic Cam  
Following a trajectory based on a master encoder  
position.  
EA  
EM  
EP  
NO  
YES  
ET  
Independent Axis Positioning  
In this mode, motion between the specified axes is independent, and each axis follows its own profile.  
The user specifies the desired absolute position (PA) or relative position (PR), slew speed (SP),  
acceleration ramp (AC), and deceleration ramp (DC), for each axis. On begin (BG), the DMC-3425  
profiler generates the corresponding trapezoidal or triangular velocity profile and position trajectory.  
The controller determines a new command position along the trajectory every sample period until the  
specified profile is complete. Motion is complete when the last position command is sent by the  
DMC-3425 profiler.  
NOTE: The actual motor motion may not be complete when the profile has been completed, however,  
the next motion command may be specified.  
The Begin (BG) command can be issued for all axes either simultaneously or independently. ABC or  
D axis specifiers are required to select the axes for motion. When no axes are specified, this causes  
motion to begin on all axes.  
The speed (SP) and the acceleration (AC) can be changed at any time during motion; however, the  
deceleration (DC) and position (PR or PA) cannot be changed until motion is complete. Remember,  
motion is complete when the profiler is finished, not when the actual motor is in position. The Stop  
command (ST) can be issued at any time to decelerate the motor to a stop before it reaches its final  
position.  
An incremental position movement (IP) may be specified during motion as long as the additional move  
is in the same direction. Here, the user specifies the desired position increment, n. The new target is  
equal to the old target plus the increment, n. Upon receiving the IP command, a revised profile will be  
generated for motion towards the new end position. The IP command does not require a BG.  
NOTE: If the motor is not moving, the IP command is equivalent to the PR and BG command  
combination.  
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Command Summary - Independent Axis  
COMMAND  
PR a,b,c,d  
PA a,b,c,d  
SP a,b,c,d  
AC a,b,c,d  
DC a,b,c,d  
BG ABCD  
ST ABCD  
IP a,b,c,d  
DESCRIPTION  
Specifies relative distance  
Specifies absolute position  
Specifies slew speed  
Specifies acceleration rate  
Specifies deceleration rate  
Starts motion  
Stops motion before end of move  
Changes position target  
IT a,b,c,d  
Time constant for independent motion smoothing  
Trippoint for profiler complete  
Trippoint for "in position"  
AM ABCD  
MC ABCD  
The lower case specifiers (a,b,c,d) represent position values for each axis.  
The DMC-3425 also allows use of single axis specifiers such as PRA=2000  
Operand Summary - Independent Axis  
OPERAND  
DESCRIPTION  
_ACn  
Return acceleration rate for the axis specified by ‘n  
Return deceleration rate for the axis specified by ‘n’  
Returns the speed for the axis specified by ‘n’  
_DCn  
_SPn  
_PAn  
Returns current destination if ‘n’ axis is moving, otherwise returns the current commanded  
position if not in a move.  
_PRn  
Returns current incremental distance specified for the ‘n’ axis  
Examples  
Absolute Position Movement  
Instruction  
Interpretation  
PA 10000,20000  
Specify absolute A,B position  
Acceleration for A,B  
Deceleration for A,B  
Speeds for A,B  
AC 1000000,1000000  
DC 1000000,1000000  
SP 50000,30000  
BG AB  
Begin motion  
Multiple Move Sequence  
Required Motion Profiles:  
A-Axis  
1000 counts  
Position  
15000 count/sec  
Speed  
2
Acceleration/Deceleration  
500000 counts/sec  
500 counts  
B-Axis  
Position  
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10000 count/sec  
Speed  
2
Acceleration/Deceleration  
500000 counts/sec  
100 counts  
C-Axis  
Position  
5000 counts/sec  
500000 counts/sec  
Speed  
Acceleration/Deceleration  
This example will specify a relative position movement on A, B and C axes. The movement on each  
axis will be separated by 20 msec. Fig. 6.1 shows the velocity profiles for the A,B and C axis.  
Instruction  
#A  
Interpretation  
Begin Program  
PR 1000,500,100  
Specify relative position movement of 1000, 500 and 100 counts  
for A,B and C axes.  
SP 15000,10000,5000  
Specify speed of 10000, 15000, and 5000 counts / sec  
Specify acceleration of 500000 counts / sec2 for all axes  
Specify deceleration of 500000 counts / sec2 for all axes  
Begin motion on the A axis  
AC 500000,500000,500000  
DC 500000,500000,500000  
BG A  
WT 20  
BG B  
WT 20  
BG C  
EN  
Wait 20 msec  
Begin motion on the B axis  
Wait 20 msec  
Begin motion on C axis  
End Program  
VELOCITY  
(COUNTS/SEC)  
A axis velocity profile  
B axis velocity profile  
20000  
15000  
10000  
C axis velocity profile  
5000  
TIME (ms)  
100  
0
20  
80  
40  
60  
Figure 6.1 - Velocity Profiles of ABC  
Notes on fig 6.1: The A and B axis have a ‘trapezoidal’ velocity profile, while the C axis has a  
‘triangular’ velocity profile. The A and B axes accelerate to the specified speed, move at this constant  
speed, and then decelerate such that the final position agrees with the command position, PR. The C  
axis accelerates, but before the specified speed is achieved, must begin deceleration such that the axis  
will stop at the commanded position. All 3 axes have the same acceleration and deceleration rate,  
hence, the slope of the rising and falling edges of all 3 velocity profiles are the same.  
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Independent Jogging  
The jog mode of motion is very flexible because speed, direction and acceleration can be changed  
during motion. The user specifies the jog speed (JG), acceleration (AC), and the deceleration (DC)  
rate for each axis. The direction of motion is specified by the sign of the JG parameters. When the  
begin command is given (BG), the motor accelerates up to speed and continues to jog at that speed  
until a new speed or stop (ST) command is issued. If the jog speed is changed during motion, the  
controller will make a accelerated (or decelerated) change to the new speed.  
An instant change to the motor position can be made with the use of the IP command. Upon receiving  
this command, the controller commands the motor to a position which is equal to the specified  
increment plus the current position. This command is useful when trying to synchronize the position  
of two motors while they are moving.  
Note that the controller operates as a closed-loop position controller while in the jog mode. The DMC-  
3425 converts the velocity profile into a position trajectory and a new position target is generated every  
sample period. This method of control results in precise speed regulation with phase lock accuracy.  
Command Summary - Jogging  
COMMAND  
AC a,b,c,d  
BG ABCD  
DC a,b,c,d  
IP a,b,c,d  
DESCRIPTION  
Specifies acceleration rate  
Begins motion  
Specifies deceleration rate  
Increments position instantly  
Time constant for independent motion smoothing  
Specifies jog speed and direction  
Stops motion  
IT a,b,c,d  
JG +/- a,b,c,d  
ST ABCD  
Parameters can be set with individual axes specifiers such as JGB=2000 (set jog speed for B axis to  
2000) or ACBH=400000 (set acceleration for B and H axes to 400000).  
Operand Summary - Independent Axis  
OPERAND  
DESCRIPTION  
_ACn  
Return acceleration rate for the axis specified by ‘n’  
Return deceleration rate for the axis specified by ‘n’  
Returns the jog speed for the axis specified by ‘n’  
Returns the actual velocity of the axis specified by ‘n’ (averaged over .25 sec)  
_DCn  
_SPn  
_TVn  
Examples  
Jog in A and C axes  
Jog A motor at 50000 count/s. After A motor is at its jog speed, begin jogging C in reverse direction at  
25000 count/s.  
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Instruction  
#A  
Interpretation  
Label  
AC 20000,,20000  
DC 20000,,20000  
JG 50000,,-25000  
BG A  
Specify A,C acceleration of 20000 cts / sec  
Specify A,C deceleration of 20000 cts / sec  
Specify jog speed and direction for A and C axis  
Begin A motion  
AS A  
Wait until A is at speed  
BG C  
Begin C motion  
EN  
Joystick Jogging  
The jog speed can also be changed using an analog input such as a joystick. Assume that for a 10 Volt  
input the speed must be 50000 counts/sec.  
Instruction  
#JOY  
Interpretation  
Label  
JG0  
Set in Jog Mode  
Begin motion  
Label for loop  
Read analog input  
Compute speed  
Change JG speed  
Loop  
BGA  
#B  
V1 =@AN[1]  
VEL=V1*50000/10  
JG VEL  
JP #B  
Linear Interpolation Mode (Local Mode)  
The DMC-3425 provides a linear interpolation mode for 2 axes. In linear interpolation mode, motion  
between the axes is coordinated to maintain the prescribed vector speed, acceleration, and deceleration  
along the specified path. The motion path is described in terms of incremental distances for each axis.  
An unlimited number of incremental segments may be given in a continuous move sequence, making  
the linear interpolation mode ideal for following a piece-wise linear path. There is no limit to the total  
move length.  
The LM command selects the Linear Interpolation mode and axes for interpolation. Since the  
DMC3425 is a 2-axis controller, the LM command would specify LM AB.  
When using the linear interpolation mode, the LM command only needs to be specified once unless the  
axes for linear interpolation change.  
Specifying Linear Segments  
The command LI x,y or LI a,b specifies the incremental move distance for each axis. This means  
motion is prescribed with respect to the current axis position. Up to 511 incremental move segments  
may be given prior to the Begin Sequence (BGS) command. Once motion has begun, additional LI  
segments may be sent to the controller.  
The clear sequence (CS) command can be used to remove LI segments stored in the buffer prior to the  
start of the motion. To stop the motion, use the instructions STS or AB. The command, ST, causes a  
decelerated stop. The command, AB, causes an instantaneous stop and aborts the program, and the  
command AB1 aborts the motion only.  
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The Linear End (LE) command must be used to specify the end of a linear move sequence. This  
command tells the controller to decelerate to a stop following the last LI command. If an LE command  
is not given, an Abort AB1 must be used to abort the motion sequence.  
It is the responsibility of the user to keep enough LI segments in the DMC-3425 sequence buffer to  
ensure continuous motion. If the controller receives no additional LI segments and no LE command,  
the controller will stop motion instantly at the last vector. There will be no controlled deceleration.  
LM? or _LM returns the available spaces for LI segments that can be sent to the buffer. 511 returned  
means the buffer is empty and 511 LI segments can be sent. A zero means the buffer is full and no  
additional segments can be sent. As long as the buffer is not full, additional LI segments can be sent at  
PC bus speeds.  
The instruction _CS returns the segment counter. As the segments are processed, _CS increases,  
starting at zero. This function allows the host computer to determine which segment is being  
processed.  
Additional Commands  
The commands VS n, VA n, and VD n are used to specify the vector speed, acceleration and  
deceleration. The vector speed is computed using the equation:  
2
2
2
VS =AS +BS , where AS, and BS are the speed of the A, and B axes.  
The controller always uses the axis specifications from LM, not LI, to compute the speed.  
VT is used to set the S-curve smoothing constant for coordinated moves. The command AV n is the  
‘After Vector’ trippoint, which halts program execution until the vector distance of n has been reached.  
Specifying Vector Speed for Each Segment  
The instruction VS has an immediate effect and, therefore, must be given at the required time. In some  
applications, such as CNC, it is necessary to attach various speeds to different motion segments. This  
can be done by two functions: < n and > m  
For example:  
LI x,y < n >m  
The first command, < n, is equivalent to commanding VSn at the start of the given segment and will  
cause an acceleration toward the new commanded speeds, subjects to the other constraints.  
The second function, > m, requires the vector speed to reach the value m at the end of the segment.  
Note that the function > m may start the deceleration within the given segment or during previous  
segments, as needed to meet the final speed requirement, under the given values of VA and VD.  
Note, however, that the controller works with one > m command at a time. As a consequence, one  
function may be masked by another. For example, if the function >100000 is followed by >5000, and  
the distance for deceleration is not sufficient, the second condition will not be met. The controller will  
attempt to lower the speed to 5000, but will reach that at a different point.  
As an example, consider the following program.  
Instruction  
#ALT  
Interpretation  
Label for alternative program  
Define Position of A and B axis to be 0  
Define linear mode between A and B axes.  
DP 0,0  
LMAB  
LI 4000,0 <4000 >1000  
Specify first linear segment with a vector speed of 4000 and end  
speed 1000  
LI 1000,1000 < 4000 >1000  
LI 0,5000 < 4000 >1000  
Specify second linear segment with a vector speed of 4000 and end  
speed 1000  
Specify third linear segment with a vector speed of 4000 and end  
speed 1000  
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LE  
End linear segments  
Begin motion sequence  
Program end  
BGS  
EN  
Changing Feedrate:  
The command VR n allows the feedrate, VS, to be scaled between 0 and 10 with a resolution of .0001.  
This command takes effect immediately and causes VS to be scaled. VR also applies when the vector  
speed is specified with the ‘<’ operator. This is a useful feature for feedrate override. VR does not  
ratio the accelerations. For example, VR .5 results in the specification VS 2000 to be divided in half.  
Command Summary - Linear Interpolation  
COMMAND  
DESCRIPTION  
LM nn  
Specify axes for linear interpolation  
LM ?  
Returns number of available spaces for linear segments in DMC-3425 sequence buffer.  
Zero means buffer full. 512 means buffer empty.  
LI x,y < n  
LI a,b < n  
Specify incremental distances relative to current position, and assign vector speed n.  
VS n  
VA n  
VD n  
VR n  
BGS  
CS  
Specify vector speed  
Specify vector acceleration  
Specify vector deceleration  
Specify the vector speed ratio  
Begin Linear Sequence  
Clear sequence  
LE  
Linear End- Required at end of LI command sequence  
Returns the length of the vector (resets after 2147483647)  
Trippoint for After Sequence complete  
Trippoint for After Relative Vector distance, n  
S curve smoothing constant for vector moves  
LE?  
AMS  
AV n  
VT  
Operand Summary - Linear Interpolation  
OPERAND  
DESCRIPTION  
_AV  
Return distance traveled  
_CS  
Segment counter - returns number of the segment in the sequence, starting at zero.  
Returns length of vector (resets after 2147483647)  
_LE  
_LM  
Returns number of available spaces for linear segments in DMC-3425 sequence buffer.  
Zero means buffer full. 512 means buffer empty.  
_VPm  
Return the absolute coordinate of the last data point along the trajectory.  
(m=A,B)  
To illustrate the ability to interrogate the motion status, consider the first motion segment of our  
example, #LMOVE, where the A axis moves toward the point A=5000. Suppose that when A=3000,  
the controller is interrogated using the command ‘MG _AV’. The returned value will be 3000. The  
value of _CS, _VPA and _VPB will be zero.  
Now suppose that the interrogation is repeated at the second segment when Y=2000. The value of  
_AV at this point is 7000, _CS equals 1, _VPA=5000 and _VPB=0.  
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Example  
Linear Interpolation Motion  
In this example, the AB system is required to perform a 90° turn. In order to slow the speed around  
the corner, we use the AV 4000 trippoint, which slows the speed to 1000 count/s. Once the motors  
reach the corner, the speed is increased back to 4000 cts / s.  
Instruction  
#LMOVE  
DP 0,0  
Interpretation  
Label  
Define position of A and B axes to be 0  
Define linear mode between A and B axes.  
Specify first linear segment  
Specify second linear segment  
End linear segments  
LMAB  
LI 5000,0  
LI 0,5000  
LE  
VS 4000  
BGS  
Specify vector speed  
Begin motion sequence  
AV 4000  
VS 1000  
AV 5000  
VS 4000  
EN  
Set trippoint to wait until vector distance of 4000 is reached  
Change vector speed  
Set trippoint to wait until vector distance of 5000 is reached  
Change vector speed  
Program end  
Example - Linear Move  
Make a coordinated linear move in the AB plane. Move to coordinates 40000,30000 counts at a vector  
2
speed of 100000 counts/sec and vector acceleration of 1000000 counts/sec .  
Instruction  
LM AB  
Interpretation  
Specify axes for linear interpolation  
Specify AB distances  
Specify end move  
LI40000,30000  
LE  
VS 100000  
VA 1000000  
VD 1000000  
BGS  
Specify vector speed  
Specify vector acceleration  
Specify vector deceleration  
Begin sequence  
Note that the above program specifies the vector speed, VS, and not the actual axis speeds VA and VB  
the axis speeds are determined by the DMC-3425 from:  
2
VA2 VB  
=
+
VS  
The resulting profile is shown in Figure 6.2.  
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30000  
27000  
POSITION B  
3000  
0
0
4000  
36000  
40000  
POSITION A  
FEEDRATE  
0
0.1  
0.5  
0.6  
TIME (sec)  
VELOCITY  
A-AXIS  
TIME (sec)  
VELOCITY  
B-AXIS  
TIME (sec)  
Figure 6.2 - Linear Interpolation  
Example - Multiple Moves  
This example makes a coordinated linear move in the AB plane. The Arrays VA and VB are used to  
store 750 incremental distances which are filled by the program #LOAD.  
Instruction  
Interpretation  
Load Program  
Define Array  
#LOAD  
DM VA [750],VB [750]  
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COUNT=0  
Initialize Counter  
N=10  
Initialize position increment  
LOOP  
#LOOP  
VA [COUNT]=N  
VB [COUNT]=N  
N=N+10  
Fill Array VA  
Fill Array VB  
Increment position  
Increment counter  
COUNT=COUNT+1  
JP #LOOP,COUNT<750  
#A  
Loop if array not full  
Label  
LM AB  
Specify linear mode for AB  
Initialize array counter  
If sequence buffer full, wait  
Begin motion on 500th segment  
Specify linear segment  
Increment array counter  
Repeat until array done  
End Linear Move  
COUNT=0  
#LOOP2;JP#LOOP2,_LM=0  
JS#C,COUNT=500  
LI VA[COUNT],VB[COUNT]  
COUNT=COUNT+1  
JP #LOOP2,COUNT<750  
LE  
AMS  
After Move sequence done  
Send Message  
MG "DONE"  
EN  
End program  
#C;BGS;EN  
Begin Motion Subroutine  
Vector Mode: Linear and Circular Interpolation (Local Mode)  
The DMC-3425 allows a long 2-D path consisting of linear and arc segments to be prescribed. Motion  
along the path is continuous at the chosen vector speed even at transitions between linear and circular  
segments. The DMC-3425 performs all the complex computations of linear and circular interpolation,  
freeing the host PC from this time intensive task.  
The coordinated motion mode is similar to the linear interpolation mode. Any pair of two axes may be  
selected for coordinated motion consisting of linear and circular segments. Note that only one pair of  
axes can be specified for coordinated motion at any given time.  
Specifying Vector Segments  
The motion segments are described by two commands; VP for linear segments and CR for circular  
segments. Once a set of linear segments and/or circular segments have been specified, the sequence is  
ended with the command VE. This defines a sequence of commands for coordinated motion.  
Immediately prior to the execution of the first coordinated movement, the controller defines the current  
position to be zero for all movements in a sequence. Note: This ‘local’ definition of zero does not  
affect the absolute coordinate system or subsequent coordinated motion sequences.  
The command, VP a,b specifies the coordinates of the end points of the vector movement with respect  
to the starting point. The command, CR r,θ,δ define a circular arc with a radius r, starting angle of θ,  
and a traversed angle δ. The notation for θ is that zero corresponds to the positive horizontal direction,  
and for both θ and δ, the counter-clockwise (CCW) rotation is positive.  
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Up to 511 segments of CR or VP may be specified in a single sequence and must be ended with the  
command VE. The motion can be initiated with a Begin Sequence (BGS) command. Once motion  
starts, additional segments may be added.  
The Clear Sequence (CS) command can be used to remove previous VP and CR commands that were  
stored in the buffer prior to the start of the motion. To stop the motion, use the instructions STS or  
AB1. ST stops motion at the specified deceleration. AB1 aborts the motion instantaneously.  
The Vector End (VE) command must be used to specify the end of the coordinated motion. This  
command tells the controller to decelerate to a stop following the last motion in the sequence. If a VE  
command is not given, an Abort (AB1) must be used to abort the coordinated motion sequence.  
The user must keep enough motion segments in the DMC-3425 sequence buffer to ensure continuous  
motion. If the controller receives no additional motion segments and no VE command, the controller  
will stop motion instantly at the last vector. There will be no controlled deceleration. LM? or _LM  
returns the available spaces for motion segments that can be sent to the buffer. 511 returned means the  
buffer is empty and 511 segments can be sent. A zero means the buffer is full and no additional  
segments can be sent. As long as the buffer is not full, additional segments can be sent at the PCI bus  
speed.  
The operand _CS can be used to determine the value of the segment counter.  
Additional commands  
The commands VS n, VA n and VD n are used for specifying the vector speed, acceleration, and  
deceleration.  
VT is the motion smoothing constant used for coordinated motion.  
Specifying Vector Speed for Each Segment:  
The vector speed may be specified by the immediate command VS. It can also be attached to a motion  
segment with the instructions  
VP x,y < n >m  
CR r,θ,δ < n >m  
The first parameter, <n, is equivalent to commanding VSn at the start of the given segment and will  
cause an acceleration toward the new commanded speeds, subjects to the other constraints.  
The second parameter, > m, requires the vector speed to reach the value m at the end of the segment.  
Note that the function > m may start the deceleration within the given segment or during previous  
segments, as needed to meet the final speed requirement, under the given values of VA and VD.  
Note, however, that the controller works with one > m command at a time. As a consequence, one  
function may be masked by another. For example, if the function >100000 is followed by >5000, and  
the distance for deceleration is not sufficient, the second condition will not be met. The controller will  
attempt to lower the speed to 5000, but will reach that at a different point.  
Changing Feedrate:  
The command VR n allows the feedrate, VS, to be scaled from 0 and 10 times with a resolution of  
.0001. This command takes effect immediately and causes VS scaled. VR also applies when the  
vector speed is specified with the ‘<’ operator. This is a useful feature for feedrate override. VR does  
not ratio the accelerations. For example, VR .5 results in the specification VS 2000 act as VS 1000.  
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Compensating for Differences in Encoder Resolution:  
By default, the DMC-3425 uses a scale factor of 1:1 for the encoder resolution when used in vector  
mode. If this is not the case, the command, ES can be used to scale the encoder counts. The ES  
command accepts two arguments that represent the ratio of the encoder resolutions. For more  
information refer to ES in the Command Reference.  
Trippoints:  
The AV n command is the After Vector trippoint, which waits for the vector relative distance of n to  
occur before executing the next command in a program.  
Command Summary - Coordinated Motion Sequence  
COMMAND  
VM m,n  
DESCRIPTION  
Specifies the axes for the planar motion where m and n represent the planar axes.  
Return coordinate of last point, where m=A,B,C or D.  
VP m,n  
CR r,θ,δ  
Specifies arc segment where r is the radius, θ is the starting angle and δ is the travel  
angle. Positive direction is CCW.  
VS n  
VA n  
VD n  
VR n  
BGS  
CS  
Specify vector speed or feedrate of sequence.  
Specify vector acceleration along the sequence.  
Specify vector deceleration along the sequence.  
Specify vector speed ratio  
Begin motion sequence  
Clear sequence.  
AV n  
AMS  
ES m,n  
VT  
Trippoint for After Relative Vector distance, n.  
Holds execution of next command until Motion Sequence is complete.  
Ellipse scale factor.  
S curve smoothing constant for coordinated moves  
LM?  
Return number of available spaces for linear and circular segments in DMC-3425  
sequence buffer. Zero means buffer is full. 512 means buffer is empty.  
Operand Summary - Coordinated Motion Sequence  
COMMAND  
DESCRIPTION  
_VPM  
The absolute coordinate of the axes at the last intersection along the sequence.  
Distance traveled.  
_AV  
_LM  
Number of available spaces for linear and circular segments in DMC-3425 sequence  
buffer. Zero means buffer is full. 512 means buffer is empty.  
_CS  
_VE  
Segment counter - Number of the segment in the sequence, starting at zero.  
Vector length of coordinated move sequence.  
When AV is used as an operand, _AV returns the distance traveled along the sequence.  
The operands _VPA and _VPB can be used to return the coordinates of the last point specified along  
the path.  
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Example:  
Traverse the path shown in Fig. 6.3. Feedrate is 20000 counts/sec. Plane of motion is AB  
Instruction  
VM AB  
Interpretation  
Specify motion plane  
Specify vector speed  
Specify vector acceleration  
Specify vector deceleration  
Segment AB  
VS 20000  
VA 1000000  
VD 1000000  
VP -4000,0  
CR 1500,270,-180  
VP 0,3000  
CR 1500,90,-180  
VE  
Segment BC  
Segment CD  
Segment DA  
End of sequence  
Begin Sequence  
BGS  
The resulting motion starts at the point A and moves toward points B, C, D, A. Suppose that we  
interrogate the controller when the motion is halfway between the points A and B.  
The value of _AV is 2000  
The value of _CS is 0  
_VPA and _VPB contain the absolute coordinate of the point A  
Suppose that the interrogation is repeated at a point, halfway between the points C and D.  
The value of _AV is 4000+1500π+2000=10,712  
The value of _CS is 2  
_VPA, _VPB contain the coordinates of the point C  
C (-4000,3000)  
D (0,3000)  
R = 1500  
B (-4000,0)  
A (0,0)  
Figure 6.3 - The Required Path  
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Electronic Gearing (Local Mode)  
This mode allows one axis to be electronically geared to the other axis. The master may rotate in both  
directions and the geared axes will follow at the specified gear ratio. The gear ratio may be different  
for each axis and changed during motion.  
The command GA specifies the master axis. GR n,n specifies the gear ratios for the slaves where the  
ratio may be a number between +/-127.9999 with a fractional resolution of .0001. There are two  
modes: standard gearing and gantry mode. The gantry mode is enabled with the command GM. GR  
0,0 turns off gearing in both modes. A limit switch or ST command disables gearing in the standard  
mode but not in the gantry mode.  
The command GM n,n selects the axes to be controlled under the gantry mode. The parameter 1  
enables gantry mode, and 0 disables it.  
GR causes the specified axes to be geared to the actual position of the master. The master axis is  
commanded with motion commands such as PR, PA, or JG.  
When the master axis is driven by the controller in the jog mode or an independent motion mode, it is  
possible to define the master as the command position of that axis, rather than the actual position. The  
designation of the commanded position master is by the letter C. For example, GACD indicates that  
the gearing is the commanded position of D.  
Electronic gearing allows the geared motor to perform a second independent or coordinated move in  
addition to the gearing. For example, when a geared motor follows a master at a ratio of 1:1, it may be  
advanced an additional distance with PR, JG, VP, or LI commands.  
Command Summary - Electronic Gearing  
COMMAND  
DESCRIPTION  
GA n  
Specifies master axes for gearing where:  
n = A,B for main encoder as master  
n = CA, CB for commanded position.  
GR n,n  
GM n,n  
MF n,n  
MR n,n  
GA?  
Sets gear ratio for slave axes. 0 disables electronic gearing for specified axis.  
1 sets gantry mode, 0 disables gantry mode  
Trippoint for forward motion past specified value. Only one field may be used.  
Trippoint for reverse motion past specified value. Only one field may be used.  
Retuns the GA command setting  
Example – Electronic Gearing  
Objective: Gear an A-axis slave motor at a speed of 2.5 times the speed of the B-axis master.  
GAB  
Specify B-axis as the master for A  
GR2.5  
Specify gear ratio for A to be 2.5 times the B axis master.  
Example - Gantry Mode  
In applications where both the master and the follower are controlled by the DMC-3425 controller, it  
may be desired to synchronize the follower with the commanded position of the master, rather than the  
actual position. This eliminates the possibility of an oscillation on the master passing the oscillation on  
to the slave.  
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For example, assume that a gantry is driven by two axes, A and B, one on each side. This requires the  
gantry mode for strong coupling between the motors. The A-axis is the master and the B-axis is the  
follower. To synchronize B with the commanded position of A, use the instructions:  
GA, CA  
Specify the commanded position of A as master for B.  
Set gear ratio for B as 1:1  
Set gantry mode  
GR,1  
GM,1  
PR 3000  
BG A  
Command A motion  
Start motion on A axis  
You may also perform profiled position corrections in the electronic gearing mode. Suppose, for  
example, that you need to advance the slave 10 counts. Simply command  
IP ,10  
Specify an incremental position movement of 10 on the B axis.  
Under these conditions, this IP command is equivalent to:  
PR,10  
Specify position relative movement of 10 on the B axis  
BGB  
Begin motion on the B axis  
Often the correction is quite large. Such requirements are common when synchronizing cutting knives  
or conveyor belts.  
Example - Synchronize two conveyor belts with trapezoidal velocity correction.  
Instruction  
GA,A  
Interpretation  
Define A as the master axis for B.  
Set gear ratio 2:1 for B  
GR,2  
PR,300  
Specify correction distance  
Specify correction speed  
Specify correction acceleration  
Specify correction deceleration  
Start correction  
SP,5000  
AC,100000  
DC,100000  
BGB  
Electronic Cam (Local Mode)  
The electronic cam is a motion control mode that enables the periodic synchronization of several axes  
of motion. Similar to the gearing mode, the DMC-3425 uses only A and B main axes as the master or  
slave.  
The electronic cam is a more general type of electronic gearing which allows a table-based relationship  
between the axes. It allows synchronizing all the controller axes.  
To illustrate the procedure of setting the cam mode, consider the cam relationship for the slave axis B,  
when the master is A. Such a graphic relationship is shown in Figure 6.4.  
Step 1. Selecting the master axis  
The first step in the electronic cam mode is to select the master axis. This is done with the instruction  
EAp where p = A,B  
p is the selected master axis  
For the given example, since the master is a, we specify EAA  
Step 2. Specify the master cycle and the change in the slave axis (es).  
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In the electronic cam mode, the position of the master is always expressed within one cycle. In this  
example, the position of a is always expressed in the range between 0 and 6000. Similarly, the slave  
position is also redefined such that it starts at zero and ends at 1500. At the end of a cycle when the  
master is 6000 and the slave is 1500, the positions of both a and b are redefined as zero. To specify the  
master cycle and the slave cycle change, we use the instruction EM.  
EM a,b  
where a,b specify the cycle of the master and the total change of the slaves over one cycle.  
The cycle of the master is limited to 8,388,607 whereas the slave change per cycle is limited to  
2,147,483,647. If the change is a negative number, the absolute value is specified. For the given  
example, the cycle of the master is 6000 counts and the change in the slave is 1500. Therefore, we use  
the instruction:  
EM 6000,1500  
Step 3. Specify the master interval and starting point.  
Next we need to construct the ECAM table. The table is specified at uniform intervals of master  
positions. Up to 256 intervals are allowed. The size of the master interval and the starting point are  
specified by the instruction:  
EP m,n  
where m is the interval width in counts, and n is the starting point.  
For the given example, we can specify the table by specifying the position at the master points of 0,  
2000, 4000 and 6000. We can specify that by  
EP 2000,0  
Step 4. Specify the slave positions.  
Next, we specify the slave positions with the instruction  
ET[n]=x,y  
where n indicates the order of the point.  
The value, n, starts at zero and may go up to 256. The parameters x,y indicate the corresponding slave  
position. For this example, the table may be specified by  
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ET[0]=,0  
ET[1]=,3000  
ET[2]=,2250  
ET[3]=,1500  
This specifies the ECAM table.  
Step 5. Enable the ECAM  
To enable the ECAM mode, use the command  
EB n  
where n=1 enables ECAM mode and n=0 disables ECAM mode.  
Step 6. Engage the slave motion  
To engage the slave motion, use the instruction  
EG a,b  
where a,b are the master positions at which the corresponding slaves must be engaged.  
If the value of any parameter is outside the range of one cycle, the cam engages immediately. When  
the cam is engaged, the slave position is redefined, modulo one cycle.  
Step 7. Disengage the slave motion  
To disengage the cam, use the command  
EQ a,b  
where a,b are the master positions at which the corresponding slave axes are disengaged.  
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3000  
2250  
1500  
0
2000  
4000  
6000  
Master X  
Figure 6.4 - Electronic Cam Example  
This disengages the slave axis at a specified master position. If the parameter is outside the master  
cycle, the stopping is instantaneous.  
To illustrate the complete process, consider the cam relationship described by  
the equation:  
Y = 0.5 X + 100 sin (0.18 X)  
*
*
where A is the master, with a cycle of 2000 counts.  
The cam table can be constructed manually, point by point, or automatically by a program. The  
following program includes the set-up.  
The instruction EAA defines A as the master axis. The cycle of the master is  
2000. Over that cycle, B varies by 1000. This leads to the instruction EM 2000,1000.  
Suppose we want to define a table with 100 segments. This implies increments of 20 counts each. If  
the master points are to start at zero, the required instruction is EP 20,0.  
The following routine computes the table points. As the phase equals 0.18X and A varies in  
increments of 20, the phase varies by increments of 3.6°. The program then computes the values of B  
according to the equation and assigns the values to the table with the instruction ET[N] = ,B.  
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Instruction  
#SETUP  
EAA  
Interpretation  
Label  
Select A as master  
Cam cycles  
EM 2000,1000  
EP 20,0  
Master position increments  
Index  
N = 0  
#LOOP  
Loop to construct table from equation  
Note 3.6 = 0.1820  
Define sine position  
P = N3.6  
S = @SIN [P] 100  
*
Y = N 10+S  
*
Define slave position  
Define table  
ET [N] =, B  
N = N+1  
JP #LOOP, N<=100  
EN  
Repeat the process  
Now suppose that the slave axis is engaged with a start signal, input 1, but that both the engagement  
and disengagement points must be done at the center of the cycle: A = 1000 and B = 500. This  
implies that B must be driven to that point to avoid a jump.  
This is done with the program:  
Instruction  
#RUN  
EB1  
Interpretation  
Label  
Enable cam  
PA,500  
SP,5000  
BGB  
B starting position  
B speed  
Move B motor  
After B moved  
Wait for start signal  
Engage slave  
Wait for stop signal  
Disengage slave  
End  
AM  
AI1  
EG,1000  
AI – 1  
EQ,1000  
EN  
The following example illustrates a cam program with a master axis, A, and a single slave B.  
Instruction  
#A;V1=0  
Interpretation  
Label; Initialize variable  
PA 0,0;BGAB;AMAB  
EA A  
Go to position 0,0 on A and B axes  
A axis as the Master for ECAM  
Change for A is 4000, zero for B  
ECAM interval is 400 counts with zero start  
When master is at 0 position; 1st point.  
2nd point in the ECAM table  
EM 4000,0  
EP400,0  
ET[0]=,0  
ET[1]=,20  
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ET[2]=,60  
ET[3]=,120  
ET[4]=,140  
ET[5]=,140  
ET[6]=,140  
ET[7]=,120  
ET[8]=,60  
ET[9]=,20  
ET[10]=,0  
EB 1  
3rd point in the ECAM table  
4th point in the ECAM table  
5th point in the ECAM table  
6th point in the ECAM table  
7th point in the ECAM table  
8th point in the ECAM table  
9th point in the ECAM table  
10th point in the ECAM table  
Starting point for next cycle  
Enable ECAM mode  
JGA=4000  
EG ,0  
Set A to jog at 4000  
Engage both A and B when Master = 0  
Begin jog on A axis  
BGA  
#LOOP;JP#LOOP,V1=0  
EQ,2000  
MF2000  
Loop until the variable is set  
Disengage B when Master = 2000  
Wait until the Master goes to 2000  
Stop the A axis motion  
ST A  
EB 0  
Exit the ECAM mode  
EN  
End of the program  
The above example shows how the ECAM program is structured and how the commands can be given  
to the controller. The next page provides the results captured by the WSDK program. This shows how  
the motion will be seen during the ECAM cycles. The first graph is for the A axis, the master, and the  
second graph shows the cycle on the B axis.  
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Contour Mode (Local Mode)  
The DMC-3425 also provides a contouring mode. This mode allows any arbitrary position curve to be  
prescribed for any motion axes. This is ideal for following computer generated paths such as  
parabolic, spherical or user-defined profiles. The path is not limited to straight line and arc segments  
and the path length may be infinite.  
Specifying Contour Segments  
The Contour Mode is specified with the command, CM. For example, CMAB specifies contouring on  
the A and B axes. Any axes that are not being used in the contouring mode may be operated in other  
modes.  
A contour is described by position increments which are described with the command, CD a,b over a  
n
time interval, DT n. The parameter, n, specifies the time interval. The time interval is defined as 2  
ms, where n is a number between 1 and 8. The controller performs linear interpolation between the  
specified increments, where one point is generated for each millisecond.  
Consider, for example, the trajectory shown in Fig. 6.5. The position A may be described by the  
points:  
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Point 1  
Point 2  
Point 3  
Point 4  
A=0 at T=0ms  
A=48 at T=4ms  
A=288 at T=12ms  
A=336 at T=28ms  
The same trajectory may be represented by the increments  
Increment 1  
Increment 2  
Increment 3  
DA=48  
DA=240  
DA=48  
Time Increment =4  
Time Increment =8  
Time Increment =16  
DT=2  
DT=3  
DT=4  
When the controller receives the command to generate a trajectory along these points, it interpolates  
linearly between the points. The resulting interpolated points include the position 12 at 1 msec,  
position 24 at 2 msec, etc.  
The programmed commands to specify the above example are:  
Instruction  
#A  
Description  
Label  
CMA  
Specifies A axis for contour mode  
Specifies first time interval, 22 ms  
Specifies first position increment  
Specifies second time interval, 23 ms  
Specifies second position increment  
Specifies the third time interval, 24 ms  
Specifies the third position increment  
Exits contour mode  
DT 2  
CD 48;WC  
DT 3  
CD 240;WC  
DT 4  
CD 48;WC  
DT0;CD0  
EN  
POSITION  
(COUNTS)  
336  
288  
240  
192  
96  
48  
TIME (ms)  
0
4
8
28  
12  
20  
24  
16  
SEGMENT 1  
SEGMENT 2  
SEGMENT 3  
Figure 6.5 - The Required Trajectory  
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Additional Commands  
The command, WC, is used as a trippoint "When Complete" or “Wait for Contour Data”. This allows  
the DMC-3425 to use the next increment only when it is finished with the previous one. Zero  
parameters for DT followed by zero parameters for CD exit the contour mode.  
If no new data record is found and the controller is still in the contour mode, the controller waits for  
new data. No new motion commands are generated while waiting. If bad data is received, the  
controller responds with a ?.  
Command Summary - Contour Mode  
Command  
Description  
CM AB  
Specifies which axes for contouring mode. Any non-contouring axes may be operated in  
other modes.  
CD a,b  
DT n  
Specifies position increment over time interval. Range is +/-32,000. Zero ends contour  
mode.  
Specifies time interval 2n msec for position increment, where n is an integer between 1 and  
8. Zero ends contour mode. If n does not change, it does not need to be specified with each  
CD.  
WC  
Waits for previous time interval to be complete before next data record is processed.  
Operand Summary - Contour Mode  
Operand  
Description  
_CS  
Return segment number  
General Velocity Profiles  
The Contour Mode is ideal for generating an arbitrary velocity profile. The velocity profile can be  
specified as a mathematical function or as a collection of points.  
The design includes two parts: Generating an array with data points and running the program.  
Generating an Array - An Example  
Consider the velocity and position profiles shown in Fig. 6.6. The objective is to rotate a motor a  
distance of 6000 counts in 120 ms. The velocity profile is sinusoidal to reduce the jerk and the system  
vibration. If we describe the position displacement in terms of A counts in B milliseconds, we can  
describe the motion in the following manner:  
ω = (A/B) [1 - cos (2πΤ/B)]  
X = (AT/B) - (A/2π)sin (2πΤ/B)  
Note: ω is the angular velocity; X is the position; and T is the variable, time, in milliseconds.  
In the given example, A=6000 and B=120, the position and velocity profiles are:  
X = 50T - (6000/2π) sin (2π T/120)  
Note that the velocity, ω, in count/ms, is  
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ω = 50 [1 - cos 2π T/120]  
Figure 6.6 - Velocity Profile with Sinusoidal Acceleration  
The DMC-3425 can compute trigonometric functions. However, the argument must be expressed in  
degrees. Using our example, the equation for X is written as:  
X = 50T - 955 sin 3T  
A complete program to generate the contour movement in this example is given below. To generate an  
array, we compute the position value at intervals of 8 ms. This is stored at the array POS. Then, the  
difference between the positions is computed and is stored in the array DIF. Finally the motors are run  
in the contour mode.  
Contour Mode Example  
Instruction  
#POINTS  
DM POS[16]  
DM DIF[15]  
C=0  
Interpretation  
Program defines A points  
Allocate memory  
Set initial conditions, C is index  
T is time in ms  
T=0  
#A  
V1=50*T  
V2=3*T  
Argument in degrees  
Compute position  
Integer value of V3  
Store in array POS  
V3=-955*@SIN[V2]+V1  
V4=@INT[V3]  
POS[C]=V4  
T=T+8  
C=C+1  
JP #A,C<16  
#B  
Program to find position differences  
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C=0  
#C  
D=C+1  
DIF[C]=POS[D]-POS[C]  
Compute the difference and store  
C=C+1  
JP #C,C<15  
EN  
End first program  
Program to run motor  
Contour Mode  
#RUN  
CMA  
DT3  
4 millisecond intervals  
C=0  
#E  
CD DIF[C]  
WC  
Contour Distance is in DIF  
Wait for completion  
C=C+1  
JP #E,C<15  
DT0  
CD0  
Stop Contour  
EN  
End the program  
Teach (Record and Play-Back)  
Several applications require teaching the machine a motion trajectory. Teaching can be accomplished  
using the DMC-3425 automatic array capture feature to capture position data. The captured data may  
then be played back in the contour mode. The following array commands are used:  
DM C[n]  
RA C[]  
Dimension array  
Specify array for automatic record  
Specify data for capturing (such as _TPA or _TPB)  
RD _TPA  
RC n,m  
Specify capture time interval where n is 2n msec, m is number of records to be  
captured  
RC? or _RC  
Returns a 1 if recording  
Record and Playback Example:  
Instruction  
#RECORD  
DM APOS[501]  
RA APOS[]  
RD _TPA  
Interpretation  
Begin Program  
Dimension array with 501 elements  
Specify automatic record  
Specify A position to be captured  
Turn A motor off  
MOA  
RC2  
Begin recording; 4 msec interval  
Continue until done recording  
Compute DX  
#A;JP#A,_RC=1  
#COMPUTE  
DM DX[500]  
C=0  
Dimension Array for DX  
Initialize counter  
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#L  
Label  
D=C+1  
DELTA=XPOS[D]-XPOS[C] Compute the difference  
DX[C]=DELTA  
C=C+1  
Store difference in array  
Increment index  
JP #L,C<500  
#PLAYBCK  
CMA  
Repeat until done  
Begin Playback  
Specify contour mode  
Specify time increment  
Initialize array counter  
Loop counter  
DT2  
I=0  
#B  
CD XPOS[I];WC  
Specify contour data I=I+1 Increment array counter JP #B,I<500 Loop until  
done  
DT 0;CD0  
EN  
End contour mode  
End program  
For additional information about automatic array capture, see Chapter 7, Arrays.  
Virtual Axis (Local Mode)  
The DMC-3425 controller has an internal motion profiler, also referred to as a virtual axis. This axis is  
designated as the N axis and has no encoder input and no DAC output. With the N axis, a commanded  
position profile can be generated using the following modes of motion:  
Mode of Motion  
Virtual Axis usage  
Commands  
Relative Independent  
Axis Positioning  
N axis profile is specified with a relative distance, velocity,  
acceleration and deceleration. The N axis profile follows the  
prescribed velocity profile.  
PRN=<value>  
ACN=<value>  
DCN=<value>  
SPN=<value>  
Absolute Independent  
Axis Positioning  
N axis profile is specified with an absolute distance, velocity, PAN=<value>  
acceleration and deceleration. The N axis profile follows the  
prescribed velocity profile.  
ACN=<value>  
DCN=<value>  
SPN=<value>  
Independent Jogging  
Vector Motion  
N axis profile is specified with a prescribed velocity with no  
final endpoint. The motion is specified with velocity,  
acceleration and deceleration. Motion stops on Stop  
command.  
JGN=<value>  
ACN=<value>  
DCN=<value>  
STN=<value>  
N axis profile replaces one of the 2 axes specified for 2-D  
motion. Vector velocity, vector acceleration and vector  
deceleration are specified. The vector motion follows the  
prescribed velocity profile.  
VMxN  
VMNx  
x represents the 2nd  
axis used for  
vector motion  
Electronic Gearing  
Electronic Cam  
N axis can be used as a master axis for gearing  
GAx=N  
GA N,N  
N axis can be used as a master axis for electronic CAM  
EA N  
EMN=<value>  
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The main use of the virtual axis is to serve as a virtual master in ECAM modes, and to perform an  
unnecessary part of a vector mode. These applications are illustrated by the following examples.  
Ecam Master Example  
Suppose that the motion of the AB axes is constrained along a path that can be described by an  
electronic cam table. Further assume that the ecam master is not an external encoder but has to be a  
controlled variable.  
This can be achieved by defining the N axis as the master with the command EAN and setting the  
modulo of the master with a command such as EMN= 4000. Next, the table is constructed. To move  
the constrained axes, simply command the N axis in the jog mode or with the PR and PA commands.  
For example,  
PAN = 2000  
BGN  
will cause the AB axes to move to the corresponding points on the motion cycle.  
Sinusoidal Motion Example  
The A axis must perform a sinusoidal motion of 10 cycles with an amplitude of 1000 counts and a  
frequency of 20 Hz.  
This can be performed by commanding the A and N axes to perform circular motion. Note that the  
value of VS must be  
VS = 2π * R * F  
where R is the radius, or amplitude and F is the frequency in Hz.  
Set VA and VD to maximum values for the fastest acceleration.  
Instruction  
VMAN  
Interpretation  
Select Axes  
VA 68000000  
VD 68000000  
VS 125664  
CR 1000, -90, 3600  
VE  
Maximum Acceleration  
Maximum Deceleration  
VS for 20 Hz  
Ten Cycles  
BGS  
Stepper Motor Operation  
When configured for stepper motor operation, several commands are interpreted differently than from  
servo mode. The following describes operation with stepper motors.  
NOTE: If two steppers are to be used with the DMC-3425, the controller must be ordered from the  
factory as a DMC-3425-Stepper.  
Specifying Stepper Motor Operation  
In order to command stepper motor operation, the appropriate stepper mode jumpers must be installed.  
See chapter 2 for this installation.  
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Stepper motor operation is specified by the command MT. The argument for MT is as follows:  
2
specifies a stepper motor with active low step output pulses  
-2  
specifies a stepper motor with active high step output pulses  
2.5  
-2.5  
specifies a stepper motor with active low step output pulses and reversed direction  
specifies a stepper motor with active high step output pulse and reversed direction  
Stepper Motor Smoothing  
The command, KS, provides stepper motor smoothing. The effect of the smoothing can be thought of  
as a simple Resistor-Capacitor (single pole) filter. The filter occurs after the motion profiler and has  
the effect of smoothing out the spacing of pulses for a more smooth operation of the stepper motor.  
Use of KS is most applicable when operating in full step or half step operation. KS will cause the step  
pulses to be delayed in accordance with the time constant specified.  
When operating with stepper motors, you will always have some amount of stepper motor smoothing,  
KS. Since this filtering effect occurs after the profiler, the profiler may be ready for additional moves  
before all of the step pulses have gone through the filter. It is important to consider this effect since  
steps may be lost if the controller is commanded to generate an additional move before the previous  
move has been completed. See the discussion below, Monitoring Generated Pulses vs. Commanded  
Pulses.  
The general motion smoothing command, IT, can also be used. The purpose of the command, IT, is to  
smooth out the motion profile and decrease 'jerk' due to acceleration.  
Monitoring Generated Pulses vs. Commanded Pulses  
For proper controller operation, it is necessary to make sure that the controller has completed  
generating all step pulses before making additional moves. This is most particularly important if you  
are moving back and forth. For example, when operating with servo motors, the trippoint AM (After  
Motion) is used to determine when the motion profiler is complete and is prepared to execute a new  
motion command. However when operating in stepper mode, the controller may still be generating  
step pulses when the motion profiler is complete. This is caused by the stepper motor smoothing filter,  
KS. To understand this, consider the steps the controller executes to generate step pulses:  
First, the controller generates a motion profile in accordance with the motion commands.  
Second, the profiler generates pulses as prescribed by the motion profile. The pulses that are generated  
by the motion profiler can be monitored by the command, RP (Reference Position). RP gives the  
absolute value of the position as determined by the motion profiler. The command, DP, can be used to  
set the value of the reference position. For example, DP 0, defines the reference position of the A axis  
to be zero.  
Third, the output of the motion profiler is filtered by the stepper smoothing filter. This filter adds a  
delay in the output of the stepper motor pulses. The amount of delay depends on the parameter that is  
specified by the command, KS. As mentioned earlier, there will always be some amount of stepper  
motor smoothing. The default value for KS is 2, which corresponds to a time constant of 6 sample  
periods.  
Fourth, the output of the stepper smoothing filter is buffered and is available for input to the stepper  
motor driver. The pulses that are generated by the smoothing filter can be monitored by the command,  
TD (Tell Dual). TD gives the absolute value of the position as determined by actual output of the  
buffer. The command, DP sets the value of the step count register as well as the value of the reference  
position. For example, DP 0, defines the reference position of the A axis to be zero.  
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Stepper Smoothing Filter  
(Adds a Delay)  
Output  
(To Stepper Driver)  
Motion Profiler  
Output Buffer  
Reference Position (RP)  
Step Count Register (TD)  
Motion Complete Trippoint  
When used in stepper mode, the MC command will hold up execution of the proceeding commands  
until the controller has generated the same number of steps out of the step count register as specified in  
the commanded position. The MC trippoint (Motion Complete) is generally more useful than AM  
trippoint (After Motion) since the step pulses can be delayed from the commanded position due to  
stepper motor smoothing.  
Using an Encoder with Stepper Motors  
An encoder may be used on a stepper motor to check the actual motor position with the commanded  
position. If an encoder is used, it must be connected to the main encoder input.  
NOTE: The auxiliary encoder is not available while operating with stepper motors. The position of  
the encoder can be interrogated by using the command, TP. The position value can be defined by  
using the command, DE.  
NOTE: Closed loop operation with a stepper motor is not possible.  
Command Summary - Stepper Motor Operation  
Command  
Description  
DE  
DP  
IT  
Define Encoder Position (When using an encoder)  
Define Reference Position and Step Count Register  
Motion Profile Smoothing - Independent Time Constant  
Stepper Motor Smoothing  
KS  
MT  
RP  
TD  
TP  
Motor Type (2,-2,2.5 or -2.5 for stepper motors)  
Report Commanded Position  
Report number of step pulses generated by controller  
Tell Position of Encoder  
Operand Summary - Stepper Motor Operation  
Operand  
_DEa  
_DPa  
_ITa  
Description  
Contains the value of the step count register for the ‘a’ axis  
Contains the value of the main encoder for the ‘a’ axis  
Contains the value of the Independent Time constant for the 'a' axis  
Contains the value of the Stepper Motor Smoothing Constant for the 'a' axis  
Contains the motor type value for the 'a' axis  
_KSa  
_MTa  
_RPa  
Contains the commanded position generated by the profiler for the ‘a’ axis  
Contains the value of the step count register for the ‘a’ axis  
Contains the value of the main encoder for the ‘a’ axis  
_TDa  
_TPa  
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Dual Loop (Auxiliary Encoder)  
The DMC-3415 provides an interface for a second encoder except when configured for stepper motor  
operation or circular compare. Please note, the DMC-3425 has only a single encoder per axis. When  
used, the second encoder is typically mounted on the motor or the load, but may be mounted in any  
position. The most common use for the second encoder is backlash compensation, described below.  
The second encoder may be a standard quadrature type, or it may provide pulse and direction. The  
controller also offers the provision for inverting the direction of the encoder rotation. The main and  
the auxiliary encoders are configured with the CE command. The command form is CEa, where the  
parameter a equals the sum of two integers m and n. m configures the main encoder and n configures  
the auxiliary encoder.  
NOTE: This operation is not available when the DMC-3415 is configured for a stepper motor.  
Using the CE Command  
m=  
Main Encoder  
n=  
Second Encoder  
0
1
2
3
Normal quadrature  
Pulse & direction  
0
Normal quadrature  
4
Pulse & direction  
Reverse quadrature  
Reverse pulse & direction  
8
Reversed quadrature  
Reversed pulse & direction  
12  
For example, to configure the main encoder for reversed quadrature, m=2, and a second encoder of  
pulse and direction, n=4, the total is 6, and the command for the A axis is  
CE 6  
Additional Commands for the Auxiliary Encoder  
The command, DEa can be used to define the position of the auxiliary encoder. For example,  
DE 500  
sets the initial value.  
The position of the auxiliary encoder may be interrogated with the command, DE?.  
The auxiliary encoder position may be assigned to variables with the instructions  
V1= _DEA  
The command, TD a,b,c,d, returns the current position of the auxiliary encoder.  
The command, DV a,b,c,d, configures the auxiliary encoder to be used for backlash compensation.  
Backlash Compensation  
There are two methods for backlash compensation using the auxiliary encoder:  
1. Continuous dual loop  
2. Sampled dual loop  
To illustrate the problem, consider a situation in which the coupling between the motor and the load  
has a backlash. To compensate for the backlash, position encoders are mounted on both the motor and  
the load.  
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The continuous dual loop combines the two feedback signals to achieve stability. This method  
requires careful system tuning, and depends on the magnitude of the backlash. However, once  
successful, this method compensates for the backlash continuously.  
The second method, the sampled dual loop, reads the load encoder only at the end point and performs a  
correction. This method is independent of the size of the backlash. However, it is effective only in  
point-to-point motion systems that require position accuracy only at the endpoint.  
Example  
Continuous Dual Loop  
Connect the load encoder to the main encoder port and connect the motor encoder to the dual encoder  
port. The dual loop method splits the filter function between the two encoders. It applies the KP  
(proportional) and KI (integral) terms to the position error, based on the load encoder, and applies the  
KD (derivative) term to the motor encoder. This method results in a stable system.  
The dual loop method is activated with the instruction DV (Dual Velocity), where  
DV1  
activates the dual loop and  
DV0  
disables the dual loop.  
Note that the dual loop compensation depends on the backlash magnitude, and in extreme cases will  
not stabilize the loop. The proposed compensation procedure is to start with KP=0, KI=0 and to  
maximize the value of KD under the condition DV1. Once KD is found, increase KP gradually to a  
maximum value, and finally, increase KI, if necessary.  
Sampled Dual Loop  
In this example, we consider a linear slide that is run by a rotary motor via a lead screw. Since the lead  
screw has a backlash, it is necessary to use a linear encoder to monitor the position of the slide. For  
stability reasons, it is best to use a rotary encoder on the motor.  
Connect the rotary encoder to the A-axis and connect the linear encoder to the auxiliary encoder of A.  
Assume that the required motion distance is one inch, and that this corresponds to 40,000 counts of the  
rotary encoder and 10,000 counts of the linear encoder.  
The design approach is to drive the motor a distance, which corresponds to 40,000 rotary counts. Once  
the motion is complete, the controller monitors the position of the linear encoder and performs position  
corrections.  
This is done by the following program.  
Instruction  
#DUALOOP  
CE 0  
Interpretation  
Label  
Configure encoder  
Set initial value  
DE0  
PR 40000  
Main move  
BGA  
Start motion  
#CORRECT  
AMA  
Correction loop  
Wait for motion completion  
Find linear encoder error  
Compensate for motor error  
Exit if error is small  
v1=10000-_DEA  
v2=-_TEA/4+v1  
JP#END,@ABS[v2]<2  
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PR v2*4  
BGA  
Correction move  
Start correction  
Repeat  
JP#CORRECT  
#END  
EN  
Motion Smoothing  
The DMC-3425 controller allows the smoothing of the velocity profile to reduce the mechanical  
vibration of the system.  
Trapezoidal velocity profiles have acceleration rates that change abruptly from zero to maximum  
value. The discontinuous acceleration results in jerk which causes vibration. The smoothing of the  
acceleration profile leads to a continuous acceleration profile and reduces the mechanical shock and  
vibration.  
Using the IT and VT Commands:  
When operating with servo motors, motion smoothing can be accomplished with the IT and VT  
command. These commands filter the acceleration and deceleration functions to produce a smooth  
velocity profile. The resulting velocity profile has continuous acceleration and results in reduced  
mechanical vibrations.  
The smoothing function is specified by the following commands:  
IT a  
Independent time constant  
VT n  
Vector time constant  
The command, IT, is used for smoothing independent moves of the type JG, PR, PA and the command,  
VT, is used to smooth vector moves of the type VM and LM.  
The smoothing parameter a and n are numbers between 0 and 1 and determine the degree of filtering.  
The maximum value of 1 implies no filtering, resulting in trapezoidal velocity profiles. Smaller values  
of the smoothing parameters imply heavier filtering and smoother moves.  
The following example illustrates the effect of smoothing. Fig. 6.7 shows the trapezoidal velocity  
profile and the modified acceleration and velocity.  
Note that the smoothing process results in longer motion time.  
Example  
Instruction  
PR 20000  
AC 100000  
DC 100000  
SP 5000  
Interpretation  
Position  
Acceleration  
Deceleration  
Speed  
IT .5  
Filter for smoothing  
Begin  
BG A  
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ACCELERATION  
TIME  
TIME  
TIME  
TIME  
VELOCITY  
ACCELERATION WITH  
SMOOTHING  
VELOCITY WITH  
SMOOTHING  
Figure 6.7 - Trapezoidal velocity and smooth velocity profiles  
Homing  
The Find Edge (FE) and Home (HM) instructions may be used to home the motor to a mechanical  
reference. This reference is connected to the Home input line. The HM command initializes the motor  
to the encoder index pulse in addition to the Home input. The configure command (CN) is used to  
define the polarity of the home input.  
The Find Edge (FE) instruction is useful for initializing the motor to a home switch. The home switch  
is connected to the Homing Input. When the Find Edge command and Begin is used, the motor will  
accelerate up to the slew speed and slew until a transition is detected on the Homing line. The motor  
will then decelerate to a stop. A high deceleration value must be input before the find edge command  
is issued for the motor to decelerate rapidly after sensing the home switch. The velocity profile  
generated is shown in Fig. 6.7.  
The Home (HM) command can be used to position the motor on the index pulse after the home switch  
is detected. This allows for finer positioning on initialization. The command sequence HM and BG  
causes the following sequence of events to occur.  
1. Upon Begin, motor accelerates to the slew speed. The direction of its motion is  
determined by the state of the homing input. A zero (GND) will cause the motor to start  
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in the forward direction; +5V will cause it to start in the reverse direction. The CN  
command is used to define the polarity of the home input.  
2. Upon detecting the home switch changing state, the motor begins decelerating to a stop.  
3. The motor then traverses very slowly back until the home switch toggles again.  
4. The motor then traverses forward until the encoder index pulse is detected.  
5. The DMC-3425 defines the home position (0) as the position at which the index was  
detected.  
Example  
Instruction  
Interpretation  
Label  
#HOME  
AC 1000000  
DC 1000000  
SP 5000  
HM A  
Acceleration Rate  
Deceleration Rate  
Speed for Home Search  
Home A  
BG A  
Begin Motion  
After Complete  
Send Message  
End  
AM A  
MG "AT HOME"  
EN  
#EDGE  
Label  
AC 2000000  
DC 2000000  
SP 8000  
FE B  
Acceleration rate  
Deceleration rate  
Speed  
Find edge command  
Begin motion  
After complete  
Send message  
Define position as 0  
End  
BG B  
AM B  
MG "FOUND HOME"  
DP,0  
EN  
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_HMA=1  
_HMA=0  
POSITION  
HOME SWITCH  
VELOCITY  
MOTION BEGINS  
TOWARD HOME  
DIRECTION  
POSITION  
POSITION  
VELOCITY  
MOTION REVERSE  
TOWARD HOME  
DIRECTION  
VELOCITY  
MOTION TOWARD  
INDEX  
DIRECTION  
POSITION  
INDEX PULSES  
POSITION  
Figure 6.8 - Motion intervals in the Home sequence  
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Command Summary - Homing Operation  
COMMAND  
FE ABCD  
FI ABCD  
DESCRIPTION  
Find Edge Routine. This routine monitors the Home Input  
Find Index Routine - This routine monitors the Index Input  
Home Routine - This routine combines FE and FI as Described Above  
Stop Code  
HM ABCD  
SC ABCD  
TS ABCD  
Tell Status of Switches and Inputs  
Operand Summary - Homing Operation  
OPERAND  
DESCRIPTION  
_HMn  
Contains the value of the state of the Home Input  
Contains stop code  
_SCn  
_TSn  
Contains status of switches and inputs  
High Speed Position Capture (Latch)  
Often it is desirable to capture the position precisely for registration applications. The DMC-3425  
provides a position latch feature. This feature allows the position of the encoders of A or B axis to be  
captured when the latch input changes state. This function can be setup such that the position is  
captured when the latch input goes high or low. The inputs on these controllers are TTL. Latch time  
latency on a high or low going signal is less than 1μsec. Each axis has one general input associated to  
the axis for position capture:  
Input  
IN1  
Function  
A Axis Latch  
B Axis Latch  
IN2  
The DMC-3425 software commands, AL and RL, are used to arm the latch and report the latched  
position. The steps to use the latch are as follows:  
1. Give the AL AB command to arm the latch.  
2. Test to see if the latch has occurred (Input goes low) by testing the operand, _ALA or  
_ALB. Example, V1=_ALA returns the state of the A latch into V1. V1 is 1 if the latch  
has not occurred.  
3. After the latch has occurred, read the captured position with the command RL AB or RL  
AB command or monitor the value of the operands _RLA and _RLB.  
NOTE: The latch must be re-armed after each latching event.  
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Example  
Instruction  
Interpretation  
#Latch  
Latch program  
JG,5000  
BG B  
Jog B  
Begin motion on B axis  
Arm Latch for B axis  
AL B  
#Wait  
#Wait label for loop  
JP #Wait,_ALB=1  
Result=_RLB  
Result=  
EN  
Jump to #Wait label if latch has not occurred  
Set ‘Result’ equal to the reported position of B axis  
Print result  
End  
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Chapter 7 Application Programming  
Overview  
The DMC-3425 provides a powerful programming language that allows users to customize the  
controller for their particular application. Programs can be downloaded into the DMC-3425 memory  
freeing the host computer for other tasks. However, the host computer can send commands to the  
controller at any time, even while a program is being executed. Only ASCII commands can be used  
for application programming.  
In addition to standard motion commands, the DMC-3425 provides commands that allow the DMC-  
3425 to make its own decisions. These commands include conditional jumps, event triggers and  
subroutines. For example, the command JP#LOOP, n<10 causes a jump to the label #LOOP if the  
variable n is less than 10.  
For greater programming flexibility, the DMC-3425 provides user-defined variables, arrays and  
arithmetic functions. For example, with a cut-to-length operation, the length can be specified as a  
variable in a program that the operator can change as necessary.  
Global vs. Local Programming  
As mentioned previously, multiple DMC-3425 controllers can be connected through an Ethernet hub.  
The DMC-3425 controllers can be setup to operate in 2 modes; LOCAL OPERATION and  
GLOBAL OPERATION.  
In Local Operation, the host computer can download a program to any DMC-3425 and all program  
commands refer to the two axes on the controller as A and B. Each controller operates independently.  
This type of program is referred to as a LOCAL PROGRAM.  
In Global Operation, up to eight axes of DMC-3425 and DMC-3415 controllers act as a “virtual multi-  
axis controller”. One DMC-3425 is designated as the master controller and the other controllers are  
designated as slave controllers. The host computer can download a program to the master DMC-3425.  
The master controller program contains commands that address all axes in the system. This GLOBAL  
PROGAM will operate as if it was a program on a traditional multi-axis controller. In addition, each  
slave controller can also be programmed with a LOCAL PROGRAM that applies only to the 2 axes  
of the controller.  
The type of program, global program or local program, will affect the command syntax. In a global  
program, all axes have a unique axis designator (A-H). In a local program, each program addresses  
only the 2 axes of the controller. These two axes are always referred to as A and B.  
The following sections in this chapter discuss each aspect of creating an applications program. Where  
applicable, subjects are identified as applicable only to LOCAL PROGRAMS with the word LOCAL  
next to each header.  
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The program memory size for each DMC-3425 is 80 characters per line and 500 lines long.  
Entering Programs  
The DMC-3425 has an internal editor that may be used to create and edit programs in the controller's  
memory. The internal editor is a rudimentary editor and is only recommended when operating with  
Galil’s DOS utilities or through a simple RS-232 communication interface such as the Windows Utility  
Hyperterminal.  
The internal editor is opened by the command ED. Note that the command ED will not open the  
internal editor if issued from Galil's Window based software - in this case, a Windows based editor will  
be automatically opened. The Windows based editor provides much more functionality and ease-of-  
use, therefore, the internal editor is most useful when using a simple terminal with the controller and a  
Windows based editor is not available.  
Once the ED command has been given, each program line is automatically numbered sequentially  
starting with 000. If no parameter follows the ED command, the editor prompter will default to the last  
line of the last program in memory. If desired, the user can edit a specific line number or label by  
specifying a line number or label following ED.  
Instruction  
:ED  
Interpretation  
Puts Editor at end of last program  
Puts Editor at line 5  
:ED 5  
:ED #BEGIN  
Puts Editor at label #BEGIN  
Line numbers appear as 000,001,002 and so on. Program commands are entered following the line  
numbers. Multiple commands may be given on a single line as long as the total number of characters  
doesn't exceed 80 characters per line.  
While in the Edit Mode, the programmer has access to special instructions for saving, inserting and  
deleting program lines. These special instructions are listed below:  
Edit Mode Commands  
<RETURN>  
Typing the return key causes the current line of entered instructions to be saved. The editor will  
automatically advance to the next line. Thus, hitting a series of <RETURN> will cause the editor to  
advance a series of lines. Note, changes on a program line will not be saved unless a <return> is given.  
<cntrl>P  
The <cntrl>P command moves the editor to the previous line.  
<cntrl>I  
The <cntrl>I command inserts a line above the current line. For example, if the editor is at line number  
2 and <cntrl>I is applied, a new line will be inserted between lines 1 and 2. This new line will be  
labeled line 2. The old line number 2 is renumbered as line 3.  
<cntrl>D  
The <cntrl>D command deletes the line currently being edited. For example, if the editor is at line  
number 2 and <cntrl>D is applied, line 2 will be deleted. The previous line number 3 is now  
renumbered as line number 2.  
<cntrl>Q  
The <cntrl>Q quits the editor mode. In response, the DMC-3425 will return a colon.  
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After the Edit session is over, the user may list the entered program using the LS command. If no  
operand follows the LS command, the entire program will be listed. The user can start listing at a  
specific line or label using the operand n. A command and new line number or label following the start  
listing operand specifies the location at which listing is to stop.  
Example:  
Instruction  
Interpretation  
:LS  
List entire program  
:LS 5  
Begin listing at line 5  
:LS 5,9  
List lines 5 thru 9  
:LS #A,9  
:LS #A, #A +5  
List line label #A thru line 9  
List line label #A and additional 5 lines  
Program Format  
A DMC program consists of instructions combined to solve a machine control application. Action  
instructions, such as starting and stopping motion, are combined with Program Flow instructions to  
form the complete program. Program Flow instructions evaluate real-time conditions, such as elapsed  
time or motion complete, and alter program flow accordingly.  
Each DMC-3425 instruction in a program must be separated by a delimiter. Valid delimiters are the  
semicolon (;) or carriage return. The semicolon is used to separate multiple instructions on a single  
program line where the maximum number of instructions on a line is limited by 80 characters. A  
carriage return enters the final command on a program line.  
Using Labels in Programs  
All DMC-3425 programs must begin with a label and end with an End (EN) statement. Labels start  
with the pound (#) sign followed by a maximum of seven characters. The first character must be a  
letter; after that, numbers are permitted. Spaces are not permitted.  
The maximum number of labels that may be defined is 254.  
Valid labels  
#BEGIN  
#SQUARE  
#X1  
#BEGIN1  
Invalid labels  
#1Square  
#123  
Example  
Instruction  
Interpretation  
#START  
Beginning of the Program  
Specify relative distances on A and B axes  
Begin Motion  
PR 10000,20000  
BG AB  
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AM  
Wait for motion complete  
Wait 2 sec  
WT 2000  
JP #START  
EN  
Jump to label START  
End of Program  
The above program moves A and B 10000 and 20000 units. After the motion is complete, the motors  
rest for 2 seconds. The cycle repeats indefinitely until the stop command is issued.  
Special Labels  
The DMC-3425 has some special labels, which are used to define input interrupt subroutines, limit  
switch subroutines, error handling subroutines, command error subroutines and auto start and recovery  
routines.  
#AUTO  
Label for automatic execution of program upon power up. This program  
must be saved in the non-volatile memory with the BP command.  
#AUTOERR  
Label for detecting errors in the #AUTO routine. If a Checksum error  
were to occur, the #AUTO would fail to start at power up. This  
#AUTOERR routine would be called instead.  
#ININT  
Label for Input Interrupt subroutine  
#LIMSWI  
#POSERR  
#MCTIME  
#CMDERR  
#COMINT  
#TCPERR  
Label for Limit Switch subroutine  
Label for excess Position Error subroutine  
Label for timeout on Motion Complete trip point  
Label for incorrect command subroutine  
Label for communication interrupt on the aux. serial port  
Ethernet communication error  
Commenting Programs  
There are two methods for commenting programs. The first method uses the NO command and allows  
for comments to be embedded into Galil programs. The second method used the REM statement and  
requires the use of Galil software.  
NO Command and the Apostrophe (‘)  
Programs on the DMC-3425 can be commented using the command, NO, or the apostrophe. These  
commands allow the user to include up to 78 characters on a single line. This can be used to include  
comments from the programmer as in the following example:  
Instruction  
Interpretation  
#PATH  
Label  
NO 2-D CIRCULAR PATH  
VMAB  
Comment - No Operation  
Vector Mode  
NO VECTOR MOTION ON A AND B  
VS 10000  
Comment - No Operation  
Vector Speed  
NO VECTOR SPEED IS 10000  
VP -4000,0  
Comment - No Operation  
Vector Position  
NO BOTTOM LINE  
CR 1500,270,-180  
NO HALF CIRCLE MOTION  
Comment - No Operation  
Circle Motion  
Comment - No Operation  
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VP 0,3000  
Vector Position  
‘ TOP LINE  
Comment - No Operation  
Circle  
CR 1500,90,-180  
‘ HALF CIRCLE MOTION  
Comment - No Operation  
Vector End  
VE  
‘ END VECTOR SEQUENCE  
Comment - No Operation  
Begin Sequence  
BGS  
‘ BEGIN SEQUENCE MOTION  
EN  
Comment - No Operation  
End of Program  
‘ END OF PROGRAM  
Comment - No Operation  
NOTE: NO and the apostrophe are controller commands. Therefore, inclusion of these commands  
will require a small process time by the controller.  
REM Command  
If you are using Galil software to communicate with the DMC-3425 controller, you may also include  
REM statements. ‘REM’ statements begin with the word ‘REM’ and may be followed by any  
comments that are on the same line. The Galil terminal software will remove these statements when  
the program is downloaded to the controller. For example:  
#PATH  
REM 2-D CIRCULAR PATH  
VMAB  
REM VECTOR MOTION ON A AND B  
VS 10000  
REM VECTOR SPEED IS 10000  
VP -4000,0  
REM BOTTOM LINE  
CR 1500,270,-180  
REM HALF CIRCLE MOTION  
VP 0,3000  
REM TOP LINE  
CR 1500,90,-180  
REM HALF CIRCLE MOTION  
VE  
REM END VECTOR SEQUENCE  
BGS  
REM BEGIN SEQUENCE MOTION  
EN  
REM END OF PROGRAM  
These REM statements will be removed when this program is downloaded to the controller.  
Executing Programs - Multitasking  
The DMC-3425 can run 2 independent programs simultaneously. These programs are called threads  
and are numbered 0 and 1, where 0 is the main thread. Multitasking is useful for executing independent  
operations such as PLC functions that occur independently of motion.  
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The main thread differs from the others in the following ways:  
1. Only the main thread, thread 0, may use the input command, IN.  
2. When automatic subroutines are implemented for limit switches, position errors or command errors,  
they are executed in thread 0.  
To begin execution of the various programs, use the following instruction:  
XQ #A, n  
Where n indicates the thread number. To halt the execution of any thread, use the instruction  
HX n  
where n is the thread number.  
Note that both the XQ and HX commands can be performed by an executing program.  
The example below produces a waveform on Output 1 independent of a move.  
Instruction  
#TASK1  
AT0  
Interpretation  
Task1 label  
Initialize reference time  
Clear Output 1  
CB1  
#LOOP1  
AT 10  
Loop1 label  
Wait 10 msec from reference time  
Set Output 1  
SB1  
AT –40  
CB1  
Wait 40 msec from reference, then initialize reference  
Clear Output 1  
JP #LOOP1  
#TASK0  
XQ #TASK1,1  
#LOOP2  
PR 1000  
BGA  
Repeat Loop1  
Task2 label  
Execute Task1  
Loop2 label  
Define relative distance  
Begin motion  
AMA  
After motion done  
Wait 10 msec  
WT 10  
JP #LOOP2,@IN[2]=1  
HX  
Repeat motion unless Input 2 is low  
Halt all tasks  
EN  
End of Program  
The program above is executed with the instruction XQ #TASK0,0 which designates TASK0 as the  
main thread (i.e. Thread 0). #TASK1 is executed within TASK0.  
Debugging Programs  
The DMC-3425 provides commands and operands that are useful in debugging application programs.  
These commands include interrogation commands to monitor program execution, determine the state  
of the controller and the contents of the controllers program, array, and variable space. Operands also  
contain important status information that can help to debug a program. Breakpoint and single stepping  
commands are available to actively debug a program while in operation.  
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Trace Command  
The trace command causes the controller to send each line in a program to the host computer  
immediately prior to execution. Tracing is enabled with the command, TR1. TR0 turns the trace  
function off.  
NOTE: When the trace function is enabled, the line numbers as well as the command line will be  
displayed as each command line is executed.  
Error Code Command  
When there is a program error, the DMC-3425 halts the program execution at the point where the error  
occurs. To display the last line number of program execution, issue the command, MG _ED.  
The user can obtain information about the type of error condition that occurred by using the command,  
TC1. This command reports back a number and a text message that describes the error condition. The  
command, TC0 or TC, will return the error code without the text message. For more information about  
the command, TC, see the Command Reference.  
Example  
The following program has an error. It attempts to specify a relative movement while the A-axis is  
already in motion. When the program is executed, the controller stops at line 003. The user can then  
query the controller using the command, TC1. The controller responds with the corresponding  
explanation:  
Instruction  
Interpretation  
Edit Mode  
:ED  
000 #A  
Program Label  
Position Relative 1000  
Begin  
001 PR1000  
002 BGA  
003 PR5000  
Position Relative 5000  
End  
004 EN  
<cntrl> Q  
Quit Edit Mode  
Execute #A  
:XQ #A  
?003 PR5000  
Error on Line 3  
Tell Error Code  
Command not valid while running  
Edit Line 3  
:TC1  
?7 Command not valid while running.  
:ED 3  
003 AMA;PR5000;BGA  
<cntrl> Q  
Add After Motion Done  
Quit Edit Mode  
Execute #A  
:XQ #A  
Stop Code Command  
The status of motion for each axis can be determined by using the stop code command, SC. This can  
be useful when motion on an axis has stopped unexpectedly. The command SC will return a number  
representing the motion status. See the command reference for further information.  
RAM Memory Interrogation Commands  
For debugging the status of the program memory, array memory, or variable memory, the DMC-3425  
has several useful commands. The command, DM ?, will return the number of array elements  
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currently available. The command, DA?, will return the number of arrays which can be currently  
defined. The DMC-3425 will have a maximum of 2000 array elements in up to 14 arrays. If an array  
of 100 elements is defined, the command DM? will return the value 1900 and the command DA? will  
return 13.  
To list the contents of the variable space, use the interrogation command LV (List Variables). To list  
the contents of array space, use the interrogation command, LA (List Arrays). To list the contents of  
the Program space, use the interrogation command, LS (List). To list the application program labels  
only, use the interrogation command, LL (List Labels).  
Operands  
An operand is a value in the controller. Below is a list of specific operands that are particularly  
valuable for program debugging. To display an operand, the message command may be used. For  
example, since the operand, _ED contains the last line of program execution, the command MG _ED  
will display this line number.  
_ED contains the last line of program execution. Useful to determine where program stopped.  
_DL contains the number of available labels.  
_UL contains the number of available variables.  
_DA contains the number of available arrays.  
_DM contains the number of available array elements.  
_AB contains the state of the Abort Input  
_LFx contains the state of the forward limit switch for the 'x' axis  
_LRx contains the state of the reverse limit switch for the 'x' axis  
Breakpoints and single stepping  
The DMC-3425 has commands which allow active debugging of programs. The BK command is a  
breakpoint which may be set to trigger upon execution of a specified line and thread. Upon the  
program executing the specified line, the program or thread will pause at that line. The SL command  
may then be used to single step through the program from that breakpoint. See the command reference  
for more information on the BK and SL command.  
EEPROM Memory Interrogation Operands  
When the DMC-3425 powers up, any data stored in the EEPROM memory is automatically loaded for  
use. This data includes the user program, variables and arrays, and controller parameters. If the  
EEPROM has been corrupted, the corresponding memory sector is flagged as in error. The operand  
_RS contains the state of the EEPROM as follows:  
Bit  
Error Condition  
Bit 3  
Bit 2  
Bit 1  
Bit 0  
Master reset error  
Program checksum error  
Parameter checksum error  
Variable checksum error  
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Program Flow Commands  
The DMC-3425 provides instructions to control program flow. The DMC-3425 program sequencer  
normally executes program instructions sequentially. The program flow can be altered with the use of  
event triggers, trippoints, and conditional jump statements.  
Event Triggers & Trippoints  
To function independently from the host computer, the DMC-3425 can be programmed to make  
decisions based on the occurrence of an event. Such events include waiting for motion to be complete,  
waiting for a specified amount of time to elapse, or waiting for an input to change logic levels.  
The DMC-3425 provides several event triggers that cause the program sequencer to halt until the  
specified event occurs. Normally, a program is automatically executed sequentially one line at a time.  
When an event trigger instruction is decoded, however, the actual program sequence is halted. The  
program sequence does not continue until the event trigger is "tripped". For example, the motion  
complete trigger can be used to separate two move sequences in a program. The commands for the  
second move sequence will not be executed until the motion is complete on the first motion sequence.  
In this way, the DMC-3425 can make decisions based on its own status or external events without  
intervention from a host computer.  
NOTE: Event triggers should only be used within a program and not sent to the controller as a direct  
command.  
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DMC-3425 Event Triggers  
Command  
Function  
AM A B C D E F G H or S  
Halts program execution until motion is complete on  
the specified axes or motion sequence(s). AM with no  
parameter tests for motion complete on all axes. This  
command is useful for separating motion sequences in  
a program.  
AD A or B or C or D or E or F or G or H  
AR A or B or C or D or E or F or G or H  
Halts program execution until position command has  
reached the specified relative distance from the start of  
the move. Only one axis may be specified at a time.  
Halts program execution until after specified distance  
from the last AR or AD command has elapsed. Only  
one axis may be specified at a time.  
AP A or B or C or D or E or F or G or H  
MF A or B or C or D or E or F or G or H  
Halts program execution until after absolute position  
occurs. Only one axis may be specified at a time.  
Halt program execution until after forward motion  
reached absolute position. Only one axis may be  
specified. If position is already past the point, then  
MF will trip immediately. Will function on geared  
axis or aux. inputs.  
MR A or B or C or D or E or F or G or H  
MC A or B or C or D or E or F or G or H  
Halt program execution until after reverse motion  
reached absolute position. Only one axis may be  
specified. If position is already past the point, then  
MR will trip immediately. Will function on geared  
axis or aux. inputs.  
Halt program execution until after the motion profile  
has been completed and the encoder has entered or  
passed the specified position. TW a,b,c,d sets timeout  
to declare an error if not in position. If timeout  
occurs, then the trippoint will clear and the stopcode  
will be set to 99. An application program will jump to  
label #MCTIME.  
AI +/- n  
Halts program execution until after specified input is  
at specified logic level. n specifies input line.  
Positive is high logic level; negative is low level.  
AS A B C D E F G H  
AT +/-n  
Halts program execution until specified axis has  
reached its slew speed.  
Halts program execution until n msec from reference  
time. AT 0 sets reference. AT n waits n msec from  
reference. AT -n waits n msec from reference and sets  
new reference after elapsed time.  
AV n  
WT n  
Halts program execution until specified distance along  
a coordinated path has occurred.  
Halts program execution until specified time in msec  
has elapsed.  
Example- Multiple Move Sequence  
The AM trippoint is used to separate the two PR moves. If AM is not used, the controller returns a ?  
for the second PR command because a new PR cannot be given until motion is complete.  
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Instruction  
#TWOMOVE  
PR 2000  
BGA  
Interpretation  
Label  
Position Command  
Begin Motion  
AMA  
Wait for Motion Complete  
Next Position Move  
Begin 2nd move  
End program  
PR 4000  
BGA  
EN  
Example- Set Output after Distance  
Set output bit 1 after a distance of 1000 counts from the start of the move. The accuracy of the  
trippoint is the speed multiplied by the sample period.  
Instruction  
#SETBIT  
SP 10000  
PA 20000  
BGA  
Interpretation  
Label  
Speed is 10000  
Specify Absolute position  
Begin motion  
AD 1000  
SB1  
Wait until 1000 counts  
Set output bit 1  
End program  
EN  
Example- Repetitive Position Trigger  
To set the output bit every 10000 counts during a move, the AR trippoint is used as shown in the next  
example.  
Instruction  
#TRIP  
Interpretation  
Label  
JG 50000  
BGA;n=0  
#REPEAT  
AR 10000  
TPA  
Specify Jog Speed  
Begin Motion  
# Repeat Loop  
Wait 10000 counts  
Tell Position  
Set output 1  
Wait 50 msec  
Clear output 1  
Increment counter  
Repeat 5 times  
Stop  
SB1  
WT50  
CB1  
n=n+1  
JP #REPEAT,n<5  
STA  
EN  
End  
Example - Start Motion on Input  
This example waits for input 1 to go low and then starts motion.  
NOTE: The AI command actually halts execution of the program until the input occurs. If you do not  
want to halt the program sequences, you can use the Input Interrupt function (II) or use a conditional  
jump on an input, such as JP #GO,@IN[1] = 1.  
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Instruction  
#INPUT  
AI-1  
Interpretation  
Program Label  
Wait for input 1 low  
Position command  
Begin motion  
PR 10000  
BGA  
EN  
End program  
Example - Set Output when At Speed  
Instruction  
#ATSPEED  
JG 50000  
AC 10000  
BGA  
Interpretation  
Program Label  
Specify jog speed  
Acceleration rate  
Begin motion  
ASA  
Wait for at slew speed 50000  
Set output 1  
SB1  
EN  
End program  
Example - Change Speed along Vector Path  
The following program changes the feedrate or vector speed at the specified distance along the vector.  
The vector distance is measured from the start of the move or from the last AV command.  
Instruction  
#VECTOR  
VMAB;VS 5000  
VP 10000,20000  
VP 20000,30000  
VE  
Interpretation  
Label  
Coordinated path  
Vector position  
Vector position  
End vector  
BGS  
Begin sequence  
After vector distance  
Reduce speed  
End  
AV 5000  
VS 1000  
EN  
Example - Multiple Move with Wait  
This example makes multiple relative distance moves by waiting for each to be complete before  
executing new moves.  
Instruction  
#MOVES  
PR 12000  
SP 20000  
AC 100000  
BGA  
Interpretation  
Label  
Distance  
Speed  
Acceleration  
Start Motion  
AD 10000  
SP 5000  
Wait a distance of 10,000 counts  
New Speed  
AMA  
Wait until motion is completed  
Wait 200 ms  
WT 200  
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PR -10000  
SP 30000  
AC 150000  
BGA  
New Position  
New Speed  
New Acceleration  
Start Motion  
End  
EN  
Example- Define Output Waveform Using AT  
The following program causes Output 1 to be high for 10 msec and low for 40 msec. The cycle repeats  
every 50 msec.  
Instruction  
#OUTPUT  
AT0  
Interpretation  
Program label  
Initialize time reference  
SB1  
Set Output 1  
#LOOP  
AT 10  
CB1  
Loop  
After 10 msec from reference,  
Clear Output 1  
AT -40  
SB1  
Wait 40 msec from reference and reset reference  
Set Output 1  
Loop  
JP #LOOP  
EN  
Conditional Jumps  
The DMC-3425 provides Conditional Jump (JP) and Conditional Jump to Subroutine (JS) instructions  
for branching to a new program location based on a specified condition. The conditional jump  
determines if a condition is satisfied and then branches to a new location or subroutine. Unlike event  
triggers, the conditional jump instruction does not halt the program sequence. Conditional jumps are  
useful for testing events in real-time. They allow the DMC-3425 to make decisions without a host  
computer. For example, the DMC-3425 can decide between two motion profiles based on the state of  
an input line.  
Command Format - JP and JS  
Format:  
Description  
JS destination, logical condition  
JP destination, logical condition  
Jump to subroutine if logical condition is satisfied  
Jump to location if logical condition is satisfied  
The destination is a program line number or label where the program sequencer will jump if the  
specified condition is satisfied. Note that the line number of the first line of program memory is 0.  
The comma designates "IF". The logical condition tests two operands with logical operators.  
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Logical operators:  
OPERATOR  
DESCRIPTION  
less than  
<
>
greater than  
=
equal to  
<=  
>=  
<>  
less than or equal to  
greater than or equal to  
not equal  
Conditional Statements  
The conditional statement is satisfied if it evaluates to any value other than zero. The conditional  
statement can be any valid DMC-3425 numeric operand, including variables, array elements, numeric  
values, functions, keywords, and arithmetic expressions. If no conditional statement is given, the jump  
will always occur.  
Number  
V1=6  
Numeric Expression  
V1=V7*6  
@ABS[V1]>10  
V1<Count[2]  
V1<V2  
Array Element  
Variable  
Internal Variable  
_TPA=0  
_TVA>500  
V1>@AN[2]  
@IN[1]=0  
I/O  
Multiple Conditional Statements  
The DMC-3425 will accept multiple conditions in a single jump statement. The conditional statements  
are combined in pairs using the operands “&” and “|”. The “&” operand between any two conditions,  
requires that both statements must be true for the combined statement to be true. The “|” operand  
between any two conditions, requires that only one statement be true for the combined statement to be  
true.  
NOTE: Each condition must be placed in parentheses for proper evaluation by the controller. In  
addition, the DMC-3425 executes operations from left to right. For further information on  
Mathematical Expressions and the bit-wise operators ‘&’ and ‘|’, see pg. 127.  
Example using variables named V1, V2, V3 and V4:  
JP #TEST, (V1<V2) & (V3<V4)  
In this example, this statement will cause the program to jump to the label #TEST if V1 is less than V2  
and V3 is less than V4. To illustrate this further, consider this same example with an additional  
condition:  
JP #TEST, ((V1<V2) & (V3<V4)) | (V5<V6)  
This statement will cause the program to jump to the label #TEST under two conditions; 1. If V1 is  
less than V2 and V3 is less than V4. OR 2. If V5 is less than V6.  
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Examples  
If the condition for the JP command is satisfied, the controller branches to the specified label or line  
number and continues executing commands from this point. If the condition is not satisfied, the  
controller continues to execute the next commands in sequence.  
Instruction  
Interpretation  
JP #Loop, COUNT<10  
JS #MOVE2,@IN[1]=1  
Jump to #Loop if the variable, COUNT, is less than 10  
Jump to subroutine #MOVE2 if input 1 is logic level high. After  
the subroutine MOVE2 is executed, the program sequencer  
returns to the main program location where the subroutine was  
called.  
JP #BLUE,@ABS[V2]>2  
JP #C,V1*V7<=V8*V2  
JP#A  
Jump to #BLUE if the absolute value of variable, V2, is greater  
than 2  
Jump to #C if the value of V1 times V7 is less than or equal to the  
value of V8*V2  
Jump to #A  
Move the A motor to absolute position 1000 counts and back to zero ten times. Wait 100 msec  
between moves.  
Instruction  
#BEGIN  
COUNT=10  
#LOOP  
Interpretation  
Begin Program  
Initialize loop counter  
Begin loop  
PA 1000  
BGA  
Position absolute 1000  
Begin move  
AMA  
Wait for motion complete  
Wait 100 msec  
WT 100  
PA 0  
Position absolute 0  
Begin move  
BGA  
AMA  
Wait for motion complete  
Wait 100 msec  
WT 100  
COUNT=COUNT-1  
JP #LOOP,COUNT>0  
EN  
Decrement loop counter  
Test for 10 times thru loop  
End Program  
If, Else, and Endif  
The DMC-3425 provides a structured approach to conditional statements using IF, ELSE and ENDIF  
commands.  
Using the IF and ENDIF Commands  
An IF conditional statement is formed by the combination of an IF and ENDIF command. The IF  
command has as its arguments one or more conditional statements. If the conditional statement(s)  
evaluates true, the command interpreter will continue executing commands which follow the IF  
command. If the conditional statement evaluates false, the controller will ignore commands until the  
associated ENDIF command is executed OR an ELSE command occurs in the program (see discussion  
of ELSE command below).  
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NOTE: An ENDIF command must always be executed for every IF command that has been executed.  
It is recommended that the user not include jump commands inside IF conditional statements since this  
causes re-direction of command execution. In this case, the command interpreter may not execute an  
ENDIF command.  
Using the ELSE Command  
The ELSE command is an optional part of an IF conditional statement and allows for the execution of  
command only when the argument of the IF command evaluates False. The ELSE command must  
occur after an IF command and has no arguments. If the argument of the IF command evaluates false,  
the controller will skip commands until the ELSE command. If the argument for the IF command  
evaluates true, the controller will execute the commands between the IF and ELSE command.  
Nesting IF Conditional Statements  
The DMC-3425 allows for IF conditional statements to be included within other IF conditional  
statements. This technique is known as 'nesting' and the DMC-3425 allows up to 255 IF conditional  
statements to be nested. This is a very powerful technique allowing the user to specify a variety of  
different cases for branching.  
Command Format - IF, ELSE and ENDIF  
Format:  
Description  
IF <condition>  
Execute commands proceeding IF command (up to ELSE command) if  
conditional statement(s) is true, otherwise continue executing at ENDIF command  
or optional ELSE command.  
ELSE  
Optional command. Allows for commands to be executed when argument of IF  
command evaluates not true. Can only be used with IF command.  
ENDIF  
Command to end IF conditional statement. Program must have an ENDIF  
command for every IF command.  
Instruction  
#TEST  
Interpretation  
Begin Main Program "TEST"  
Enable interrupts on input 1 and input 2  
II,,3  
MG "WAITING FOR INPUT 1, INPUT 2"  
Output message  
#LOOP  
Label to be used for endless loop  
Endless loop  
JP #LOOP  
EN  
End of main program  
#ININT  
Input Interrupt Subroutine  
IF (@IN[1]=0)  
IF conditional statement based on input 1  
2nd IF executed if 1st IF conditional true  
Message executed if 2nd IF is true  
ELSE command for 2nd IF statement  
Message executed if 2nd IF is false  
End of 2nd conditional statement  
ELSE command for 1st IF statement  
Message executed if 1st IF statement  
End of 1st conditional statement  
Label to be used for a loop  
IF (@IN[2]=0)  
MG "INPUT 1 AND INPUT 2 ARE ACTIVE"  
ELSE  
MG "ONLY INPUT 1 IS ACTIVE  
ENDIF  
ELSE  
MG"ONLY INPUT 2 IS ACTIVE"  
ENDIF  
#WAIT  
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JP#WAIT,(@IN[1]=0) | (@IN[2]=0)  
RI0  
Loop until Input 1& 2 are not active  
End Input Interrupt Routine without restoring  
trippoints  
Subroutines  
A subroutine is a group of instructions beginning with a label and ending with an end command (EN).  
Subroutines are called from the main program with the jump subroutine instruction JS, followed by a  
label or line number, and conditional statement. Up to 8 subroutines can be nested. After the  
subroutine is executed, the program sequencer returns to the program location where the subroutine  
was called unless the subroutine stack is manipulated as described in the following section.  
An example of a subroutine to draw a square 500 counts per side is given below. The square is drawn  
at vector position 1000,1000.  
Instruction  
Interpretation  
#M  
Begin Main Program  
Clear Output Bit 1 (pick up pen)  
Define vector position; move pen  
Wait for after motion trippoint  
Set Output Bit 1 (put down pen)  
Jump to square subroutine  
End Main Program  
CB1  
VP 1000,1000;LE;BGS  
AMS  
SB1  
JS #Square;CB1  
EN  
#Square  
Square subroutine  
V1=500;JS #L  
V1=-V1;JS #L  
EN  
Define length of side  
Switch direction  
End subroutine  
#L;PR V1,V1;BGA  
AMA;BGB;AMA  
EN  
Define A,B; Begin A  
After motion on A, Begin B  
End subroutine  
Stack Manipulation  
It is possible to manipulate the subroutine stack by using the ZS command. Every time a JS  
instruction, interrupt or automatic routine (such as #POSERR or #LIMSWI) is executed, the subroutine  
stack is incremented by 1. Normally the stack is restored with an EN instruction. Occasionally it is  
desirable not to return back to the program line where the subroutine or interrupt was called. The ZS1  
command clears 1 level of the stack. This allows the program sequencer to continue to the next line.  
The ZS0 command resets the stack to its initial value.  
Auto-Start and Auto Error Routine  
The DMC-3425 has two special labels for automatic program execution. A program which has been  
saved into the controllers non-volatile memory can be automatically executed upon power up or reset  
by beginning the program with the label #AUTO. The program must be saved into non-volatile  
memory using the command, BP.  
If the program loaded onto the EEPROM has a checksum error at power-up, the routine #AUTOERR  
will run instead, allowing the user to determine the nature of the checksum error. The _RS operand  
may be used to determine what sector of the EEPROM has been corrupted.  
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Automatic Subroutines for Monitoring Conditions  
Often it is desirable to monitor certain conditions continuously without tying up the host or DMC-3425  
program sequences. The DMC-3425 can monitor several important conditions in the background.  
These conditions include checking for the occurrence of a limit switch, a defined input, position error,  
or a command error. Automatic monitoring is enabled by inserting a special, predefined label in the  
applications program, and having an application program actively executing on the controller. The  
pre-defined labels are:  
SUBROUTINE  
#LIMSWI  
DESCRIPTION  
Limit switch on any axis goes low  
Input specified by II goes low  
#ININT  
#POSERR  
#MCTIME  
#CMDERR  
#TCPERR  
Position error exceeds limit specified by ER  
Motion Complete timeout occurred. Timeout period set by TW command  
Bad command given  
Ethernet Communication Error  
The following examples illustrate the use of the automatic subroutines:  
Example - Limit Switch:  
This simple program prints a message upon the occurrence of a limit switch. For the #LIMSWI sub-  
routine to execute, the DMC-3425 must be executing an applications program from memory and the  
controller must be commanding the motor to move. The RE command is used to return from the  
#LIMSWI subroutine. The #LIMSWI subroutine will be re-executed if the limit switch remains active.  
Instruction  
#LOOP  
Interpretation  
Dummy Program  
Jump to Loop  
JP #LOOP;EN  
#LIMSWI  
Limit Switch Label  
Print Message  
MG "LIMIT OCCURRED"  
RE  
Return to main program  
Example - Position Error  
Instruction  
:ED  
Interpretation  
Edit Mode  
000 #LOOP  
001 JP #LOOP;EN  
002 #POSERR  
003 V1=_TEA  
Dummy Program  
Loop  
Position Error Routine  
Read Position Error  
Print Message  
004 MG "EXCESS POSITION ERROR"  
005 MG "ERROR=",V1=  
006 RE  
Print Error  
Return from Error  
Quit Edit Mode  
Execute Dummy Program  
Jog at High Speed  
Begin Motion  
<control> Q  
:XQ #LOOP  
:JG 100000  
:BGA  
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Example - Input Interrupt  
This simple program jogs the A and C motors (C motor is the first motor of the first slave controller of  
a distributed control system). When the first input of the master (input 1), goes low, the controller will  
stop motion on both axes. When the input returns high, the motors will resume jogging.  
Instruction  
Interpretation  
Label  
#A  
II1  
Input Interrupt on 1  
Jog  
JG 30000,,60000  
BGAD  
Begin Motion  
Loop  
#LOOP;JP#LOOP;EN  
#ININT  
Input Interrupt  
Stop Motion  
Test for Input 1 still low  
Restore Velocities  
Begin motion  
STAD;AMAD  
#TEST;JP #TEST, @IN[1]=0  
JG 30000,,,6000  
BGAD  
RI0  
Return from interrupt routine to Main Program and do not  
re-enable trippoints  
Example - Motion Complete Timeout  
This simple program will issue the message “A fell short” if the A axis does not reach the commanded  
position within 1 second of the end of the profiled move.  
Instruction  
#BEGIN  
TW 1000  
PA 10000  
BGA  
Interpretation  
Begin main program  
Set the time out to 1000 ms  
Position Absolute command  
Begin motion  
MCA  
Motion Complete trip point  
End main program  
EN  
#MCTIME  
MG “A fell short”  
EN  
Motion Complete Subroutine  
Send out a message  
End subroutine  
Example - Command Error  
The above program prompts the operator to enter a jog speed. If the operator enters a number out of  
range (greater than 8 million), the #CMDERR routine will be executed prompting the operator to enter  
a new number.  
In multitasking applications, there is an alternate method for handling command errors from different  
threads. Using the XQ command along with the special operands described below allows the  
controller to either skip or retry invalid commands.  
Instruction  
Interpretation  
Begin main program  
Prompt for speed  
Begin motion  
#BEGIN  
IN "ENTER SPEED", SPEED  
JG SPEED;BGA;  
JP #BEGIN  
Repeat  
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EN  
End main program  
Command error utility  
Check if error on line 2  
Check if out of range  
Send message  
#CMDERR  
JP#DONE,_ED<>2  
JP#DONE,_TC<>6  
MG "SPEED TOO HIGH"  
MG "TRY AGAIN"  
ZS1  
Send message  
Adjust stack  
JP #BEGIN  
#DONE  
Return to main program  
End program if other error  
Zero stack  
ZS0  
EN  
End program  
OPERAND  
_ED1  
FUNCTION  
Returns the number of the thread that generated an error  
_ED2  
Retry failed command (operand contains the location of the failed command)  
_ED3  
Skip failed command (operand contains the location of the command after the  
failed command)  
The operands are used with the XQ command in the following format:  
XQ _ED2 (or _ED3),_ED1,1  
Where the “,1” at the end of the command line indicates a restart; therefore, the existing program stack  
will not e removed when the above format executes.  
The following example shows an error correction routine that uses the operands.  
Example - Command Error w/Multitasking  
The following program illustrates a common program problem. In this case, a variable is used as a  
command argument and the variable is inadvertently set to an illegal value. This simple command  
error subroutine recognizes the type of error, modifies the variable and continues the program at the  
point of the error. If the program has an invalid command error, skip the command and continue to  
execute the program. To demonstrate the program, while the simple loop #A is executing on thread 0  
(XQ#A,0), begin execution of the second task, XQ#B,1  
Instruction  
#A  
Interpretation  
Begin thread 0 (continuous loop)  
JP#A  
EN  
End of thread 0  
#B  
Begin thread 1  
KP -1  
Set KP to value of N, an invalid value  
Issue invalid command  
End of thread 1  
TY  
EN  
#CMDERR  
IF(_TC=6)  
N=1  
Begin command error subroutine  
If error is “Number Out of Range” (-1).  
Set N to a valid number  
Retry KP N command  
XQ _ED2,_ED1,1  
ENDIF  
IF( _TC=1)  
If error is “Invalid Command” (TY)  
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XQ _ED3,_ED1,1  
Skip invalid command  
ENDIF  
EN  
End of command error routine  
Example – Ethernet Communication Error  
This simple program executes in the DMC-3425 and indicates (via the serial port) when a  
communication handle fails. By monitoring the serial port, the user can re-establish communication if  
needed.  
Instruction  
#LOOP  
Interpretation  
Simple program loop  
JP#LOOP  
EN  
#TCPERR  
MG {P1}_IA4  
Ethernet communication error auto routine  
Send message to serial port indicating which handle  
did not receive proper acknowledgment  
RE  
Mathematical and Functional Expressions  
Mathematical Operators  
For manipulation of data, the DMC-3425 provides the use of the following mathematical operators:  
Operator  
Function  
+
-
Addition  
Subtraction  
*
/
Multiplication  
Division  
&
|
Logical And (Bit-wise)  
Logical Or (On some computers, a solid vertical line  
appears as a broken line)  
()  
Parenthesis  
The numeric range for addition, subtraction and multiplication operations is +/-2,147,483,647.9999.  
The precision for division is 1/65,000.  
Mathematical operations are executed from left to right. Calculations within parentheses have  
precedence.  
SPEED=7.5*V1/2  
The variable, SPEED, is equal to 7.5 multiplied by V1 and  
divided by 2  
COUNT=COUNT+2  
The variable, COUNT, is equal to the current value plus 2.  
RESULT=_TPA-(@COS[45]*40)  
Puts the position of A - 28.28 in RESULT. 40 * cosine of  
45° is 28.28  
TEMP=@IN[1]&@IN[2]  
TEMP is equal to 1 only if Input 1 and Input 2 are high  
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Bit-Wise Operators  
The mathematical operators & and | are bit-wise operators. The operator, &, is a Logical And. The  
operator, |, is a Logical Or. These operators allow for bit-wise operations on any valid DMC-3425  
numeric operand, including variables, array elements, numeric values, functions, keywords, and  
arithmetic expressions. The bit-wise operators may also be used with strings. This is useful for  
separating characters from an input string. When using the input command for string input, the input  
variable will hold up to 6 characters. These characters are combined into a single value that is  
represented as 32 bits of integer and 16 bits of fraction. Each ASCII character is represented as one  
byte (8 bits), therefore the input variable can hold up to six characters. The first character of the string  
will be placed in the top byte of the variable and the last character will be placed in the lowest  
significant byte of the fraction. The characters can be individually separated by using bit-wise  
operations as illustrated in the following example:  
Instruction  
Interpretation  
#TEST  
Begin main program  
IN "ENTER",LEN{S6}  
Input character string of up to 6 characters into  
variable ‘LEN’  
FLEN=@FRAC[LEN]  
FLEN=$10000*FLEN  
LEN1=(FLEN&$00FF)  
Define variable ‘FLEN’ as fractional part of  
variable ‘LEN’  
Shift FLEN by 32 bits (IE - convert fraction,  
FLEN, to integer)  
Mask top byte of FLEN and set this value to  
variable ‘LEN1’  
LEN2=(FLEN&$FF00)/$100  
LEN3=LEN&$000000FF  
LEN4=(LEN&$0000FF00)/$100  
LEN5=(LEN&$00FF0000)/$10000  
LEN6=(LEN&$FF000000)/$1000000  
MG LEN6 {S4}  
Let variable, ‘LEN2’ = top byte of FLEN  
Let variable, ‘LEN3’ = bottom byte of LEN  
Let variable, ‘LEN4’ = second byte of LEN  
Let variable, ‘LEN5’ = third byte of LEN  
Let variable, ‘LEN6’ = fourth byte of LEN  
Display ‘LEN6’ as string message of up to 4 chars  
Display ‘LEN5’ as string message of up to 4 chars  
Display ‘LEN4’ as string message of up to 4 chars  
Display ‘LEN3’ as string message of up to 4 chars  
Display ‘LEN2’ as string message of up to 4 chars  
Display ‘LEN1’ as string message of up to 4 chars  
MG LEN5 {S4}  
MG LEN4 {S4}  
MG LEN3 {S4}  
MG LEN2 {S4}  
MG LEN1 {S4}  
EN  
This program will accept a string input of up to 6 characters, parse each character, and then display  
each character. Notice also that the values used for masking are represented in hexadecimal (as  
denoted by the preceding ‘$’). For more information, see section Sending Messages.  
To illustrate further, if the user types in the string “TESTME” at the input prompt, the controller will  
respond with the following:  
T
E
S
Response from command MG LEN6 {S4}  
Response from command MG LEN5 {S4}  
Response from command MG LEN4 {S4}  
Response from command MG LEN3 {S4}  
Response from command MG LEN2 {S4}  
Response from command MG LEN1 {S4}  
T
M
E
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Functions  
FUNCTION DESCRIPTION  
@SIN[n]  
Sine of n (n in degrees, with range of -32768 to 32767 and 16-bit fractional resolution)  
@COS[n]  
@TAN[n]  
@ASIN*[n]  
@ACOS* [n}  
@ATAN* [n]  
@COM[n]  
@ABS[n]  
@FRAC[n]  
@INT[n]  
Cosine of n (n in degrees, with range of -32768 to 32767 and 16-bit fractional resolution)  
Tangent of n (n in degrees, with range of -32768 to 32767 and 16-bit fractional resolution)  
Arc Sine of n, between -90° and +90°. Angle resolution in 1/64000 degrees.  
Arc Cosine of n, between 0 and 180°. Angle resolution in 1/64000 degrees.  
Arc Tangent of n, between -90° and +90°. Angle resolution in 1/64000 degrees  
1’s Complement of n  
Absolute value of n  
Fraction portion of n  
Integer portion of n  
@RND[n]  
@SQR[n]  
@IN[n]  
Round of n (Rounds up if the fractional part of n is .5 or greater)  
Square root of n (Accuracy is +/-.0001)  
Return digital input at general input n (where n starts at 1)  
Return digital output at general output n (where n starts at 1)  
Return analog input at general analog in n (where n starts at 1)  
@OUT[n]  
@AN[n]  
* Note that these functions are multi-valued. An application program may be used to find the correct  
band.  
Functions may be combined with mathematical expressions. The order of execution of mathematical  
expressions is from left to right and can be over-ridden by using parentheses.  
Instruction  
Interpretation  
V1=@ABS[V7]  
V2=5*@SIN[POS]  
The variable, V1, is equal to the absolute value of variable V7.  
The variable, V2, is equal to five times the sine of the variable,  
POS.  
V3=@IN[1]  
The variable, V3, is equal to the digital value of input 1.  
V4=2*(5+@AN[5]) The variable, V4, is equal to the value of analog input 5 plus 5,  
then multiplied by 2.  
Variables  
For applications that require a parameter that is variable, the DMC-3425 provides 126 variables.  
These variables can be numbers or strings. A program can be written in which certain parameters,  
such as position or speed, are defined as variables. The variables can later be assigned by the operator  
or determined by program calculations. For example, a cut-to-length application may require that a cut  
length be variable.  
Instruction  
PR POSA  
Interpretation  
Assigns variable POSA to PR command  
Assigns variable RPMB multiplied by 70 to JG command.  
JG RPMB70  
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Programmable Variables  
The DMC-3425 allows the user to create up to 126 variables. Each variable is defined by a name that  
can be up to eight characters. The name must start with an alphabetic character, however, numbers are  
permitted in the rest of the name. Spaces are not permitted. Variable names should not be the same as  
DMC-3425 instructions. For example, PR is not a good choice for a variable name.  
Examples of valid and invalid variable names are:  
Valid Variable Names  
POSA  
POS1  
SPEEDC  
Invalid Variable Names  
REALLONGNAME  
123  
; Cannot have more than 8 characters  
; Cannot begin variable name with a number  
; Cannot have spaces in the name  
SPEED C  
Assigning Values to Variables  
Assigned values can be numbers, internal variables and keywords, functions, controller parameters and  
strings;  
The range for numeric variable values is 4 bytes of integer (231) followed by two bytes of fraction  
(+/-2,147,483,647.9999).  
Numeric values can be assigned to programmable variables using the equal sign.  
Any valid DMC-3425 function can be used to assign a value to a variable. For example, V1=@ABS[V2]  
or V2=@IN[1]. Arithmetic operations are also permitted.  
To assign a string value, the string must be in quotations. String variables can contain up to six characters  
that must be in quotation.  
Instruction  
POSX=_TPA  
SPEED=5.75  
INPUT=@IN[2]  
V2=V1+V3*V4  
VAR="CAT"  
Interpretation  
Assigns returned value from TPA command to variable POSX.  
Assigns value 5.75 to variable SPEED  
Assigns logical value of input 2 to variable INPUT  
Assigns the value of V1 plus V3 times V4 to the variable V2.  
Assign the string, CAT, to VAR  
Assigning Variable Values to Controller Parameters  
Variable values may be assigned to controller parameters such as GN or PR.  
PR V1  
Assign V1 to PR command  
SP VS*2000  
Assign VS*2000 to SP command  
Displaying the value of variables at the terminal  
Variables may be sent to the screen using the format, variable=. For example, V1= , returns the value of  
the variable V1.  
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Example - Using Variables for Joystick  
The example below reads the voltage of an A-B joystick and assigns it to variables VA and VB to drive the  
motors at proportional velocities, where  
10 Volts = 3000 rpm = 200000 c/sec  
Speed/Analog input = 200000/10 = 20000  
Instruction  
#JOYSTIK  
JG 0,0  
Interpretation  
Label  
Set in Jog mode  
Begin Motion  
Loop  
BGAB  
#LOOP  
VX=@AN[1]*20000  
VY=@AN[2]*20000  
JG VA,VB  
JP#LOOP  
Read joystick A  
Read joystick B  
Jog at variable VA,VB  
Repeat  
EN  
End  
Operands  
Operands allow motion or status parameters of the DMC-3425 to be incorporated into programmable  
variables and expressions. Most DMC-3425 commands have an equivalent operand - which are  
designated by adding an underscore (_) prior to the DMC-3425 command. The command reference  
indicates which commands have an associated operand.  
Status commands such as Tell Position return actual values, whereas action commands such as KP or  
SP return the values in the DMC-3425 registers. The axis designation is required following the  
command.  
Instruction  
Interpretation  
POSA=_TPA  
Assigns value from Tell Position A to the variable POSA.  
Assigns value from KPA multiplied by two to variable, VAR1.  
Jump to #LOOP if the position error of A is greater than 5  
Jump to #ERROR if the error code equals 1.  
VAR1=_KPA*2  
JP #LOOP,_TEA>5  
JP #ERROR,_TC=1  
Operands can be used in an expression and assigned to a programmable variable, but they cannot be  
assigned a value. For example: _TPA=2 is invalid.  
Special Operands  
The DMC-3425 provides a few additional operands that give access to internal variables that are not  
accessible by standard DMC-3425 commands.  
Operand  
_BGn  
_BN  
Function  
*Returns a 1 if motion on axis ‘n’ is complete, otherwise returns 0.  
*Returns serial # of the board.  
_DA  
*Returns the number of arrays available  
*Returns the number of available labels for programming  
*Returns the available array memory  
_DL  
_DM  
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_HMn  
_LFn  
_LRn  
_UL  
*Returns status of Home Switch (equals 0 or 1)  
Returns status of Forward Limit switch input of axis ‘n’ (equals 0 or 1)  
Returns status of Reverse Limit switch input of axis ‘n’ (equals 0 or 1)  
*Returns the number of available variables  
TIME  
Free-Running Real Time Clock (off by 2.4% - Resets with power-on).  
NOTE: TIME does not use an underscore character (_) as other operands.  
* These operands have corresponding commands while the operands _LF, _LR and TIME do not have  
any associated commands. All operands are listed in the Command Reference Manual.  
Examples  
V1=_LFA  
V3=TIME  
V4=_HMD  
Assign V1 the state of the Forward Limit Switch on the A-axis  
Assign V3 the current value of the time clock  
Assign V4 the logical state of the Home input on the D-axis  
Arrays  
For storing and collecting numerical data, the DMC-3425 provides array space for 2000 elements.  
The arrays are one-dimensional and up to 14 different arrays may be defined. The array data is  
available to both threads on each controller. When operating with multiple controllers, arrays are only  
defined within the same controller.  
31  
Each array element has a numeric range of 4 bytes of integer (2 ) followed by two bytes of fraction  
(+/-2,147,483,647.9999).  
Arrays can be used to capture real-time data, such as position, torque and analog input values. In the  
contouring mode, arrays are convenient for holding the points of a position trajectory in a record and  
playback application.  
Defining Arrays  
An array is defined with the command DM. The user must specify a name and the number of entries  
to be held in the array. An array name can contain up to eight characters, starting with an uppercase  
alphabetic character. The number of entries in the defined array is enclosed in [ ].  
DM POSA[7]  
DM SPEED[100]  
DM POSA[0]  
Defines an array names POSA with seven entries  
Defines an array named speed with 100 entries  
Frees array space  
Assignment of Array Entries  
Like variables, each array element can be assigned a value. Assigned values can be numbers or  
returned values from instructions, functions and keywords.  
Array elements are addressed starting at count 0. For example the first element in the POSA array  
(defined with the DM command, DM POSA[7]) would be specified as POSA[0].  
Values are assigned to array entries using the equal sign. Assignments are made one element at a time  
by specifying the element number with the associated array name.  
NOTE: Arrays must be defined using the command, DM, before assigning entry values.  
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DM SPEED[10]  
Dimension Speed Array  
SPEED[1]=7650.2  
SPEED[1]=  
Assigns the first element of the array the value 7650.2  
Returns array element value  
POSX[10]=_TPA  
CON[2]=@COS[POS]*2  
TIMER[1]=TIME  
Assigns the 11th element the position of A.  
Assigns the 3rd element of the array the cosine of POS * 2.  
Assigns the 2nd element of the array TIME  
Using a Variable to Address Array Elements  
An array element number can also be a variable. This allows array entries to be assigned sequentially  
using a counter.  
This example records 10 position values at a rate of one value per 10 msec. The values are stored in an  
array named POS. The variable, COUNT, is used to increment the array element counter. This  
example can also be executed with the automatic data capture feature described below.  
Instruction  
#A  
Interpretation  
Begin Program  
COUNT=0;DM POS[10]  
#LOOP  
Initialize counter and define array  
Begin loop  
WT 10  
Wait 10 msec  
POS[COUNT]=_TPA  
POS[COUNT]=  
COUNT=COUNT+1  
JP #LOOP,COUNT<10  
EN  
Record position into array element  
Report position  
Increment counter  
Loop until 10 elements have been stored  
End Program  
Uploading and Downloading Arrays to On Board Memory  
Arrays may be uploaded and downloaded using the QU and QD commands.  
QU array[],start,end,delim  
QD array[],start,end  
where array is an array name such as A[].  
Start is the first element of array (default=0)  
End is the last element of array (default=last element)  
Delim specifies whether the array data is separated by a comma (delim=1) or a carriage return  
(delim=0).  
The file is terminated using <control>Z, <control>Q, <control>D or \.  
Automatic Data Capture into Arrays  
The DMC-3425 provides a special feature for automatic capture of data such as position, position  
error, inputs or torque. This is useful for teaching motion trajectories or observing system  
performance. Up to four types of data can be captured and stored in four arrays. The capture rate or  
time interval may be specified. Recording can be done as a one time event or as a circular continuous  
recording.  
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Command Summary - Automatic Data Capture  
Command  
Description  
RA n[],m[],o[],p[]  
Selects up to four arrays for data capture. The arrays must be defined  
with the DM command.  
RD type1,type2,type3,type4  
RC n,m  
Selects the type of data to be recorded, where type1, type2, type3, and  
type 4 represent the various types of data (see table below). The order  
of data type is important and corresponds with the order of n,m,o,p  
arrays in the RA command.  
The RC command begins data collection. Sets data capture time  
interval where n is an integer between 1 and 8 and designates 2n msec  
between data. m is optional and specifies the number of elements to  
be captured. If m is not defined, the number of elements defaults to  
the smallest array defined by DM. When m is a negative number, the  
recording is done continuously in a circular manner. _RD is the  
recording pointer and indicates the address of the next array element.  
n=0 stops recording.  
RC?  
Returns a 0 or 1 where, 0 denotes not recording, 1 specifies recording  
in progress  
Data Types for Recording:  
Data Type  
_DEA  
_TPA  
_TEA  
_SHA  
_RLA  
_TI  
Description  
2nd encoder position (dual encoder)  
Encoder position  
Position error  
Commanded position  
Latched position  
Inputs  
_OP  
Output  
_TSA  
_SCA  
_NOA  
_TTA  
Switches (only bit 0-4 valid)  
Stop code  
Status bits  
Torque (reports digital value +/-8097)  
NOTE: B, C, D, E, F, G, or H may replace A for capturing data on other axes.  
Operand Summary - Automatic Data Capture  
_RC  
Returns a 0 or 1 where, 0 denotes not recording, 1 specifies recording in progress  
_RD  
Returns address of next array element.  
Example - Recording into An Array  
Instruction  
Interpretation  
#RECORD  
Begin program  
DM APOS[300],BPOS[300]  
DM AERR[300],BERR[300]  
RA APOS[],AERR[],BPOS[],BERR[]  
RD _TPA,_TEA,_TPB,_TEB  
PR 10000,20000  
Define A,B position arrays  
Define A,B error arrays  
Select arrays for capture  
Select data types  
Specify move distance  
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RC1  
Start recording now, at rate of 2 msec  
Begin motion  
Loop until done  
Print message  
End program  
BG AB  
#A;JP #A,RC=1  
MG "DONE"  
EN  
#PLAY  
Play back  
N=0  
Initial Counter  
Exit if done  
JP# DONE,N>300  
N=  
Print Counter  
A POS[N]=  
B POS[N]=  
AERR[N]=  
BERR[N]=  
N=N+1  
Print A position  
Print B position  
Print A error  
Print B error  
Increment Counter  
Done  
#DONE  
EN  
End Program  
Deallocating Array Space  
Array space may be deallocated using the DA command followed by the array name. DA*[0]  
deallocates all the arrays.  
Outputting Numbers and Strings  
Numerical and string data can be output from the controller using several methods. The message  
command, MG, can output string and numerical data. Also, the controller can be commanded to return  
the values of variables and arrays, as well as other information using the interrogation commands (the  
interrogation commands are described in chapter 5).  
Sending Messages  
Messages may be sent to the bus using the message command, MG. This command sends specified  
text and numerical or string data from variables or arrays to the screen.  
Text strings are specified in quotes and variable or array data is designated by the name of the variable  
or array. For example:  
MG "The Final Value is", RESULT  
In addition to variables, functions and commands, responses can be used in the message command.  
For example:  
MG "Analog input is", @AN[1]  
MG "The Position of A is", _TPA  
Specifying the Port for Messages:  
By default, messages will be sent through the port from which the data was requested. However, the  
port can be specified with the specifier, {P1} for the main serial port or {Ea} for the Ethernet handle.  
‘a’ will be the handle letter, A through H.  
MG {P1} "Hello World"  
Sends message to Serial  
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Formatting Messages  
String variables can be formatted using the specifier, {Sn} where n is the number of characters, 1 thru  
6. For example:  
MG STR {S3}  
This statement returns 3 characters of the string variable named STR.  
Numeric data may be formatted using the {Fn.m} expression following the completed MG statement.  
{$n.m} formats data in HEX instead of decimal. The actual numerical value will be formatted with n  
characters to the left of the decimal and m characters to the right of the decimal. Leading zeros will be  
used to display specified format.  
For example::  
MG "The Final Value is", RESULT {F5.2}  
If the value of the variable RESULT is equal to 4.1, this statement returns the following:  
The Final Value is 00004.10  
If the value of the variable RESULT is equal to 999999.999, the above message statement returns the  
following:  
The Final Value is 99999.99  
The message command normally sends a carriage return and line feed following the statement. The  
carriage return and the line feed may be suppressed by sending {N} at the end of the statement. This is  
useful when a text string needs to surround a numeric value.  
Example:  
#A  
JG 50000;BGA;ASA  
MG "The Speed is", _TVA {F5.1} {N}  
MG "counts/sec"  
EN  
When #A is executed, the above example will appear on the screen as:  
The speed is 50000 counts/sec  
Using the MG Command to Configure Terminals  
The MG command can be used to configure a terminal. Any ASCII character can be sent by using the  
format {^n} where n is any integer between 1 and 255.  
Example:  
MG {^07} {^255}  
sends the ASCII characters represented by 7 and 255 to the bus.  
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Summary of Message Functions  
Function  
" "  
Description  
Surrounds text string  
{Fn.m}  
Formats numeric values in decimal n digits to the right of the  
decimal point and m digits to the left  
{P1}or {Ea}  
{$n.m}  
{^n}  
Send message to Main Serial Port or Ethernet Port  
Formats numeric values in hexadecimal  
Sends ASCII character specified by integer n  
Suppresses carriage return/line feed  
{N}  
{Sn}  
Sends the first n characters of a string variable, where n is 1 thru 6.  
Displaying Variables and Arrays  
Variables and arrays may be sent to the screen using the format, variable= or array[x]=. For example,  
V1= , returns the value of V1.  
Example - Printing a Variable and an Array element  
Instruction  
#DISPLAY  
DM POSA[7]  
PR 1000  
Interpretation  
Label  
Define Array POSA with 7 entries  
Position Command  
Begin  
BGA  
AMA  
After Motion  
V1=_TPA  
POSA[1]=_TPA  
V1=  
Assign Variable V1  
Assign the first entry  
Print V1  
Interrogation Commands  
The DMC-3425 has a set of commands that directly interrogate the controller. When these command  
are entered, the requested data is returned in decimal format on the next line followed by a carriage  
return and line feed. The format of the returned data can be changed using the Position Format (PF),  
and Leading Zeros (LZ) command. For a complete description of interrogation commands, see Ch 5.  
Using the PF Command to Format Response from Interrogation Commands  
The command, PF, can change format of the values returned by these interrogation commands:  
BL ?  
DE ?  
DP ?  
EM ?  
FL ?  
IP ?  
LE ?  
PA ?  
PR ?  
TN ?  
VE ?  
TE  
TP  
The numeric values may be formatted in decimal or hexadecimal with a specified number of digits to  
the right and left of the decimal point using the PF command.  
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Position Format is specified by:  
PF m.n  
where m is the number of digits to the left of the decimal point (0 thru 10) and n is the number of digits  
to the right of the decimal point (0 thru 4) A negative sign for m specifies hexadecimal format.  
Hex values are returned preceded by a $ and in 2's complement. Hex values should be input as signed  
2's complement, where negative numbers have a negative sign. The default format is PF 10.0.  
If the number of decimal places specified by PF is less than the actual value, a nine appears in all the  
decimal places.  
Example  
Instruction  
:DP21  
:TPA  
Interpretation  
Define position  
Tell position  
0000000021  
:PF4  
Default format  
Change format to 4 places  
Tell position  
:TPA  
0021  
New format  
:PF-4  
Change to hexadecimal format  
Tell Position  
:TPA  
$0015  
:PF2  
Hexadecimal value  
Format 2 places  
:TPA  
Tell Position  
99  
Returns 99 if position greater than 99  
Removing Leading Zeros from Response to Interrogation Commands  
The leading zeros on data returned as a response to interrogation commands can be removed by the use  
of the command, LZ.  
LZ0  
Disables the LZ function  
TP  
Tell Position Interrogation Command  
Response (With Leading Zeros)  
-0000000009, 0000000005  
LZ1  
Enables the LZ function  
TP  
Tell Position Interrogation Command  
Response (Without Leading Zeros)  
-9, 5  
Local Formatting of Response of Interrogation Commands  
The response of interrogation commands may be formatted locally. To format locally, use the  
command, {Fn.m} or {$n.m} on the same line as the interrogation command. The symbol F specifies  
that the response should be returned in decimal format and $ specifies hexadecimal. n is the number of  
digits to the left of the decimal, and m is the number of digits to the right of the decimal.  
TP {F2.2}  
Tell Position in decimal format 2.2  
-05.00, 05.00, 00.00, 07.00  
TP {$4.2}  
Response from Interrogation Command  
Tell Position in hexadecimal format 4.2  
Response from Interrogation Command  
FFFB.00,$0005.00,$0000.00,$0007.00  
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Formatting Variables and Array Elements  
The Variable Format (VF) command is used to format variables and array elements. The VF  
command is specified by:  
VF m.n  
where m is the number of digits to the left of the decimal point (0 thru 10) and n is the number of digits  
to the right of the decimal point (0 thru 4).  
A negative sign for m specifies hexadecimal format. The default format for VF is VF 10.4  
Hex values are returned preceded by a $ and in 2's complement.  
Instruction  
V1=10  
V1=  
Interpretation  
Assign V1  
Return V1  
:0000000010.0000  
VF2.2  
Response - Default format  
Change format  
Return V1  
V1=  
:10.00  
Response - New format  
Specify hex format  
Return V1  
VF-2.2  
V1=  
$0A.00  
VF1  
Response - Hex value  
Change format  
Return V1  
V1=  
:9  
Response - Overflow  
Local Formatting of Variables  
PF and VF commands are global format commands that affect the format of all relevant returned  
values and variables. Variables may also be formatted locally. To format locally, use the command,  
{Fn.m} or {$n.m} following the variable name and the ‘=’ symbol. F specifies decimal and $ specifies  
hexadecimal. n is the number of digits to the left of the decimal, and m is the number of digits to the  
right of the decimal.  
Instruction  
V1=10  
Interpretation  
Assign V1  
V1=  
Return V1  
:0000000010.0000  
V1={F4.2}  
:0010.00  
Default Format  
Specify local format  
New format  
V1={$4.2}  
:$000A.00  
V1="ALPHA"  
V1={S4}  
Specify hex format  
Hex value  
Assign string "ALPHA" to V1  
Specify string format first 4 characters  
:ALPH  
The local format is also used with the MG command.  
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Converting to User Units  
Variables and arithmetic operations make it easy to input data in desired user units such as inches or  
RPM.  
The DMC-3425 position parameters such as PR, PA and VP have units of quadrature counts. Speed  
parameters such as SP, JG and VS have units of counts/sec. Acceleration parameters such as AC, DC,  
2
VA and VD have units of counts/sec . The controller interprets time in milliseconds.  
All input parameters must be converted into these units. For example, an operator can be prompted to  
input a number in revolutions. A program could be used such that the input number is converted into  
counts by multiplying it by the number of counts/revolution.  
Instruction  
Interpretation  
Label  
#RUN  
IN "ENTER # OF REVOLUTIONS",N1  
Prompt for revs  
Convert to counts  
Prompt for RPMs  
Convert to counts/sec  
Prompt for ACCEL  
Convert to counts/sec2  
Begin motion  
PR N1*2000  
IN "ENTER SPEED IN RPM",S1  
SP S1*2000/60  
IN "ENTER ACCEL IN RAD/SEC2",A1  
AC A1*2000/(2*3.14)  
BG  
EN  
End program  
Hardware I/O  
Digital Outputs  
The DMC-3425 has 3 uncommitted outputs. Each bit on the output port may be set and cleared with  
the software instructions SB (Set Bit) and CB(Clear Bit), or OB (define output bit).  
Example- Set Bit and Clear Bit  
Instruction  
Interpretation  
SB3  
Sets bit 3 of output port  
Clears bit 2 of output port  
CB2  
Example- Output Bit  
The Output Bit (OB) instruction is useful for setting or clearing outputs depending on the value of a  
variable, array, input or expression. Any non-zero value results in a set bit.  
Instruction  
Interpretation  
OB1, POS  
Set Output 1 if the variable POS is non-zero. Clear Output 1 if  
POS equals 0.  
OB 2, @IN [1]  
Set Output 2 if Input 1 is high. If Input 1 is low, clear Output 2.  
Set Output 3 only if Input 1 and Input 2 are high.  
OB 3, @IN [1]&@IN [2]  
OB 3, COUNT [1]  
Set Output 3 if element 1 in the array COUNT is non-zero.  
The output port can be set by specifying an 8-bit word using the instruction OP (Output Port). This  
0
1
instruction allows a single command to define the state of the output port, where 2 is output 1, 2 is  
output 2 and so on. A 1 designates that the output is on.  
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Example- Output Port  
Instruction  
Interpretation  
OP6  
1
2
Sets outputs 2 and 3 of output port to high. All other bits are 0. (2 + 2 =  
6)  
OP0  
Clears all bits of output port to zero  
Sets all bits of output port to one.  
OP 255  
The output port is useful for setting relays or controlling external switches and events during a motion  
sequence.  
Example - Turn on output after move  
Instruction  
Interpretation  
#OUTPUT  
Label  
PR 2000  
BG  
Position Command  
Begin  
AM  
After move  
Set Output 1  
Wait 1000 msec  
Clear Output 1  
End  
SB1  
WT 1000  
CB1  
EN  
Digital Inputs  
The general digital inputs for are accessed by using the @IN[n] function or the TI command. The  
@IN[n] function returns the logic level of the specified input, n.  
Example - Using Inputs to control program flow  
Instruction  
JP #A,@IN[1]=0  
JP #B,@IN[2]=1  
AI 7  
Interpretation  
Jump to A if input 1 is low  
Jump to B if input 2 is high  
Wait until input 7 is high  
Wait until input 6 is low  
AI -6  
Example - Start Motion on Switch  
Motor A must turn at 4000 counts/sec when the user flips a panel switch to on. When panel switch is  
turned to off position, motor A must stop turning.  
Solution: Connect panel switch to input 1 of DMC-3425. High on input 1 means switch is in on  
position.  
Instruction  
#S;JG 4000  
AI 1;BGA  
AI -1;STA  
AMA;JP #S  
EN;  
Interpretation  
Set speed  
Begin after input 1 goes high  
Stop after input 1 goes low  
After motion, repeat  
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Input Interrupt Function  
The DMC-3425 provides an input interrupt function which causes the program to automatically  
execute the instructions following the #ININT label. This function is enabled using the II m,n,o  
command. The m specifies the beginning input and n specifies the final input in the range. The  
parameter o is an interrupt mask. If m and n are unused, o contains a number with the mask. A 1  
designates that input to be enabled for an interrupt, where 20 is bit 1, 21 is bit 2 and so on. For  
example, II,,5 enables inputs 1 and 3 (20 + 22 = 5). The RI command (not EN) is used to return from  
the #ININT subroutine  
A low input on any of the specified inputs will cause automatic execution of the #ININT subroutine.  
The Return from Interrupt (RI) command is used to return from this subroutine to the place in the  
program where the interrupt had occurred. If it is desired to return to somewhere else in the program  
after the execution of the #ININT subroutine, the Zero Stack (ZS) command is used followed by  
unconditional jump statements.  
Example - Input Interrupt  
Instruction  
Interpretation  
#A  
Label #A  
II 1  
Enable input 1 for interrupt function  
Set speeds on A and B axes  
Begin motion on A and B axes  
Label #B  
JG 30000,-20000  
BG AB  
#B  
TP AB  
Report A and B axes positions  
Wait 1000 milliseconds  
Jump to #B  
WT 1000  
JP #B  
EN  
End of program  
#ININT  
Interrupt subroutine  
MG "Interrupt has occurred"  
Displays the message  
Stops motion on A and B axes  
Loop until Interrupt cleared  
Specify new speeds  
ST AB  
#LOOP;JP #LOOP,@IN[1]=0  
JG 15000,10000  
WT 300  
BG AB  
Wait 300 milliseconds  
Begin motion on A and B axes  
Return from Interrupt subroutine  
RI  
Analog Inputs  
The DMC-3425 provides two analog inputs. The value of these inputs in volts may be read using the  
@AN[n] function where n is the analog input 1 or 2. The resolution of the standard Analog-to-Digital  
conversion is 12 bits. Analog inputs are useful for reading special sensors such as temperature, tension  
or pressure.  
The following examples show programs that cause the motor to follow an analog signal. The first  
example is a point-to-point move. The second example shows a continuous move.  
Example - Position Follower (Point-to-Point)  
Objective - The motor must follow an analog signal. When the analog signal varies by 10V, motor  
must move 10000 counts.  
Method: Read the analog input and command A to move to that point.  
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Instruction  
#Points  
Interpretation  
Label  
SP 7000  
Speed  
AC 80000;DC 80000  
#Loop  
Acceleration  
VP=@AN[1]*1000  
PA VP  
Read and analog input, compute position  
Command position  
Start motion  
After completion  
Repeat  
BGA  
AMA  
JP #Loop  
EN  
End  
Example - Position Follower (Continuous Move)  
Method: Read the analog input, compute the commanded position and the position error. Command  
the motor to run at a speed in proportions to the position error.  
Instruction  
#Cont  
Interpretation  
Label  
AC 80000;DC 80000  
JG 0  
Acceleration rate  
Start job mode  
Start motion  
BGA  
#Loop  
VP=@AN[1]*1000  
VE=VP-_TPA  
VEL=VE*20  
JG VEL  
Compute desired position  
Find position error  
Compute velocity  
Change velocity  
Change velocity  
End  
JP #Loop  
EN  
Extended I/O of the DMC-3425 Controller  
The DMC-3425 controller offers an option for 64 additional I/O, called the daughter board DB-14064.  
This I/O is known as extended I/O and can be configured as inputs or outputs in 8 bit increments  
through software. The I/O points are accessed through 2 50-pin high-density connectors.  
Configuring the I/O of the DMC-3425  
The extended I/O can be configured as outputs in blocks of 8. The I/O is configured as all Inputs by  
default. The extended I/O is denoted as blocks 2-9 or bits 17-80.  
The command, CO, is used to configure the extended I/O as inputs or outputs. The CO command has  
one field:  
CO n  
where n is a decimal value which represents a binary number. Each bit of the binary number  
represents one block of extended I/O. When set to 1, the corresponding block is configured as an  
output.  
NOTE: The CO command must be sent to slave controllers using the SA command.  
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The least significant bit represents block 2 and the most significant bit represents block 9. The decimal  
value can be calculated by the following formula. n = n2 + 2*n3 + 4*n4 + 8*n5 +16* n6 +32* n7 +64*  
n8 +128* n9 where nx represents the block. If the nx value is a one, then the block of 8 I/O points is to  
be configured as an output. If the nx value is a zero, then the block of 8 I/O points will be configured  
as an input. For example, if block 4 and 5 is to be configured as an output, CO 12 is issued.  
8-Bit I/O  
Block  
Block  
Binary Representation  
Decimal Value for  
Block  
17-24  
25-32  
20  
2
3
1
2
1
21  
33-40  
41-48  
49-56  
57-64  
65-72  
73-80  
4
5
6
7
8
9
22  
23  
24  
25  
26  
27  
4
8
16  
32  
64  
128  
The simplest method for determining n:  
Step 1. Determine which 8-bit I/O blocks to be configured as outputs.  
Step 2. From the table, determine the decimal value for each I/O block to be set as an output.  
Step 3. Add up all of the values determined in step 2. This is the value to be used for n.  
For example, if blocks 2 and 3 are to be outputs, then n is 3 and the command, CO3, should be issued.  
NOTE: This calculation is identical to the formula: n = n2 + 2*n3 + 4*n4 + 8*n5 +16* n6 +32* n7 +64*  
n8 +128* n9 where nx represents the block.  
Saving the State of the Outputs in Non-Volatile Memory  
The configuration of the extended I/O and the state of the outputs can be stored in the EEPROM with  
the BN command. If no value has been set, the default of CO 0 is used (all blocks are inputs).  
Accessing Extended I/O  
When configured as an output, each I/O point may be defined with the SBn and CBn commands  
(where n=1 through 8 and 17 through 80). Outputs may also be defined with the conditional  
command, OBn (where n=1 through 8 and 17 through 80).  
The command, OP, may also be used to set output bits, specified as blocks of data. The OP command  
accepts 5 parameters. The first parameter sets the values of the main output port of the controller  
(Outputs 1-8, block 0). The additional parameters set the value of the extended I/O as outlined:  
OP m,a,b,c,d  
where m is the decimal representation of the bits 1-8 (values from 0 to 255) and a,b,c,d represent the  
extended I/O in consecutive groups of 16 bits. (values from 0 to 65535). Arguments given for I/O  
points that are configured as inputs will be ignored. The following table describes the arguments used  
to set the state of outputs.  
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Argument  
Blocks  
0
Bits  
Description  
General Outputs  
Extended I/O  
Extended I/O  
Extended I/O  
Extended I/O  
m
a
1-8  
2,3  
17-32  
33-48  
49-64  
65-80  
b
c
4,5  
6,7  
d
8,9  
For example, if block 8 is configured as an output, the following command may be issued:  
OP 7,,,,7  
This command will set bits 1,2,3 (block 0) and bits 65,66,67 (block 8) to 1. Bits 4 through 8 and bits  
68 through 80 will be set to 0. All other bits are unaffected.  
When accessing I/O blocks configured as inputs, use the TIn command. The argument 'n' refers to the  
block to be read (n=0,2,3,4,5,6,7,8 or 9). The value returned will be a decimal representation of the  
corresponding bits.  
Individual bits can be queried using the @IN[n] function (where n=1 through 8 or 17 through 80). If  
the following command is issued;  
MG @IN[17]  
the controller will return the state of the least significant bit of block 2 (assuming block 2 is configured  
as an input).  
Interfacing to Grayhill or OPTO-22 G4PB24  
The DMC-3425 2 50 Pin IDC connectors which are compatible with I/O mounting racks such as  
Grayhill 70GRCM32-HL and OPTO-22 G4PB24. The 50 pin ribbon cables can connect directly into  
the I/O mounting racks.  
When using the OPTO-22 G4PB24 I/O mounting rack, the user will only have access to 48 of the 64  
I/O points available on the controller. Block 5 and Block 9 must be configured as inputs and will be  
grounded by the I/O rack.  
Example Applications  
Wire Cutter  
An operator activates a start switch. This causes a motor to advance the wire a distance of 10". When  
the motion stops, the controller generates an output signal that activates the cutter. Allowing 100 ms  
for the cutting completes the cycle.  
Suppose that the motor drives the wire by a roller with a 2" diameter. Also assume that the encoder  
resolution is 1000 lines per revolution. Since the circumference of the roller equals 2π inches, and it  
corresponds to 4000 quadrature, one inch of travel equals:  
4000/2π = 637 count/inch  
This implies that a distance of 10 inches equals 6370 counts, and a slew speed of 5 inches per second,  
for example, equals 3185 count/sec.  
The input signal may be applied to I1, for example, and the output signal is chosen as output 1. The  
motor velocity profile and the related input and output signals are shown in Fig. 7.1.  
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The program starts at a state that we define as #A. Here the controller waits for the input pulse on I1.  
As soon as the pulse is given, the controller starts the forward motion.  
Upon completion of the forward move, the controller outputs a pulse for 20 ms and then waits an  
additional 80 ms before returning to #A for a new cycle.  
Instruction  
Interpretation  
#A  
Label  
AI1  
Wait for input 1  
Distance  
PR 6370  
SP 3185  
BGA  
Speed  
Start Motion  
AMA  
SB1  
After motion is complete  
Set output bit 1  
Wait 20 ms  
WT 20  
CB1  
Clear output bit 1  
Wait 80 ms  
WT 80  
JP #A  
Repeat the process  
START PULSE I1  
MOTOR VELOCITY  
OUTPUT PULSE  
output  
TIME INTERVALS  
move  
wait  
ready  
move  
Figure 7.1 - Motor Velocity and the Associated Input/Output signals  
A-B (X-Y) Table Controller  
An A-B-C system must cut the pattern shown in Fig. 7.2. The A-B table moves the plate while the C-  
axis raises and lowers the cutting tool.  
The solid curves in Fig. 7.2 indicate sections where cutting takes place. Those must be performed at a  
feedrate of 1 inch per second. The dashed line corresponds to non-cutting moves and should be  
performed at 5 inch per second. The acceleration rate is 0.1 g.  
The motion starts at point A, with the C-axis raised. An A-B motion to point B is followed by  
lowering the C-axis and performing a cut along the circle. Once the circular motion is completed, the  
C-axis is raised and the motion continues to point C, etc.  
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Assume that all of the 3 axes are driven by lead screws with 10 turns-per-inch pitch. Also assume  
encoder resolution of 1000 lines per revolution. This results in the relationship:  
1 inch = 40,000 counts  
and the speeds of  
1 in/sec = 40,000 count/sec  
5 in/sec = 200,000 count/sec  
an acceleration rate of 0.1g equals  
2
0.1g = 38.6 in/s2 = 1,544,000 count/s  
Note that the circular path has a radius of 2" or 80000 counts, and the motion starts at the angle of 270°  
and traverses 360° in the CW (negative direction). Such a path is specified with the instruction  
CR 80000,270,-360  
Further assume that the C must move 2" at a linear speed of 2" per second. The required motion is  
performed by the following instructions:  
Instruction  
Interpretation  
#A  
Label  
VM AB  
VP 160000,160000  
VE  
Circular interpolation for AB  
Positions  
End Vector Motion  
Vector Speed  
VS 200000  
VA 1544000  
BGS  
Vector Acceleration  
Start Motion  
AMS  
When motion is complete  
Move C down  
PR,,-80000  
SP,,80000  
BGC  
C speed  
Start C motion  
AMC  
Wait for completion of C motion  
Circle  
CR 80000,270,-360  
VE  
VS 40000  
BGS  
Feedrate  
Start circular move  
Wait for completion  
Move C up  
AMS  
PR,,80000  
BGC  
Start C move  
Wait for C completion  
Move A  
AMC  
PR –21600  
SP 20000  
BGA  
Speed A  
Start A  
AMA  
Wait for A completion  
Lower C  
PR,,-80000  
BGC  
AMC  
CR 80000,270,-360  
VE  
C second circle move  
VS 40000  
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BGS  
AMS  
PR,,80000  
BGC  
Raise C  
AMC  
VP -37600,-16000  
VE  
Return AB to start  
VS 200000  
BGS  
AMS  
EN  
B
R=2  
4
B
C
A
0
4
9.3  
A
Figure 7.2 - Motor Velocity and the Associated Input/Output signals  
Speed Control by Joystick  
The speed of a motor is controlled by a joystick. The joystick produces a signal in the range between -  
10V and +10V. The objective is to drive the motor at a speed proportional to the input voltage.  
Assume that a full voltage of 10 Volts must produce a motor speed of 3000 rpm with an encoder  
resolution of 1000 lines or 4000 count/rev. This speed equals:  
3000 rpm = 50 rev/sec = 200000 count/sec  
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The program reads the input voltage periodically and assigns its value to the variable VIN. To get a  
speed of 200,000 ct/sec for 10 volts, we select the speed as  
Speed = 20000 x VIN  
The corresponding velocity for the motor is assigned to the VEL variable.  
Instruction  
#A  
JG0  
BGA  
#B  
VIN=@AN[1]  
VEL=VIN*20000  
JG VEL  
JP #B  
EN  
Position Control by Joystick  
This system requires the position of the motor to be proportional to the joystick angle. Furthermore,  
the ratio between the two positions must be programmable. For example, if the control ratio is 5:1, it  
implies that when the joystick voltage is 5 Volts, corresponding to 1028 counts, the required motor  
position must be 5120 counts. The variable V3 changes the position ratio.  
Instruction  
#A  
Interpretation  
Label  
V3=5  
Initial position ratio  
Define the starting position  
Set motor in jog mode as zero  
Start  
DP0  
JG0  
BGA  
#B  
V1=@AN[1]  
V2=V1*V3  
V4=V2-_TPA-_TEA  
V5=V4*20  
JG V5  
Read analog input  
Compute the desired position  
Find the following error  
Compute a proportional speed  
Change the speed  
JP #B  
Repeat the process  
End  
EN  
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Chapter 8 Hardware & Software  
Protection  
Introduction  
The DMC-3425 provides several hardware and software features to check for error conditions and to  
inhibit the motor on error. These features help protect the system components from damage.  
WARNING: Machinery in motion can be dangerous! It is the responsibility of the user to design  
effective error handling and safety protection as part of the machine. Since the DMC-3425 is an  
integral part of the machine, the engineer should design his overall system with protection against a  
possible component failure on the DMC-3425. Galil shall not be liable or responsible for any  
incidental or consequential damages.  
Hardware Protection  
The DMC-3425 includes hardware input and output protection lines for error and mechanical limit  
conditions. These include:  
Output Protection Lines  
Amp Enable - This signal goes low when the motor off command is given, when the position error  
exceeds the value specified by the Error Limit (ER) command, or when an off-on-error condition is  
enabled (OE1) and the abort command is given. Each axis amplifier has a separate enable line. This  
signal also goes low when the watch-dog timer is activated. Note: The standard configuration of the  
AEN signal is TTL active low. Both the polarity and the amplitude can be changed if you are using the  
ICM-1460 interface board. To make these changes, see section entitled ‘Amplifier Interface’.  
Note: There is only one amplifier enable signal for the DMC-3425. Therefore, both amplifiers will be  
controlled by the same enable output.  
Error Output - The error output is a TTL signal that indicates an error condition in the controller.  
This signal is available on the interconnect module as ERROR. When the error signal is low, this  
indicates one of the following error conditions:  
1. At least one axis has a position error greater than the error limit. The error limit is set by using the  
command ER.  
2. The reset line on the controller is held low or is being affected by noise.  
3. There is a failure on the controller and the processor is resetting itself.  
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4. There is a failure with the output IC that drives the error signal.  
Input Protection Lines  
Abort - A low input stops commanded motion instantly without a controlled deceleration. For any  
axis in which the Off-On-Error function is enabled, the amplifiers will be disabled. This could cause  
the motor to ‘coast’ to a stop. If the Off-On-Error function is not enabled, the motor will  
instantaneously stop and servo at the current position. The Off-On-Error function is further discussed  
in this chapter.  
Forward Limit Switch - Low input inhibits motion in forward direction. (The CN command can be  
used to change the polarity of the limit switches.) If the motor is moving in the forward direction when  
the limit switch is activated, the motion will decelerate and stop. In addition, if the motor is moving in  
the forward direction, the controller will automatically jump to the limit switch subroutine, #LIMSWI  
(if such a routine has been written by the user).  
Reverse Limit Switch - Low input inhibits motion in reverse direction. (The CN command can be  
used to change the polarity of the limit switches.) If the motor is moving in the reverse direction when  
the limit switch is activated, the motion will decelerate and stop. In addition, if the motor is moving in  
the reverse direction, the controller will automatically jump to the limit switch subroutine, #LIMSWI  
(if such a routine has been written by the user).  
Software Protection  
The DMC-3425 provides a programmable error limit. The error limit refers to a difference in the  
actual and commanded position of the motor. This limit can be set for any number between 1 and  
32767 using the ER n command. The default value for ER is 16384.  
Example:  
ER 200,300  
Set A-axis error limit for 200, B-axis error limit to 300  
Set B-axis error limit to 1 count.  
ER,1  
The units of the error limit are quadrature counts. The error is the difference between the command  
position and actual encoder position. If the absolute value of the error exceeds the value specified by  
ER, the DMC-3425 will generate signals to warn the host system of the error condition. These signals  
include:  
Signal or Function  
State if Error Occurs  
# POSERR  
Jumps to automatic excess position error subroutine (if included in  
program)  
Error Light  
Turns on  
OE Function  
AEN Output Line  
Shuts motor off if OE1  
Goes low  
The Jump if Condition statement is useful for branching within the program due to an error. The  
position error of A and B can be monitored during execution using the TE command.  
Programmable Position Limits  
The DMC-3425 provides programmable forward and reverse position limits. These are set by the BL  
(Backwards Limit) and FL (Forward Limit) software commands. Once a position limit is specified, the  
DMC-3425 will not accept position commands beyond the limit. Motion beyond the limit is also  
prevented.  
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Example:  
DP0,0,  
Define Position  
Set Reverse position limit  
Set Forward position limit  
Jog  
BL -2000,-4000  
FL 2000,4000  
JG 2000,2000  
BG AB  
Begin  
Execution of the above example will cause the motor to slew at the given jog speed until the forward  
position limit is reached. Motion will stop once the limit is hit.  
Off-On-Error  
The DMC-3425 controller has a built in function that can turn off the motors under certain error  
conditions. This function is know as ‘Off-On-Error”. To activate the OE function for each axis,  
specify 1 for A and B axes. To disable this function, specify 0 for the axes. When the function is  
enabled, the corresponding motor will be disabled under the following 3 conditions:  
1. The position error for the specified axis exceeds the limit set with the command, ER  
2. The abort command is given  
3. The abort input is activated with a low signal.  
Note: If the motors are disabled while they are moving, they may ‘coast’ to a stop because they are no  
longer under servo control.  
To re-enable the system, use the Servo Here (SH) command. The SH command will clear any position  
error and reset the commanded position to the actual position.  
Examples:  
OE 1,1  
Enable off-on-error for A and B  
OE 0,1  
Enable off-on-error for B axis and disable off-on-error for A axis  
Automatic Error Routine  
The #POSERR label causes the statements following to be automatically executed if the error on any  
axis exceeds the error limit specified by ER. The error routine should be closed with the RE command.  
RE will cause the main program to be resumed where left off.  
NOTE: The Error Subroutine will be entered again unless the error condition is gone.  
Example:  
Instruction  
#A;JP #A;EN  
#POSERR  
MG "error"  
SB 1  
Interpretation  
"Dummy" program  
Start error routine on error  
Send message  
Fire relay  
STA  
Stop motor  
AMA  
After motor stops  
Servo motor here to clear error  
Return to main program  
SHA  
RE  
NOTE: An applications program must be executing for the #POSERR routine to function.  
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Limit Switch Routine  
The DMC-3425 provides forward and reverse limit switches that inhibit motion in the respective  
direction. There is also a special label for automatic execution of a limit switch subroutine. The  
#LIMSWI label specifies the start of the limit switch subroutine. This label causes the statements  
following to be automatically executed if any limit switch is activated. The RE command ends the  
subroutine and resumes the main program where it left off.  
The state of the forward and reverse limit switches may also be interrogated or used in a conditional  
statement. The _LR condition specifies the reverse limit and _LF specifies the forward limit. A or B  
following _LR or _LF specifies the axis. The CN command can be used to configure the polarity of the  
limit switches.  
Limit Switch Example:  
Instruction  
#A;JP #A;EN  
#LIMSWI  
Interpretation  
Dummy Program  
Limit Switch Utility  
Check state of forward limit  
Check state of reverse limit  
Jump to #LF if forward limit = low  
Jump to #LR if reverse limit = low  
Jump to end  
V1=_LFA  
V2=_LRA  
JP#LF,V1=0  
JP#LR,V2=0  
JP#END  
#LF  
#LF  
MG "FORWARD LIMIT"  
STA;AMA  
Send message  
Stop motion  
PR-1000;BGA;AMA  
JP#END  
Move in reverse  
End  
#LR  
#LR  
MG "REVERSE LIMIT"  
STA;AMA  
Send message  
Stop motion  
PR1000;BGA;AMA  
#END  
Move forward  
End  
RE  
Return to main program  
NOTE: An applications program must be executing for #LIMSWI to function.  
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Chapter 9 Troubleshooting  
Overview  
The following discussion may help you get your system to work.  
Potential problems have been divided into groups as follows:  
1. Installation  
2. Communication  
3. Stability and Compensation  
4. Operation  
The various symptoms along with the cause and the remedy are described in the following tables.  
Installation  
Symptom  
Cause  
Remedy  
Motor runs away when connected to  
amplifier with no additional inputs.  
Amplifier offset too large.  
Adjust amplifier offset  
Same as above, but offset adjustment does Damaged amplifier.  
not stop the motor.  
Replace amplifier.  
Replace amplifier.  
Check encoder wiring.  
Same as above, but offset adjustment does Damaged amplifier.  
not stop the motor.  
Controller does not read changes in  
encoder position.  
Wrong encoder connections.  
Same as above  
Bad encoder  
Check the encoder signals.  
Replace encoder if necessary.  
Same as above  
Bad controller  
Connect the encoder to  
different axis input. If it works,  
controller failure. Repair or  
replace.  
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Communication  
Symptom  
Cause  
Remedy  
Using terminal emulator, cannot  
Selected comport incorrect  
Try another comport  
communicate with controller.  
Same as above  
Selected baud rate incorrect  
Check to be sure that baud rate  
same as dip switch settings on  
controller, change as necessary.  
Stability  
Symptom  
Cause  
Remedy  
Motor runs away when the loop is closed. Wrong feedback polarity.  
Invert the polarity of the loop by  
inverting the motor leads (brush  
type) or the encoder.  
Motor oscillates.  
Too high gain or too little  
damping.  
Decrease KI and KP. Increase KD.  
Operation  
Symptom  
Cause  
Remedy  
Controller rejects command. Responded  
with a ?  
Anything.  
Interrogate the cause with TC or  
TC1.  
Motor does not complete move.  
Noise on limit switches  
stops the motor.  
To verify cause, check the stop  
code (SC). If caused by limit  
switch noise, reduce noise.  
During a periodic operation, motor drifts  
slowly.  
Encoder noise  
Interrogate the position  
periodically. If controller states  
that the position is the same at  
different locations it implies  
encoder noise. Reduce noise. Use  
differential encoder inputs.  
Same as above.  
Programming error.  
Avoid resetting position error at  
end of move with SH command.  
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Chapter 10 Theory of Operation  
Overview  
The following discussion covers the operation of motion control systems. A typical motion control  
system consists of the elements shown in Fig 10.1.  
COMPUTER  
CONTROLLER  
DRIVER  
ENCODER  
MOTOR  
Figure 10.1 - Elements of Servo Systems  
The operation of such a system can be divided into three levels, as illustrated in Fig. 10.2. The levels  
are:  
1. Closing the Loop  
2. Motion Profiling  
3. Motion Programming  
The first level, the closing of the loop, assures that the motor follows the commanded position. This is  
done by closing the position loop using a sensor. The operation at the basic level of closing the loop  
involves the subjects of modeling, analysis, and design. These subjects will be covered in the  
following discussions.  
The motion profiling is the generation of the desired position function. This function, R(t), describes  
where the motor should be at every sampling period. Note that the profiling and the closing of the loop  
are independent functions. The profiling function determines where the motor should be and the  
closing of the loop forces the motor to follow the commanded position  
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The highest level of control is the motion program. This can be stored in the host computer or in the  
controller. This program describes the tasks in terms of the motors that need to be controlled, the  
distances and the speed.  
LEVEL  
MOTION  
PROGRAMMING  
3
MOTION  
PROFILING  
2
CLOSED-LOOP  
CONTROL  
1
Figure 10.2 - Levels of Control Functions  
The three levels of control may be viewed as different levels of management. The top manager, the  
motion program, may specify the following instruction, for example.  
PR 6000,4000  
SP 20000,20000  
AC 200000,00000  
BG A  
AD 2000  
BG B  
EN  
This program corresponds to the velocity profiles shown in Fig. 10.3. Note that the profiled positions  
show where the motors must be at any instant of time.  
Finally, it remains up to the servo system to verify that the motor follows the profiled position by  
closing the servo loop.  
The following section explains the operation of the servo system. First, it is explained qualitatively,  
and then the explanation is repeated using analytical tools for those who are more theoretically  
inclined.  
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X VELOCITY  
Y VELOCITY  
X POSITION  
Y POSITION  
TIME  
Figure 10.3 - Velocity and Position Profiles  
Operation of Closed-Loop Systems  
To understand the operation of a servo system, we may compare it to a familiar closed-loop operation,  
adjusting the water temperature in the shower. One control objective is to keep the temperature at a  
comfortable level, say 90 degrees F. To achieve that, our skin serves as a temperature sensor and  
reports to the brain (controller). The brain compares the actual temperature, which is called the  
feedback signal, with the desired level of 90 degrees F. The difference between the two levels is called  
the error signal. If the feedback temperature is too low, the error is positive, and it triggers an action  
which raises the water temperature until the temperature error is reduced sufficiently.  
The closing of the servo loop is very similar. Suppose that we want the motor position to be at 90  
degrees. The motor position is measured by a position sensor, often an encoder, and the position  
feedback is sent to the controller. Like the brain, the controller determines the position error, which is  
the difference between the commanded position of 90 degrees and the position feedback. The  
controller then outputs a signal that is proportional to the position error. This signal produces a  
proportional current in the motor, which causes a motion until the error is reduced. Once the error  
becomes small, the resulting current will be too small to overcome the friction, causing the motor to  
stop.  
The analogy between adjusting the water temperature and closing the position loop carries further. We  
have all learned the hard way, that the hot water faucet should be turned at the "right" rate. If you turn  
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it too slowly, the temperature response will be slow, causing discomfort. Such a slow reaction is called  
over damped response.  
The results may be worse if we turn the faucet too fast. The overreaction results in temperature  
oscillations. When the response of the system oscillates, we say that the system is unstable. Clearly,  
unstable responses are bad when we want a constant level.  
What causes the oscillations? The basic cause for the instability is a combination of delayed reaction  
and high gain. In the case of the temperature control, the delay is due to the water flowing in the pipes.  
When the human reaction is too strong, the response becomes unstable.  
Servo systems also become unstable if their gain is too high. The delay in servo systems is between  
the application of the current and its effect on the position. Note that the current must be applied long  
enough to cause a significant effect on the velocity, and the velocity change must last long enough to  
cause a position change. This delay, when coupled with high gain, causes instability.  
This motion controller includes a special filter that is designed to help the stability and accuracy.  
Typically, such a filter produces, in addition to the proportional gain, damping and integrator. The  
combination of the three functions is referred to as a PID filter.  
The filter parameters are represented by the three constants KP, KI and KD, which correspond to the  
proportional, integral and derivative term respectively.  
The damping element of the filter acts as a predictor, thereby reducing the delay associated with the  
motor response.  
The integrator function, represented by the parameter KI, improves the system accuracy. With the KI  
parameter, the motor does not stop until it reaches the desired position exactly, regardless of the level  
of friction or opposing torque.  
The integrator also reduces the system stability. Therefore, it can be used only when the loop is stable  
and has a high gain.  
The output of the filter is applied to a digital-to-analog converter (DAC). The resulting output signal in  
the range between +10 and -10 Volts is then applied to the amplifier and the motor.  
The motor position, whether rotary or linear is measured by a sensor. The resulting signal, called  
position feedback, is returned to the controller for closing the loop.  
The following section describes the operation in a detailed mathematical form, including modeling,  
analysis and design.  
System Modeling  
The elements of a servo system include the motor, driver, encoder and the controller. These elements  
are shown in Fig. 10.4. The mathematical model of the various components is given below.  
CONTROLLER  
X
Y
R
V
E
DIGITAL  
FILTER  
ZOH  
DAC  
AMP  
MOTOR  
P
Σ
C
ENCODER  
Figure 10.4 - Functional Elements of a Motion Control System  
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Motor-Amplifier  
The motor amplifier may be configured in three modes:  
1. Voltage Drive  
2. Current Drive  
3. Velocity Loop  
The operation and modeling in the three modes is as follows:  
Voltage Drive  
The amplifier is a voltage source with a gain of Kv [V/V]. The transfer function relating the input  
voltage, V, to the motor position, P, is  
P V = KV K S ST +1 ST +1  
(
)(  
)
]
[
t
m
e
where  
and  
Tm = RJ Kt2 [s]  
Te = L R  
[s]  
and the motor parameters and units are  
K
Torque constant [Nm/A]  
t
R
J
Armature Resistance Ω  
2
Combined inertia of motor and load [kg.m ]  
Armature Inductance [H]  
L
When the motor parameters are given in English units, it is necessary to convert the quantities to MKS  
units. For example, consider a motor with the parameters:  
K = 14.16 oz - in/A = 0.1 Nm/A  
t
R = 2 Ω  
2
-4  
2
J = 0.0283 oz-in-s = 2.10 kg . m  
L = 0.004H  
Then the corresponding time constants are  
T
= 0.04 sec  
m
and  
T = 0.002 sec  
e
Assuming that the amplifier gain is Kv = 4, the resulting transfer function is  
P/V = 40/[s(0.04s+1)(0.002s+1)]  
Current Drive  
The current drive generates a current I, which is proportional to the input voltage, V, with a gain of Ka.  
The resulting transfer function in this case is  
2
P/V = K K / Js  
a
t
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where Kt and J are as defined previously. For example, a current amplifier with K = 2 A/V with the  
a
motor described by the previous example will have the transfer function:  
2
P/V = 1000/s  
[rad/V]  
If the motor is a DC brushless motor, it is driven by an amplifier that performs the commutation. The  
combined transfer function of motor amplifier combination is the same as that of a similar brush  
motor, as described by the previous equations.  
Velocity Loop  
The motor driver system may include a velocity loop where the motor velocity is sensed by a  
tachometer and is fed back to the amplifier. Such a system is illustrated in Fig. 10.5. Note that the  
transfer function between the input voltage V and the velocity ω is:  
ω /V = [K K /Js]/[1+K K K /Js] = 1/[K (sT +1)]  
a
t
a
t
g
g
1
where the velocity time constant, T1, equals  
T1 = J/K K K  
a
t
g
This leads to the transfer function  
P/V = 1/[K s(sT1+1)]  
g
V
Ka  
Kt/Js  
Σ
Kg  
Figure 10.5 - Elements of velocity loops  
The resulting functions derived above are illustrated by the block diagram of Fig. 10.6.  
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VOLTAGE SOURCE  
E
W
W
W
P
P
P
V
1/Ke  
1
Kv  
(STm+1)(STe+1)  
S
CURRENT SOURCE  
I
V
Kt  
1
Ka  
JS  
S
VELOCITY LOOP  
V
1
1
Kg(ST1+1)  
S
Figure 10.6 - Mathematical model of the motor and amplifier in three operational modes  
Encoder  
The encoder generates N pulses per revolution. It outputs two signals, Channel A and B, which are in  
quadrature. Due to the quadrature relationship between the encoder channels, the position resolution is  
increased to 4N quadrature counts/rev.  
The model of the encoder can be represented by a gain of  
K = 4N/2π  
[count/rad]  
f
For example, a 1000 lines/rev encoder is modeled as  
K = 638  
f
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DAC  
The DAC or D-to-A converter converts a 16-bit number to an analog voltage. The input range of the  
numbers is 65536 and the output voltage range is +/-10V or 20V. Therefore, the effective gain of the  
DAC is  
K= 20/65536 = 0.0003  
[V/count]  
Digital Filter  
The digital filter has three elements in series: PID, low-pass and a notch filter. The transfer functions  
of the filter elements are:  
K(Z A) CZ  
PID  
D(z) =  
L(z) =  
+
Z
Z 1  
1B  
Z B  
Low-pass  
(Z z)(Z z)  
(Z p)(Z p)  
Notch  
N(z) =  
The filter parameters, K, A, C and B are selected by the instructions KP, KD, KI and PL, respectively.  
The relationship between the filter coefficients and the instructions are:  
K = (KP + KD)  
4
A = KD/(KP + KD)  
C = KI/2  
B = PL  
The PID and low-pass elements are equivalent to the continuous transfer function G(s).  
G(s) = (P + sD + I/s) a/(S+a)  
P = 4KP  
D = 4TKD  
I = KI/2T  
a = 1/T ln = (1/B)  
where T is the sampling period.  
For example, if the filter parameters of the DMC-2x00 are  
KP = 4  
KD = 36  
KI = 2  
PL = 0.75  
T = 0.001 s  
the digital filter coefficients are  
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K = 160  
A = 0.9  
C = 1  
a = 250 rad/s  
and the equivalent continuous filter, G(s), is  
G(s) = [16 + 0.144s + 1000/s} 250/ (s+250)  
The notch filter has two complex zeros, Z and z, and two complex poles, P and p.  
The effect of the notch filter is to cancel the resonance affect by placing the complex zeros on top of  
the resonance poles. The notch poles, P and p, are programmable and are selected to have sufficient  
damping. It is best to select the notch parameters by the frequency terms. The poles and zeros have a  
frequency in Hz, selected by the command NF. The real part of the poles is set by NB and the real part  
of the zeros is set by NZ.  
The simplest procedure for setting the notch filter is to identify the resonance frequency and set NF to  
the same value. Set NB to about one half of NF and set NZ to a low value between zero and 5.  
ZOH  
The ZOH, or zero-order-hold, represents the effect of the sampling process, where the motor command  
is updated once per sampling period. The effect of the ZOH can be modeled by the transfer function  
H(s) = 1/(1+sT/2)  
If the sampling period is T = 0.001, for example, H(s) becomes:  
H(s) = 2000/(s+2000)  
However, in most applications, H(s) may be approximated as one.  
This completes the modeling of the system elements. Next, we discuss the system analysis.  
System Analysis  
To analyze the system, we start with a block diagram model of the system elements. The analysis  
procedure is illustrated in terms of the following example.  
Consider a position control system with the DMC-2x00 controller and the following parameters:  
K = 0.1  
Nm/A  
Torque constant  
t
-4  
2
System moment of inertia  
J = 2.10  
R = 2  
kg.m  
Motor resistance  
Ω
K = 4  
a
Amp/Volt  
Current amplifier gain  
KP = 12.5  
KD = 245  
KI = 0  
Digital filter gain  
Digital filter zero  
No integrator  
N = 500  
T = 1  
Counts/rev  
ms  
Encoder line density  
Sample period  
The transfer functions of the system elements are:  
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Motor  
Amp  
2
M(s) = P/I = Kt/Js2 = 500/s [rad/A]  
K = 4 [Amp/V]  
a
DAC  
K = 0.0003 [V/count]  
d
Encoder  
ZOH  
K = 4N/2π = 318 [count/rad]  
f
2000/(s+2000)  
Digital Filter  
KP = 12.5, KD = 245, T = 0.001  
Therefore,  
D(z) = 1030 (z-0.95)/Z  
Accordingly, the coefficients of the continuous filter are:  
P = 50  
D = 0.98  
The filter equation may be written in the continuous equivalent form:  
G(s) = 50 + 0.98s = .098 (s+51)  
The system elements are shown in Fig. 10.7.  
AMP  
4
FILTER  
ZOH  
DAC  
MOTOR  
V
2000  
500  
S2  
50+0.980s  
0.0003  
Σ
S+2000  
ENCODER  
318  
Figure 10.7 - Mathematical model of the control system  
The open loop transfer function, A(s), is the product of all the elements in the loop.  
2
A = 390,000 (s+51)/[s (s+2000)]  
To analyze the system stability, determine the crossover frequency, ω at which A(j ω ) equals one.  
c
c
This can be done by the Bode plot of A(j ω ), as shown in Fig. 10.8.  
c
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Magnitude  
4
1
50  
200  
2000  
W (rad/s)  
0.1  
Figure 10.8 - Bode plot of the open loop transfer function  
For the given example, the crossover frequency was computed numerically resulting in 200 rad/s.  
Next, we determine the phase of A(s) at the crossover frequency.  
2
A(j200) = 390,000 (j200+51)/[(j200) . (j200 + 2000)]  
-1  
-1  
α = Arg[A(j200)] = tan (200/51)-180° -tan (200/2000)  
α = 76° - 180° - 6° = -110°  
Finally, the phase margin, PM, equals  
PM = 180° + α = 70°  
As long as PM is positive, the system is stable. However, for a well damped system, PM should be  
between 30 degrees and 45 degrees. The phase margin of 70 degrees given above indicated  
overdamped response.  
Next, we discuss the design of control systems.  
System Design and Compensation  
The closed-loop control system can be stabilized by a digital filter, which is preprogrammed in the  
DMC-2x00 controller. The filter parameters can be selected by the user for the best compensation.  
The following discussion presents an analytical design method.  
The Analytical Method  
The analytical design method is aimed at closing the loop at a crossover frequency, ω , with a phase  
c
margin PM. The system parameters are assumed known. The design procedure is best illustrated by a  
design example.  
Consider a system with the following parameters:  
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K
Nm/A  
Torque constant  
t
-4  
2
System moment of inertia  
J = 2.10  
R = 2  
kg.m  
Motor resistance  
Ω
K = 2  
a
Amp/Volt  
Current amplifier gain  
N = 1000  
Counts/rev  
Encoder line density  
The DAC of the DMC-2x00 outputs +/-10V for a 14-bit command of +/-8192 counts.  
The design objective is to select the filter parameters in order to close a position loop with a crossover  
frequency of ω = 500 rad/s and a phase margin of 45 degrees.  
c
The first step is to develop a mathematical model of the system, as discussed in the previous system.  
Motor  
2
2
M(s) = P/I = K /Js = 1000/s  
t
Amp  
K = 2  
[Amp/V]  
a
DAC  
K = 10/32768 = .0003  
d
Encoder  
ZOH  
K = 4N/2π = 636  
f
H(s) = 2000/(s+2000)  
Compensation Filter  
G(s) = P + sD  
The next step is to combine all the system elements, with the exception of G(s), into one function, L(s).  
6
2
L(s) = M(s) K K K H(s) =3.1710 /[s (s+2000)]  
a
d
f
Then the open loop transfer function, A(s), is  
A(s) = L(s) G(s)  
Now, determine the magnitude and phase of L(s) at the frequency ω = 500.  
c
6
2
L(j500) = 3.1710 /[(j500) (j500+2000)]  
This function has a magnitude of  
|L(j500)| = 0.00625  
and a phase  
-1  
Arg[L(j500)] = -180° - tan (500/2000) = -194°  
G(s) is selected so that A(s) has a crossover frequency of 500 rad/s and a phase margin of 45 degrees.  
This requires that  
|A(j500)| = 1  
Arg [A(j500)] = -135°  
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However, since  
A(s) = L(s) G(s)  
then it follows that G(s) must have magnitude of  
|G(j500)| = |A(j500)/L(j500)| = 160  
and a phase  
arg [G(j500)] = arg [A(j500)] - arg [L(j500)] = -135° + 194° = 59°  
In other words, we need to select a filter function G(s) of the form  
G(s) = P + sD  
so that at the frequency ω =500, the function would have a magnitude of 160 and a phase lead of 59  
c
degrees.  
These requirements may be expressed as:  
|G(j500)| = |P + (j500D)| = 160  
and  
-1  
arg [G(j500)] = tan [500D/P] = 59°  
The solution of these equations leads to:  
P = 160cos 59° = 82.4  
500D = 160sin 59° = 137  
Therefore,  
D = 0.274  
and  
G = 82.4 + 0.2744s  
The function G is equivalent to a digital filter of the form:  
-1  
D(z) = 4KP + 4KD(1-z )  
where  
P = 4 KP  
D = 4 KD T  
and  
4 KD = D/T  
Assuming a sampling period of T=1ms, the parameters of the digital filter are:  
KP = 20.6  
KD = 68.6  
The DMC-2x00 can be programmed with the instruction:  
KP 20.6  
KD 68.6  
In a similar manner, other filters can be programmed. The procedure is simplified by the following  
table, which summarizes the relationship between the various filters.  
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Equivalent Filter Form  
DMC-2x00  
Digital  
D(z) =[K(z-A/z) + Cz/(z-1)](1-B)/(Z-B)  
-1  
-1  
Digital  
D(z) = [4 KP + 4 KD(1-z ) + KI/2(1-z )] (1-B)/(Z-B)  
KP, KD, KI, PL K = (KP + KD)  
4
A = KD/(KP+KD)  
C = KI/2  
B = PL  
Continuous  
PID, T  
G(s) = (P + Ds + I/s) a/S+a  
P = 4 KP  
D = 4 T*KD  
I = KI/2T  
a = 1/T ln (1/PL)  
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Appendices  
Electrical Specifications  
Servo Control  
ACMD Amplifier Command:  
+/-10 Volts analog signal. Resolution 16-bit DAC or .0003  
Volts. 3 mA maximum  
A+,A-,B+,B-,IDX+,IDX- Encoder  
TTL compatible, but can accept up to +/-12 Volts.  
Quadrature phase on CHA,CHB. Can accept single-ended  
(A+,B+ only) or differential (A+,A-,B+,B-). Maximum A,B  
edge rate: 12MHz. Minimum IDX pulse width: 80 nsec.  
Input/Output  
Uncommitted Inputs, Limits, Home,  
Abort Inputs:  
TTL Can accept up to +12V signal.  
TTL.  
OUT[1] thru OUT[3] Outputs:  
Power Requirements  
+5V  
400 mA  
40 mA  
40mA  
+12V  
-12V  
Performance Specifications  
Minimum Servo Loop Update Time:  
DMC-3415  
250 μsec / 125usec with fast firmware  
(fast firmware only works on SLAVE controller)  
375 μsec / 250 usec with fast firmware  
(fast firmware only works on SLAVE controller)  
+/-1 quadrature count  
DMC-3425  
Position Accuracy:  
Velocity Accuracy:  
DMC-3425  
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Long Term  
Short Term  
Phase-locked, better than .005%  
System dependent  
Position Range:  
Velocity Range:  
+/-2147483647 counts per move  
Up to 12,000,000 counts/sec servo;  
3,000,000 pulses/sec-stepper  
2 counts/sec  
Velocity Resolution:  
Motor Command Resolution:  
Variable Size:  
16 bit or 0.0003 V  
126 user variables  
Variable Range:  
+/-2 billion  
Variable Resolution:  
-4  
1 10  
Array Size:  
2000 elements, 14 arrays  
500 lines x 80 characters  
Program Size:  
Connectors for DMC-3425  
J3 DMC-3425 General I/O; 37- PIN D-type  
1 Reset 1  
20 Error  
2 Amp Enable  
3 Output 3  
21 ACMDA (PWMA)  
22 Output 2  
4 Output 1  
23 Circular Compare  
24 Analog 2  
5 Analog 1  
6 Main Index B (Input 7) 1,2,3  
7 Reverse Limit B (Input 5) 1,3  
8 Input 3 1  
25 Home B (Input 6) 1,3  
26 Forward Limit B (Input 4) 1,3  
27 Input 2 (and B latch) 1  
28 Forward Limit A 1  
29 Reverse Limit A 1  
30 Home A 1  
9 Input 1 (and A latch) 1  
10 + 5V  
11 Ground  
12 +12V  
31 -12v  
13 Ground  
32 A Encoder A+  
33 A Encoder B+  
34 A Encoder Index+  
35 B Encoder A+  
36 B Encoder B+  
37 Abort 1  
14 A Encoder A-  
15 A Encoder B-  
16 A Encoder Index-  
17 B Encoder A-  
18 B Encoder B-  
19 ACMDY (SIGNA)  
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J3 DMC-3425-Stepper General I/O; 37- PIN D-type  
1 Reset 1  
20 PWMB  
2 SIGNB  
21 PWMA  
3 Output 3  
22 Output 2  
4 Output 1  
23 Circular Compare  
24 Analog 2  
5 Analog 1  
6 Main Index B (Input 7) 1,2,3  
7 Reverse Limit B (Input 5) 1,3  
8 Input 3 1  
25 Home B (Input 6) 1,3  
26 Forward Limit B (Input 4) 1,3  
27 Input 2 (and B latch) 1  
28 Forward Limit A 1  
29 Reverse Limit A 1  
30 Home A 1  
9 Input 1 (and A latch) 1  
10 + 5V  
11 Ground  
12 +12V  
31 -12v  
13 Ground  
32 A Encoder A+  
33 A Encoder B+  
34 A Encoder Index+  
35 B Encoder A+  
36 B Encoder B+  
37 Abort 1  
14 A Encoder A-  
15 A Encoder B-  
16 A Encoder Index-  
17 B Encoder A-  
18 B Encoder B-  
19 SIGNA  
1
2
3
These inputs are TTL active low and will be activated when set to 0V.  
All inputs are the same in terms of input range (+/-12); D13 can be used as Index B.  
Pins 6, 7, 25 and 26 represent Index B, Home B, Reverse Limit B and Forward Limit B. The states  
of these inputs are mapped to inputs 7, 6, 5 and 4 respectively. Standard input interrogation commands  
can be used to read these inputs (TI, MG@IN[n]), as well as the TS and MG@LFB or MG@LRB  
switch commands.  
J5 POWER; 6 PIN MOLEX  
1 +12V  
2 +5V  
3 +5V  
4 Ground  
5 Ground  
6 -12V  
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J1 RS232 Main port: DB-9 Pin Male:  
PC  
Galil  
1 DCD  
2 RX  
3 TX  
1 RTS  
2 TX  
3 RX  
4 CTS  
5 GND  
6 RTS  
7 CTS  
8 RTS  
9 --  
4 DTR  
5 GND  
6 DSR  
7 RTS  
8 CTS  
9 RI  
Pin-Out Description  
OUTPUTS  
DESCRIPTION  
Analog Motor  
Command  
+/- 10 Volt range signal for driving amplifier. In servo mode, motor  
command output is updated at the controller sample rate. In the motor off  
mode, this output is held at the OF command level.  
Amp Enable  
Error  
Signal to disable and enable an amplifier. Amp Enable goes low on Abort  
and OE1.  
The signal goes low when the position error on any axis exceeds the value  
specified by the error limit command, ER.  
Output 1-Output 3  
These 3 TTL outputs are uncommitted and may be designated by the user to  
toggle relays and trigger external events. The output lines are toggled by Set  
Bit, SB, and Clear Bit, CB, instructions. The OP instruction is used to define  
the state of all the bits of the Output port.  
INPUTS  
DESCRIPTION  
Encoder, A+, B+  
Position feedback from incremental encoder with two channels in  
quadrature, CHA and CHB. The encoder may be analog or TTL. Any  
resolution encoder may be used as long as the maximum frequency does not  
exceed 12,000,000 quadrature states/sec. The controller performs quadrature  
decoding of the encoder signals resulting in a resolution of quadrature counts  
(4 x encoder cycles). Note: Encoders that produce outputs in the format of  
pulses and direction may also be used by inputting the pulses into CHA and  
direction into Channel B and using the CE command to configure this mode.  
A and B axis Encoder Once-Per-Revolution encoder pulse. Used in Homing sequence or Find  
Index, I+ Index command to define home on an encoder index.  
A and B axis Encoder, Differential inputs from encoder. May be input along with CHA, CHB for  
A-, B-, I-  
noise immunity of encoder signals. The CHA- and CHB- inputs are  
optional.  
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Abort input  
Reset input  
A low input stops commanded motion instantly without a controlled  
deceleration. Also aborts motion program.  
A low input resets the state of the processor to its power-on condition. The  
previously saved state of the controller, along with parameter values, and  
saved sequences are restored.  
Forward Limit Switch When active, inhibits motion in forward direction. Also causes execution of  
limit switch subroutine, #LIMSWI. The polarity of the limit switch may be  
set with the CN command.  
Reverse Limit Switch When active, inhibits motion in reverse direction. Also causes execution of  
limit switch subroutine, #LIMSWI. The polarity of the limit switch may be  
set with the CN command.  
Home Switch  
Input for Homing (HM) and Find Edge (FE) instructions. Upon BG  
following HM or FE, the motor accelerates to slew speed. A transition on  
this input will cause the motor to decelerate to a stop. The polarity of the  
Home Switch may be set with the CN command.  
Input 1 - Input 3  
Uncommitted inputs. May be defined by the user to trigger events. Inputs  
are checked with the Conditional Jump instruction and After Input  
instruction or Input Interrupt. Input 1 is used for the high-speed latch. Only  
3 inputs for the DMC-3425.  
Latch input  
High speed position latch to capture axis position within 20 nano seconds on  
occurrence of latch signal. AL command arms latch. Input 1 is latch for A  
axis. Input 2 is latch for B axis if using DMC-3425  
Analog input  
12 bit resolution  
ICM-1460 Interconnect Module  
The ICM-1460, Rev F Interconnect Module provides easy connections between the DMC-3425 series  
controllers and other system elements, such as amplifiers, encoders, and external switches. The ICM-  
1460 accepts the 37-pin cable from the DMC-3425 and provides screw-type terminals. Each screw  
terminal is labeled for quick connection of system elements.  
The ICM-1460 is packaged as a circuit board mounted to a metal enclosure. A version of the ICM-  
1460 is also available with a single PWM brush servo amplifier, or with a 20W linear brush servo  
amplifier. (see AMP-1460 and ICM-1460-20W).  
Features  
Breaks out 37-pin ribbon cable into individual screw-type terminals.  
Clearly identifies all terminals  
Available with on-board servo drive (see AMP-1460 or ICM-1460-20W).  
10-pin IDC connectors for encoders.  
Option for Opto-isolation of all general purpose inputs, committed inputs, and digital outputs.  
Specify at time of order with the –OPTO option.  
Specifications  
Dimensions: 6.9" x 4.9" x 2.6"  
Weight: 1 pound  
DMC-3425  
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Rev A-F  
Rev G  
Label  
I/O  
Description  
Terminal#  
Terminal#  
1
1
+12V4  
-12V4  
AMPEN/SIGNY5  
ACMDX/PULSE(X)  
AN1  
O
O
O
O
O
O
--  
I
+12 Volts  
2
2
-12 Volts  
3
3
Amplifier enable X axis or Y Axis Sign Output for Stepper  
4
4
X Axis Motor command or Pulse Output for Stepper  
5
5
Analog Input 1  
6
6
AI2  
Analog Input 2  
7
7
GND  
Signal Ground  
8
8
RESET  
ERROR/PULSE(Y) 6  
OUT3  
Reset  
9
9
O
O
O
O
O
O
--  
I
Error signal or Y Axis Pulse Output for Stepper  
Output 3  
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
35  
36  
37  
8
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
35  
36  
37  
38  
39  
40  
OUT2  
Output 2  
OUT1  
CMP/ICOM 7  
Output 1  
Circular Compare / Input common for Opto option  
+ 5 Volts  
5V  
GND  
Signal Ground  
IN7/INDY+  
IN6/HOMY  
IN5/RLSY  
IN4/FLSY  
IN3/IDY-  
IN2  
Input 7 (Y Axis Main Encoder Index + for DMC-1425)  
Input 6 (Y Axis Home input for DMC-1425)  
Input 5 (Y axis reverse limit on DMC-1425)  
Input 4 (Y axis forward limit on DMC-1425)  
Input 3 (Y axis main encoder index for DMC-1425)  
Input 2  
I
I
I
I
I
IN1/LTCH  
FLSX  
I
Input 1 / Input for Latch Function  
Forward limit switch input  
I
RLSX  
I
Reverse limit switch input  
HOMX  
ABORT  
GND  
I
Home input  
I
Abort Input  
--  
I
Signal Ground  
X Axis Main Encoder A+ 5  
X Axis Main Encoder A- 5  
X Axis Main Encoder B+ 5  
MA+  
MA-  
I
MB+  
I
MB-  
I
X Axis Main Encoder B- 5  
IDX+  
I
X Axis Main Encoder Index + 5  
X Axis Main Encoder Index – 5  
X Axis Auxiliary Encoder A+ (Y Axis Main Encoder A+ for DMC-1425)  
X Axis Auxiliary Encoder A- (Y Axis Main Encoder A- for DMC-1425)  
X Axis Auxiliary Encoder B+ (Y Axis Main Encoder B+ for DMC-1425)  
X Axis Auxiliary Encoder B- (Y Axis Main Encoder B- for DMC-1425)  
2nd Motor command Signal for Sine Amplifier or SIGNX for stepper  
+ 5 Volts  
IDX-  
I
AA+  
I
AA-  
I
AB+  
I
AB-  
I
ACMD2/SIGNX  
5V  
O
O
--  
39  
40  
GND  
Signal Ground  
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4The screw terminals for ACMDX and ACMDY can provide access to 2 sets of signals, depending on  
the placement of the 2 jumpers on JP3.  
5If the Opto-isolated input option is used, the output compare is NOT brought out to the ICM-1460. If  
the output compare is to be used in conjunction with the opto-isolation, pin 23 of the Cable 37-Pin D  
must be brought out externally. There are also options for using either terminal 1 or 2 as the Common  
connection. Contact Galil for more information.  
Opto-Isolation Option for ICM-1460  
The ICM-1460 module from Galil has an option for opto-isolated inputs and outputs. This option is  
specified as ICM-1460-OPTO*. With this option, the user is able to use voltages up to 24V on the  
inputs and outputs of the controller.  
The common point for the opto-isolation may be chosen from any of the following pins: pin 1 (labeled  
as +12V), pin 2 (labeled as –12V) or pin 13 (labeled as CMP/ICOM). When pin 1 is used as  
input/output common, the +12V output be comes inaccessible, when pin 2 is used, the –12V becomes  
inaccessible, and when pin 13 is used, the output compare function is not available. This common  
point must be specified at the time of ordering.  
The ICM-1460 may also be configured such that the input/output common is jumpered to the internal  
Vcc (+5V). By doing this, no screw connection is needed so no signals are lost.  
A final option for the opto-isolation is for separate input/output commons. This allows the user to have  
different voltage levels for the inputs and outputs. However, this requires the use of both pin 1 and pin  
2 on the screw connection, making both +12V and –12V inaccessible on the screw terminals.  
Opto-isolated inputs:  
The signal "IN[x]" below is one of the isolated digital inputs where x stands for the digital input  
terminals.  
By connecting the OPTO-COMMON to the + side of an isolated power supply, the inputs will be  
activated by sinking current. By connecting the OPTO-COMMON to the GND side of the power  
supply, the inputs will be activated by sourcing current.  
The opto-isolation circuit requires 1ma drive current with approximately 400 usec response time. The  
voltage should not exceed 24V without placing additional resistance to limit the current to 11 mA.  
DMC-3425  
Appendices177  
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ICM-1460  
TO CONTROLLER  
CONNECTIONS  
VCC  
OPTO-COMMON  
RP2 / RP4 = 2.2K  
RP3 / RP1 = 4.7K OHMS  
IN[x] (To controller)  
IN[x]  
Figure A-1  
Opto-isolated outputs:  
The signal “OUT[x]" below is one of the isolated digital outputs where x stands for the digital output  
terminals.  
The OPTO-COMMON needs to be connected to an isolated power supply. The OUT[x] can be used to  
source current from the power supply. The maximum sourcing current for the OUT[x] is 25 ma.  
Sinking configuration can also be specified. Please contact Galil for details.  
The default state of the outputs may also be set through the resistor pack RP5. With this resistor in it’s  
default state, the opto-isolator will be ON. By reversing RP5 in its socket, the opto-isolator will be  
OFF by default.  
Figure A-2  
* Only available with ICM-1460  
178 • Appendices  
DMC-3425  
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64 Extended I/O of the DMC-3425 Controller  
The DMC-3425 controller offers 64 extended I/O points, which can be interfaced to Grayhill and  
OPTO-22 I/O mounting racks. These I/O points can be configured as inputs or outputs in 8 bit  
increments through software. The I/O points are accessed through two 50-pin IDC connectors, each  
with 32 I/O points.  
Configuring the I/O of the DMC-3425 with DB-14064  
The 64 extended I/O points of the DMC-3425 w/DB-14064 series controller can be configured in  
blocks of 8. The extended I/O is denoted as blocks 2-9 or bits 17-80.  
The command, CO, is used to configure the extended I/O as inputs or outputs. The CO command has  
one field:  
CO n  
Where, n is a decimal value, which represents a binary number. Each bit of the binary number  
represents one block of extended I/O. When set to 1, the corresponding block is configured as an  
output.  
Note: The CO command must be sent through the SA command to configure outputs for slave  
controller extended I/O.  
The least significant bit represents block 2 and the most significant bit represents block 9. The decimal  
value can be calculated by the following formula. n = n2 + 2*n3 + 4*n4 + 8*n5 +16* n6 +32* n7 +64*  
n8 +128* n9 where nx represents the block. If the nx value is a one, then the block of 8 I/O points is to  
be configured as an output. If the nx value is a zero, then the block of 8 I/O points will be configured  
as an input. For example, if block 4 and 5 is to be configured as an output, CO 12 is issued.  
8-Bit I/O Block  
17-24  
Block Binary Representation  
Decimal Value for Block  
0
2
1
2
2
25-32  
3
4
5
6
7
8
9
1
2
3
4
5
6
7
2
2
2
2
2
2
2
33-40  
41-48  
49-56  
57-64  
65-72  
73-80  
4
8
16  
32  
64  
128  
The simplest method for determining n:  
Step 1. Determine which 8-bit I/O blocks to be configured as outputs.  
Step 2. From the table, determine the decimal value for each I/O block to be set as an output.  
Step 3. Add up all of the values determined in step 2. This is the value to be used for n.  
DMC-3425  
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For example, if blocks 2 and 3 are to be outputs, then n is 3 and the command, CO3, should be issued.  
Note: This calculation is identical to the formula: n = n2 + 2*n3 + 4*n4 + 8*n5 +16* n6 +32* n7 +64* n8  
+128* n9 where nx represents the block.  
Saving the State of the Outputs in Non-Volatile Memory  
The configuration of the extended I/O and the state of the outputs can be stored in the EEPROM with  
the BN command. If no value has been set, the default of CO 0 is used (all blocks are inputs).  
Accessing extended I/O  
When configured as an output, each I/O point may be defined with the SBn and CBn commands  
(where n=1 through 8 and 17 through 80). Outputs may also be defined with the conditional  
command, OBn (where n=1 through 8 and 17 through 80).  
The command, OP, may also be used to set output bits, specified as blocks of data. The OP command  
accepts 5 parameters. The first parameter sets the values of the main output port of the controller  
(Outputs 1-8, block 0). The additional parameters set the value of the extended I/O as outlined:  
OP m,a,b,c,d  
where m is the decimal representation of the bits 1-8 (values from 0 to 255) and a,b,c,d represent the  
extended I/O in consecutive groups of 16 bits. (values from 0 to 65535). Arguments that are given for  
I/O points configured as inputs will be ignored. The following table describes the arguments used to  
set the state of outputs.  
Argument  
Blocks  
Bits  
Description  
M
A
B
C
D
0
1-8  
General Outputs  
Extended I/O  
Extended I/O  
Extended I/O  
Extended I/O  
2,3  
17-32  
33-48  
49-64  
65-80  
4,5  
6,7  
8,9  
180 • Appendices  
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For example, if block 8 is configured as an output, the following command may be issued:  
OP 7,,,,7  
This command will set bits 1,2,3 (block 0) and bits 65,66,67 (block 8) to 1. Bits 4 through 8 and bits  
68 through 80 will be set to 0. All other bits are unaffected.  
When accessing I/O blocks configured as inputs, use the TIn command. The argument 'n' refers to the  
block to be read (n=0,2,3,4,5,6,7,8 or 9). The value returned will be a decimal representation of the  
corresponding bits.  
Individual bits can be queried using the @IN[n] function (where n=1 through 8 or 17 through 80). If  
the following command is issued;  
MG @IN[17]  
the controller will return the state of the least significant bit of block 2 (assuming block 2 is configured  
as an input).  
Connector Description:  
The DMC-3425 controller with DB-14064 has two 50 Pin IDC header connectors. The connectors are  
compatible with I/O mounting racks such as Grayhill 70GRCM32-HL and OPTO-22 G4PB24.  
Note for interfacing to OPTO-22 G4PB24: When using the OPTO-22 G4PB24 I/O mounting rack,  
the user will only have access to 48 of the 64 I/O points available on the controller. Block 5 and Block  
9 must be configured as inputs and will be grounded by the I/O rack.  
J6 50-PIN IDC  
Pin  
Signal  
Block  
Bit @IN[n],  
Bit No  
@OUT[n]  
40  
1.  
3.  
5
7.  
I/O  
I/O  
I/O  
I/O  
I/O  
I/O  
I/O  
I/O  
I/O  
I/O  
I/O  
I/O  
I/O  
I/O  
I/O  
I/O  
I/O  
I/O  
I/O  
I/O  
I/O  
I/O  
I/O  
I/O  
+5V  
4
4
4
4
4
4
4
4
3
3
3
3
3
3
3
3
2
2
2
2
2
2
2
2
-
7
6
5
4
3
2
1
0
7
6
5
4
3
2
1
0
7
6
5
4
3
2
1
0
-
39  
38  
37  
36  
35  
34  
33  
32  
31  
30  
29  
28  
27  
26  
25  
24  
23  
22  
21  
20  
19  
18  
17  
-
9.  
11.  
13.  
15.  
17.  
19.  
21.  
23.  
25.  
27.  
29.  
31.  
33.  
35.  
37.  
39.  
41.  
43.  
45.  
47.  
49.  
DMC-3425  
Appendices181  
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2.  
4.  
6.  
8.  
I/O  
I/O  
I/O  
I/O  
I/O  
I/O  
I/O  
I/O  
GND  
GND  
GND  
GND  
GND  
GND  
GND  
GND  
GND  
GND  
GND  
GND  
GND  
GND  
GND  
GND  
GND  
5
5
5
5
5
5
5
5
-
-
-
-
-
-
-
-
-
-
-
-
-
48  
47  
46  
45  
44  
43  
42  
41  
-
-
-
-
-
-
-
-
-
-
-
-
-
0
1
2
3
4
5
6
7
-
-
-
-
-
-
-
-
-
-
-
-
-
10.  
12.  
14.  
16.  
18.  
20.  
22.  
24.  
26.  
28.  
30.  
32.  
34.  
36.  
38.  
40.  
42.  
44.  
46.  
48.  
50.  
-
-
-
-
-
-
-
-
-
-
-
-
J8 50-PIN IDC  
Pin  
Signal  
Block  
Bit @IN[n],  
Bit No  
@OUT[n]  
72  
1.  
3.  
5
7.  
I/O  
I/O  
I/O  
I/O  
I/O  
I/O  
I/O  
I/O  
I/O  
I/O  
I/O  
I/O  
I/O  
I/O  
I/O  
I/O  
I/O  
I/O  
I/O  
I/O  
I/O  
I/O  
I/O  
I/O  
+5V  
8
8
8
8
8
8
8
8
7
7
7
7
7
7
7
7
6
6
6
6
6
6
6
6
-
7
6
5
4
3
2
1
0
7
6
5
4
3
2
1
0
7
6
5
4
3
2
1
0
-
71  
70  
69  
68  
67  
66  
65  
64  
63  
62  
61  
60  
59  
58  
57  
56  
55  
54  
53  
52  
51  
50  
49  
-
9.  
11.  
13.  
15.  
17.  
19.  
21.  
23.  
25.  
27.  
29.  
31.  
33.  
35.  
37.  
39.  
41.  
43.  
45.  
47.  
49.  
182 • Appendices  
DMC-3425  
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2.  
4.  
6.  
8.  
I/O  
I/O  
I/O  
I/O  
I/O  
I/O  
I/O  
I/O  
GND  
GND  
GND  
GND  
GND  
GND  
GND  
GND  
GND  
GND  
GND  
GND  
GND  
GND  
GND  
GND  
GND  
9
9
9
9
9
9
9
9
-
-
-
-
-
-
-
-
-
-
-
-
-
80  
79  
78  
77  
76  
75  
74  
73  
-
-
-
-
-
-
-
-
-
-
-
-
-
7
6
5
4
3
2
1
0
-
-
-
-
-
-
-
-
-
-
-
-
-
10.  
12.  
14.  
16.  
18.  
20.  
22.  
24.  
26.  
28.  
30.  
32.  
34.  
36.  
38.  
40.  
42.  
44.  
46.  
48.  
50.  
-
-
-
-
-
-
-
-
-
-
-
-
IOM-1964 Opto-Isolation Module for Extended I/O  
Controllers  
Description:  
Provides 64 optically isolated inputs and outputs, each rated for 2mA at up to 28 VDC  
Configurable as inputs or outputs in groups of eight bits  
Provides 16 high power outputs capable of up to 500mA each  
Connects to controller via 100 pin shielded cable  
All I/O points conveniently labeled  
Each of the 64 I/O points has status LED  
Dimensions 6.8” x 11.4”  
Works with extended I/O controllers  
DMC-3425  
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High Current  
Buffer chips (16)  
Screw Terminals  
0 1 2 3 4 5 6 7  
IOM-1964  
REV A  
GALIL MOTION CONTROL  
MADE IN USA  
FOR INPUTS:  
UX3  
FOR OUTPUTS:  
UX1  
UX4  
UX2  
RPX4  
RPX2  
RPX3  
J5  
Banks 0 and 1  
100 pin high  
density connector  
Banks 2-7 are  
standard banks.  
provide high  
power output  
capability.  
Figure A-3  
Overview  
The IOM-1964 is an input/output module that connects to the DB-14064 extended I/O daughter board  
cards from Galil, providing optically isolated buffers for the extended inputs and outputs of the  
controller. The IOM-1964 also provides 16 high power outputs capable of 500mA of current per  
output point. The IOM-1964 splits the 64 I/O points into eight banks of eight I/O points each,  
corresponding to the eight banks of extended I/O on the controller. Each bank is individually  
configured as an input or output bank by inserting the appropriate integrated circuits and resistor packs.  
The hardware configuration of the IOM-1964 must match the software configuration of the controller  
card.  
All E-Series controllers have general purpose I/O connections. On a DMC-3425 and 3415 the standard  
uncommitted I/O consists of: three TTL digital inputs, three TTL digital outputs, and two analog  
inputs.  
The DMC-34x5 with the DB-14064, however, has an additional 64 digital input/output points than the  
6 described above for a total of 70 input/output points. The 64 I/O points on the DB-14064 are  
attached via two 50-pin ribbon cable header connectors. A CB-50-80 adapter card is used to connect  
the two 50-pin ribbon cables to an 80-pin high-density connector identical to the main axes connector.  
An 80-pin shielded cable connects from the 80-pin connector of the CB-50-80 board to the 80-pin high  
density connector J5 on the IOM-1964.  
184 • Appendices  
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Configuring Hardware Banks  
The extended I/O on the DMC-34x5 with DB-14064 is configured using the CO command. The banks  
of buffers on the IOM-1964 are configured to match by inserting the appropriate IC’s and resistor  
packs. The layout of each of the I/O banks is identical.  
For example, here is the layout of bank 0:  
Resistor Pack for  
outputs  
RP03 OUT  
Resistor Pack for  
Input Buffer IC's  
inputs  
U03  
U04  
IN  
Resistor Pack for  
outputs  
Output Buffer IC's  
Indicator LED's  
U01  
U02  
OUT  
Resistor Pack for  
LED's  
D0  
C6  
RP01  
Bank 0  
Figure A-4  
All of the banks have the same configuration pattern as diagrammed above in figure A-4. For  
example, all banks have Ux1 and Ux2 output optical isolator IC sockets, labeled in bank 0 as U01 and  
U02, in bank 1 as U11 and U12, and so on. Each bank is configured as inputs or outputs by inserting  
optical isolator IC’s and resistor packs in the appropriate sockets. A group of eight LED’s indicates  
the status of each I/O point. The numbers above the Bank 0 label indicate the number of the I/O point  
corresponding to the LED above it.  
Digital Inputs  
Configuring a bank for inputs requires that the Ux3 and Ux4 sockets be populated with NEC2505  
optical isolation integrated circuits. The IOM-1964 is shipped with a default configuration of banks 2-  
7 configured as inputs. The output IC sockets Ux1 and Ux2 must be empty. The input IC’s are labeled  
Ux3 and Ux4. For example, in bank 0 the IC’s are U03 and U04, bank 1 input IC’s are labeled U13  
and U14, and so on. Also, the resistor pack RPx4 must be inserted into the bank to finish the input  
configuration.  
DMC-3425  
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Input Circuit  
I/OCn  
1/8 RPx4  
1/4 NEC2505  
To DMC-3425* I/O  
DMC-3425* GND  
x = bank number 0-7  
n = input number 17-80  
I/On  
Figure A-5 – Input Circuit  
Connections to this optically isolated input circuit are done in a sinking or sourcing configuration,  
referring to the direction of current. Some example circuits are shown below:  
Sinking  
Sourcing  
I/OCn  
I/On  
+5V  
I/OCn  
I/On  
GND  
+5V  
GND  
Current  
Current  
There is one I/OC connection for each bank of eight inputs. Whether the input is connected as sinking  
or sourcing, when the switch is open no current flows and the digital input function @IN[n] returns 1.  
This is because of an internal pull up resistor on the DB-14064. When the switch is closed in either  
circuit, current flows. This pulls the input on the DB-14064 to ground, and the digital input function  
@IN[n] returns 0. Note that the external +5V in the circuits above is for example only. The inputs are  
optically isolated and can accept a range of input voltages from 4 to 28 VDC.  
Active outputs are connected to the optically isolated inputs in a similar fashion with respect to current.  
An NPN output is connected in a sinking configuration, and a PNP output is connected in the sourcing  
configuration.  
Sinking  
Sourcing  
I/OCn  
I/On  
I/OCn  
I/On  
+5V  
GND  
PNP  
output  
NPN  
output  
Current  
Current  
Whether connected in a sinking or sourcing circuit, only two connections are needed in each case.  
When the NPN output is 5 volts, then no current flows and the input reads 1. When the NPN output  
goes to 0 volts, then it sinks current and the input reads 0. The PNP output works in a similar fashion,  
but the voltages are reversed i.e. 5 volts on the PNP output sources current into the digital input and the  
input reads 0. As before, the 5 volt is an example, the I/OC can accept between 4-28 volts DC.  
186 • Appendices  
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Note that the current through the digital input should be kept below 3 mA in order to minimize the  
power dissipated in the resistor pack. This will help prevent circuit failures. The resistor pack RPx4 is  
standard 1.5k ohm that is suitable for power supply voltages up to 5.5 VDC. However, use of 24 VDC  
for example would require a higher resistance such as a 10k ohm resistor pack.  
High Power Digital Outputs  
The first two banks on the IOM-1964, banks 0 and 1, have high current output drive capability. The  
IOM-1964 is shipped with banks 0 and 1 configured as outputs. Each output can drive up to 500mA of  
continuous current. Configuring a bank of I/O as outputs is done by inserting the optical isolator  
NEC2505 IC’s into the Ux1 and Ux2 sockets. The digital input IC’s Ux3 and Ux4 are removed. The  
resistor packs RPx2 and RPx3 are inserted, and the input resistor pack RPx4 is removed.  
Each bank of eight outputs shares one I/OC connection, which is connected to a DC power supply  
between 4 and 28 VDC. A 10k ohm resistor pack should be used for RPx3. Here is a circuit diagram:  
I/OCn  
To DMC-3425 +5V  
1/4 NEC2505  
1/8 RPx2  
IR6210  
VCC  
OUT  
GND  
IN  
PWROUTn  
DMC-3425 I/O  
1/8 RPx3  
I/On  
OUTCn  
Figure A-6  
The load is connected between the power output and output common. The I/O connection is for test  
purposes, and would not normally be connected. An external power supply is connected to the I/OC  
and OUTC terminals, which isolates the circuitry of the DMC-3425 controller/DB-14064 daughter  
board from the output circuit.  
I/OCn  
VISO  
PWROUTn  
External  
Isolated  
Power  
L
o
a
d
Supply  
GNDISO  
OUTCn  
Figure A-7  
DMC-3425  
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The power outputs must be connected in a driving configuration as shown on the previous page. Here  
are the voltage outputs to expect after the Clear Bit and Set Bit commands are given:  
Output Command  
Result  
CBn  
SBn  
Vpwr = Viso  
Vpwr = GNDiso  
Standard Digital Outputs  
The I/O banks 2-7 can be configured as optically isolated digital outputs, however these banks do not  
have the high power capacity as in banks 0-1. In order to configure a bank as outputs, the optical  
isolator chips Ux1 and Ux2 are inserted, and the digital input isolator chips Ux3 and Ux4 are removed.  
The resistor packs RPx2 and RPx3 are inserted, and the input resistor pack RPx4 is removed.  
Each bank of eight outputs shares one I/OC connection, which is connected to a DC power supply  
between 4 and 28 VDC. The resistor pack RPx3 is optional, used either as a pull up resistor from the  
output transistor’s collector to the external supply connected to I/OC or the RPx3 is removed resulting  
in an open collector output. Figure A-8 is a schematic of the digital output circuit:  
Internal Pullup  
I/OCn  
1/8 RPx3  
To DMC-3425 +5V  
1/4 NEC2505  
1/8 RPx2  
I/On  
DMC-3425 I/O  
OUTCn  
Figure A-8 – Internal Pullup  
The resistor pack RPx3 limits the amount of current available to source, as well as affecting the low  
level voltage at the I/O output. The maximum sink current is 2mA regardless of RPx3 or I/OC voltage,  
determined by the NEC2505 optical isolator IC. The maximum source current is determined by  
dividing the external power supply voltage by the resistor value of RPx3.  
The high level voltage at the I/O output is equal to the external supply voltage at I/OC. However,  
when the output transistor is on and conducting current, the low level output voltage is determined by  
three factors. The external supply voltage, the resistor pack RPx3 value, and the current sinking limit  
of the NEC2505 all determine the low level voltage. The sink current available from the NEC2505 is  
between 0 and 2mA. Therefore, the maximum voltage drop across RPx3 is calculated by multiplying  
the 2mA maximum current times the resistor value of RPx3. For example, if a 10k ohm resistor pack  
is used for RPx3, then the maximum voltage drop is 20 volts. The digital output will never drop below  
the voltage at OUTC, however. Therefore a 10k ohm resistor pack will result in a low level voltage of  
.7 to 1.0 volts at the I/O output for an external supply voltage between 4 and 21 VDC. If a supply  
voltage greater than 21 VDC is used, a higher value resistor pack will be required.  
188 • Appendices  
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Output Command  
Result  
CBn  
SBn  
Vout = GNDiso  
Vout = Viso  
The resistor pack RPx3 is removed to provide open collector outputs. The same calculations for  
maximum source current and low level voltage applies as in the above circuit. The maximum sink  
current is determined by the NEC2505, and is approximately 2mA.  
Open Collector  
To DMC-3425 +5V  
1/4 NEC2505  
1/8 RPx2  
I/On  
DMC-3425 I/O  
OUTCn  
Figure A-9 – Open Collector  
Electrical Specifications  
I/O points, configurable as inputs or outputs in groups of 8  
Digital Inputs  
Maximum voltage: 28 VDC  
Minimum input voltage: 4 VDC  
Maximum input current: 3 mA  
High Power Digital Outputs  
Maximum external power supply voltage: 28 VDC  
Minimum external power supply voltage: 4 VDC  
Maximum source current, per output: 500mA  
Maximum sink current: sinking circuit inoperative  
Standard Digital Outputs  
Maximum external power supply voltage: 28 VDC  
Minimum external power supply voltage: 4 VDC  
Maximum source current: limited by pull up resistor value  
DMC-3425  
Appendices189  
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Maximum sink current: 2mA  
Relevant DMC Commands  
CO n  
Configures the 64 bits of extended I/O in 8 banks of 8 bits each.  
n = n2 + 2*n3 + 4*n4 + 8*n5 + 16*n6 + 32*n7 + 64*n8 + 128*n9  
where nx is a 1 or 0, 1 for outputs and 0 for inputs. The x is the bank number  
m = 8 standard digital outputs  
OP  
m,n,o,p,q  
n = extended I/O banks 0 & 1, outputs 17-32  
o = extended I/O banks 2 & 3, outputs 33-48  
p = extended I/O banks 4 & 5, outputs 49-64  
q = extended I/O banks 6 & 7, outputs 65-80  
SB n  
Sets the output bit to a logic 1, n is the number of the output from 1 to 80.  
Clears the output bit to a logic 0, n is the number of the output from 1 to 80.  
Sets the state of an output as 0 or 1, also able to use logical conditions.  
Returns the state of 8 digital inputs as binary converted to decimal, n is the bank  
number +2.  
CB n  
OB n,m  
TI n  
_TI n  
@IN[n]  
Operand (internal variable) that holds the same value as that returned by TI n.  
Function that returns state of individual input bit, n is number of the input from 1 to  
80.  
Screw Terminal Listing  
Rev A+B boards (orange) and Rev C boards (black) have the pinouts listed below.  
REV A+B  
REV C  
LABEL  
DESCRIPTION  
BANK  
TERMINAL #  
TERMINAL #  
1
GND  
Ground  
N/A  
2
2
5V  
5V DC out  
Ground  
N/A  
N/A  
N/A  
7
3
1
GND  
4
4
5V  
5V DC out  
I/O bit 80  
5
3
I/O80  
I/O79  
I/O78  
I/O77  
I/O76  
I/O75  
I/O74  
I/O73  
OUTC73-80  
I/OC73-80  
I/O72  
I/O71  
I/O70  
I/O69  
I/O68  
I/O67  
I/O66  
6
6
I/O bit 79  
7
7
5
I/O bit 78  
7
8
8
I/O bit 77  
7
9
7
I/O bit 76  
7
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
10  
9
I/O bit 75  
7
I/O bit 74  
7
12  
11  
14  
13  
16  
15  
18  
17  
20  
19  
I/O bit 73  
7
Out common for I/O 73-80  
I/O common for I/O 73-80  
I/O bit 72  
7
7
6
I/O bit 71  
6
I/O bit 70  
6
I/O bit 69  
6
I/O bit 68  
6
I/O bit 67  
6
I/O bit 66  
6
190 • Appendices  
DMC-3425  
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22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
35  
36  
37  
38  
39  
40  
41  
42  
43  
44  
45  
46  
47  
48  
49  
50  
51  
52  
53  
54  
55  
56  
57  
58  
59  
60  
61  
62  
63  
64  
65  
66  
22  
21  
24  
23  
26  
25  
28  
27  
30  
29  
32  
31  
34  
33  
36  
35  
38  
37  
40  
39  
42  
41  
44  
43  
46  
45  
48  
47  
50  
49  
52  
51  
54  
53  
56  
55  
58  
57  
60  
59  
62  
61  
64  
63  
66  
I/O65  
I/O bit 65  
6
6
6
5
5
5
5
5
5
5
5
5
5
4
4
4
4
4
4
4
4
4
4
3
3
3
3
3
3
3
3
3
3
2
2
2
2
2
2
2
2
2
2
1
1
OUTC65-72  
I/OC65-72  
I/O64  
Out common for I/O 65-72  
I/O common for I/O 65-72  
I/O bit 64  
I/O63  
I/O bit 63  
I/O62  
I/O bit 62  
I/O61  
I/O bit 61  
I/O60  
I/O bit 60  
I/O59  
I/O bit 59  
I/O58  
I/O bit 58  
I/O57  
I/O bit 57  
OUTC57-64  
I/OC57-64  
I/O56  
Out common for I/O 57-64  
I/O common for I/O 57-64  
I/O bit 56  
I/O55  
I/O bit 55  
I/O54  
I/O bit 54  
I/O53  
I/O bit 53  
I/O52  
I/O bit 52  
I/O51  
I/O bit 51  
I/O50  
I/O bit 50  
I/O49  
I/O bit 49  
OUTC49-56  
I/OC49-56  
I/O48  
Out common for I/O 49-56  
I/O common for I/O 49-56  
I/O bit 48  
I/O47  
I/O bit 47  
I/O46  
I/O bit 46  
I/O45  
I/O bit 45  
I/O44  
I/O bit 44  
I/O43  
I/O bit 43  
I/O42  
I/O bit 42  
I/O41  
I/O bit 41  
OUTC41-48  
I/OC41-48  
I/O40  
Out common for I/O 41-48  
I/O common for I/O 41-48  
I/O bit 40  
I/O39  
I/O bit 39  
I/O38  
I/O bit 38  
I/O37  
I/O bit 37  
I/O36  
I/O bit 36  
I/O35  
I/O bit 35  
I/O34  
I/O bit 34  
I/O33  
I/O bit 33  
OUTC33-40  
I/OC33-40  
I/O32  
Out common for I/O 33-40  
I/O common for I/O 33-40  
I/O bit 32  
I/O31  
I/O bit 31  
DMC-3425  
Appendices191  
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67  
68  
69  
70  
71  
72  
73  
74  
75  
76  
77  
78  
79  
80  
81  
82  
83  
84  
85  
86  
87  
88  
89  
90  
91  
92  
93  
94  
95  
96  
97  
98  
99  
100  
101  
102  
103  
104  
65  
68  
67  
70  
69  
72  
71  
74  
73  
76  
75  
78  
77  
80  
79  
82  
81  
84  
83  
86  
85  
88  
87  
90  
89  
92  
91  
94  
93  
96  
95  
98  
97  
100  
99  
102  
101  
104  
103  
I/O30  
I/O bit 30  
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
I/O29  
I/O bit 29  
I/O28  
I/O bit 28  
I/O27  
I/O bit 27  
I/O26  
I/O bit 26  
I/O25  
I/O bit 25  
OUTC25-32  
I/OC25-32  
OUTC25-32  
I/OC25-32  
PWROUT32  
PWROUT31  
PWROUT30  
PWROUT29  
PWROUT28  
PWROUT27  
PWROUT26  
PWROUT25  
I/O24  
Out common for I/O 25-32  
I/O common for I/O 25-32  
Out common for I/O 25-32  
I/O common for I/O 25-32  
Power output 32  
Power output 31  
Power output 30  
Power output 29  
Power output 28  
Power output 27  
Power output 26  
Power output 25  
I/O bit 24  
I/O23  
I/O bit 23  
I/O22  
I/O bit 22  
I/O21  
I/O bit 21  
I/O20  
I/O bit 20  
I/O19  
I/O bit 19  
I/O18  
I/O bit 18  
I/O17  
I/O bit 17  
OUTC17-24  
I/OC17-24  
OUTC17-24  
I/OC17-24  
PWROUT24  
PWROUT23  
PWROUT22  
PWROUT21  
PWROUT20  
PWROUT19  
PWROUT18  
PWROUT17  
GND  
Out common for I/O 17-24  
I/O common for I/O 17-24  
Out common for I/O 17-24  
I/O common for I/O 17-24  
Power output 24  
Power output 23  
Power output 22  
Power output 21  
Power output 20  
Power output 19  
Power output 18  
Power output 17  
Ground  
* Silkscreen on Rev A board is incorrect for these terminals.  
192 • Appendices  
DMC-3425  
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Coordinated Motion - Mathematical Analysis  
The terms of coordinated motion are best explained in terms of the vector motion. The vector velocity,  
Vs, which is also known as the feed rate, is the vector sum of the velocities along the A and B axes, Va  
and Vb.  
2
2
=
+
Vs  
Va Vb  
The vector distance is the integral of Vs, or the total distance traveled along the path. To illustrate this  
further, suppose that a string was placed along the path in the A-B plane. The length of that string  
represents the distance traveled by the vector motion.  
The vector velocity is specified independently of the path to allow continuous motion. The path is  
specified as a collection of segments. For the purpose of specifying the path, define a special A-B  
coordinate system whose origin is the starting point of the sequence. Each linear segment is specified  
by the A-B coordinate of the final point expressed in units of resolution, and each circular arc is  
defined by the arc radius, the starting angle, and the angular width of the arc. The zero angle  
corresponds to the positive direction of the A-axis and the CCW direction of rotation is positive.  
Angles are expressed in degrees, and the resolution is 1/256th of a degree. For example, the path  
shown in Fig. A-10 is specified by the instructions:  
VP  
CR  
VP  
0,10000  
10000, 180, -90  
20000, 20000  
B
C
D
2000  
1000  
B
A
A
1000  
2000  
DMC-3425  
Appendices193  
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Figure A-10 - X-Y Motion Path  
The first line describes the straight line vector segment between points A and B. The next segment is a  
circular arc, which starts at an angle of 180° and traverses -90°. Finally, the third line describes the  
linear segment between points C and D. Note that the total length of the motion consists of the  
segments:  
A-B  
Linear  
10000 units  
R Δθ 2π  
360  
B-C  
C-D  
Circular  
= 15708  
Linear  
Total  
10000  
35708 counts  
In general, the length of each linear segment is  
Lk = Xk 2 + Yk 2  
Where Xk and Yk are the changes in A and B positions along the linear segment. The length of the  
circular arc is  
L
k
= Rk ΔΘk 2π 360  
The total travel distance is given by  
n
D =  
L
k
k=1  
The velocity profile may be specified independently in terms of the vector velocity and acceleration.  
For example, the velocity profile corresponding to the path of Fig. A-10 may be specified in terms of  
the vector speed and acceleration.  
VS  
100000  
VA  
2000000  
The resulting vector velocity is shown in Fig. A-11.  
Velocity  
10000  
time (s)  
Ta  
0.05  
Ts  
0.357  
Ta  
0.407  
Figure A-11 - Vector Velocity Profile  
The acceleration time, T , is given by  
a
194 • Appendices  
DMC-3425  
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VS  
100000  
T
a
=
=
= 0.05s  
VA 2000000  
The slew time, Ts, is given by  
D
35708  
-
s
=
a
=
=
T
T
0.05 0.307s  
VS  
100000  
The total motion time, Tt, is given by  
D
T
t
=
+ Ta = 0.407s  
VS  
The velocities along the A and B axes are such that the direction of motion follows the specified path,  
yet the vector velocity fits the vector speed and acceleration requirements.  
For example, the velocities along the A and B axes for the path shown in Fig. A-10 are given in Fig. A-  
12.  
Fig. A-12(a) shows the vector velocity. It also indicates the position point along the path starting at A  
and ending at D. Between the points A and B, the motion is along the B axis. Therefore,  
Vb = Vs  
and  
Va = 0  
Between the points B and C, the velocities vary gradually and finally, between the points C and D, the  
motion is in the X direction.  
B
C
(a)  
(b)  
(c)  
A
D
time  
Figure A-12 - Vector and Axes Velocities  
DMC-3425  
Appendices195  
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List of Other Publications  
"Step by Step Design of Motion Control Systems"  
by Dr. Jacob Tal  
"Motion Control Applications"  
by Dr. Jacob Tal  
"Motion Control by Microprocessors"  
by Dr. Jacob Tal  
Training Seminars  
Galil, a leader in motion control with over 250,000 controllers working worldwide, has a proud  
reputation for anticipating and setting the trends in motion control. Galil understands your need to  
keep abreast with these trends in order to remain resourceful and competitive. Through a series of  
seminars and workshops held over the past 15 years, Galil has actively shared their market insights in a  
no-nonsense way for a world of engineers on the move. In fact, over 10,000 engineers have attended  
Galil seminars. The tradition continues with three different seminars, each designed for your particular  
skillset-from beginner to the most advanced.  
MOTION CONTROL MADE EASY  
WHO SHOULD ATTEND  
Those who need a basic introduction or refresher on how to successfully implement servo motion  
control systems.  
TIME: 4 hours (8:30 am-12:30 pm)  
ADVANCED MOTION CONTROL  
WHO SHOULD ATTEND  
Those who consider themselves a "servo specialist" and require an in-depth knowledge of motion  
control systems to ensure outstanding controller performance. Also, prior completion of "Motion  
Control Made Easy" or equivalent is required. Analysis and design tools as well as several design  
examples will be provided.  
TIME: 8 hours (8:00 am-5:00 pm)  
PRODUCT WORKSHOP  
WHO SHOULD ATTEND  
Current users of Galil motion controllers. Conducted at Galil's headquarters in Rocklin, CA, students  
will gain detailed understanding about connecting systems elements, system tuning and motion  
programming. This is a "hands-on" seminar and students can test their application on actual hardware  
and review it with Galil specialists.  
TIME: Two days (8:30 am-5:00 pm)  
196 • Appendices  
DMC-3425  
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Contacting Us  
Galil Motion Control  
3750 Atherton Road  
Rocklin, CA 95765  
Phone: 916-626-0101  
Fax: 916-626-0102  
Internet address: [email protected]  
URL: www.galilmc.com  
DMC-3425  
Appendices197  
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WARRANTY  
All products manufactured by Galil Motion Control are warranted against defects in materials and  
workmanship. The warranty period for controller boards is 1 year. The warranty period for all other  
products is 180 days.  
In the event of any defects in materials or workmanship, Galil Motion Control will, at its sole option,  
repair or replace the defective product covered by this warranty without charge. To obtain warranty  
service, the defective product must be returned within 30 days of the expiration of the applicable  
warranty period to Galil Motion Control, properly packaged and with transportation and insurance  
prepaid. We will reship at our expense only to destinations in the United States.  
Any defect in materials or workmanship determined by Galil Motion Control to be attributable to  
customer alteration, modification, negligence or misuse is not covered by this warranty.  
EXCEPT AS SET FORTH ABOVE, GALIL MOTION CONTROL WILL MAKE NO  
WARRANTIES EITHER EXPRESSED OR IMPLIED, WITH RESPECT TO SUCH PRODUCTS,  
AND SHALL NOT BE LIABLE OR RESPONSIBLE FOR ANY INCIDENTAL OR  
CONSEQUENTIAL DAMAGES.  
COPYRIGHT (3-97)  
The software code contained in this Galil product is protected by copyright and must not be reproduced  
or disassembled in any form without prior written consent of Galil Motion Control, Inc.  
198 • Appendices  
DMC-3425  
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Index  
64 Extended I/O of the DMC-3425 Contoller, 179  
Abort, 73, 79, 151, 153, 171  
Off-On-Error, 18, 39, 151, 153  
Stop Motion, 74, 79, 125, 154  
Absolute Position, 69–70, 116–17, 121  
Absolute Value, 84, 121, 129, 152  
Acceleration, 118, 140, 143–47, 194–95  
Address, 133–34, 197  
Circular Interpolation, 78–80, 133, 146–47  
Clear Bit, 140  
Clear Sequence, 73, 75, 79, 80  
Clock, 132  
CMDERR, 110, 124, 126  
Code, 131, 134–35, 145–47, 148–49  
Command  
Syntax, 59–60  
Jumpers, 43  
Ampflier Gain, 5  
Amplifier  
Command Summary, 65, 70, 72, 75, 80, 132, 134  
Commanded Position, 70–71, 82, 125, 134, 143, 157–  
59  
AMP-1460, 8  
Communication, 4, 8  
Baud Rate, 15, 43  
Handshake, 44  
Amplifier Enable, 39, 151  
Amplifier Gain, 161, 165, 168  
Amplifiers, 8  
Serial Ports, 12  
Connections, 175  
Analog Input, 73, 129–31, 132, 135, 142–43, 149  
Analysis  
Conditional jump, 107, 115, 117–21, 142  
Configuration  
Jumper, 156  
SDK, 27, 108  
Arithmetic Functions, 107, 120, 128, 130, 140  
Arm Latch, 105  
Array, 4, 77, 91–93, 107, 113, 120, 128, 131–39, 140,  
172  
Contour Mode, 89–94  
Control Filter  
Damping, 27, 156, 160  
Gain, 135  
Integrator, 27, 160  
Automatic Subroutine, 123, 124  
CMDERR, 110, 124, 126  
LIMSWI, 37, 110, 123–24, 152–54  
MCTIME, 110, 116, 124, 125  
POSERR, 110, 123–24, 152–53  
Auxiliary Encoder, 98–97  
Dual Encoder, 64, 134  
Backlash Compensation  
Dual Loop, 98–97  
Baud Rate, 15, 43  
Proportional Gain, 27, 160  
Coordinated Motion, 60, 67–68, 78–80  
Circular, 78–80, 133, 146–47  
Contour Mode, 89–94  
Ecam, 84–85, 87  
Electronic Cam, 67–68, 83, 86  
Electronic Gearing, 67–68, 82–83  
Gearing, 67–68, 82–83  
Linear Interpolation, 68, 73–75, 77, 89  
Cosine, 69, 127–29, 133  
Cycle Time  
Begin Motion, 109–12, 117–18, 131, 135, 140, 142  
Binary, 59, 62  
Clock, 132  
Bit-Wise, 120, 127  
Burn  
EEPROM, 4  
Capture Data  
DAC, 160, 164–66, 168  
Damping, 27, 156, 160  
Data Capture, 133–34  
Data Output  
Record, 91, 93, 132, 134  
Circle, 146–47  
Set Bit, 140  
Debugging, 112  
DMC-3425  
Index199  
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Differential Encoder, 19, 21, 156  
Digital Filter, 59, 164–65, 167–69  
Gain, 8  
Digital Input, 39, 129, 141  
Digital Output, 129, 140  
Clear Bit, 140  
Gear Ratio, 82  
Gearing, 67–68, 82–83  
Halt, 74, 112–16, 117–19  
Abort, 73, 79, 151, 153, 171  
Off-On-Error, 18, 39, 151, 153  
Stop Motion, 74, 79, 125, 154  
Hardware, 37, 43, 140, 151  
Address, 133–34, 197  
Amplifier Enable, 39, 151  
Clear Bit, 140  
Dip Switch  
Address, 133–34, 197  
Download, 59, 107, 133  
Dual Encoder, 64, 134  
Dual Loop, 98–97  
Jumper, 156  
Dual Loop, 98–97  
Ecam, 84–85, 87  
Electronic Cam, 67–68, 83, 86  
Edit Mode, 113  
Offset Adjustment, 155  
Output of Data, 135  
Set Bit, 140  
TTL, 6, 39, 151  
Editor, 34, 108  
EEPROM, 4  
Home Input, 38, 101, 132  
Homing, 38, 101  
Electronic Cam, 67–68, 83, 86  
Electronic Gearing, 67–68, 82–83  
Ellipse Scale, 80  
Find Edge, 38, 101  
I/O  
Amplifier Enable, 39, 151  
Analog Input, 73  
Enable  
Amplifer Enable, 39, 151  
Encoder  
Clear Bit, 140  
Digital Input, 39, 129, 141  
Digital Output, 129, 140  
Home Input, 38, 101, 132  
Output of Data, 135  
Set Bit, 140  
Auxiliary Encoder, 98–97  
Differential, 19, 21, 156  
Dual Encoder, 64, 134  
Index Pulse, 19, 38, 101  
Quadrature, 6, 140, 145, 152, 163  
Encoders  
TTL, 6, 39, 151  
ICB-1460, 8  
Index, 174  
Quadrature, 174  
ICM-1100, 17, 18, 39, 151  
Independent Motion  
Jog, 72, 82, 88, 105, 117–18, 131, 149, 153  
Index, 174  
Index Pulse, 19, 38, 101  
ININT, 110, 124–25, 142  
Input  
Error Code, 131, 134–35, 145–47, 148–49  
Error Handling, 37, 110, 123–24, 152–54  
Error Limit, 18, 20, 39, 151–53  
Off-On-Error, 18, 39, 151, 153  
Example  
Wire Cutter, 145  
Analog, 73  
Execute Program, 34  
Feedrate, 75, 79, 80, 118, 146–47  
Filter Parameter  
Input Interrupt, 110, 117, 142  
ININT, 110, 124–25, 142  
Inputs  
Damping, 27, 156, 160  
Gain, 135  
Analog, 129–31, 132, 135, 142–43, 149  
Index, 174  
Integrator, 27, 160  
PID, 21, 160, 170  
Interconnect Module, 175  
Installation, 8, 155  
Proportional Gain, 27, 160  
Stability, 155–56, 160, 166  
Find Edge, 38, 101  
Formatting, 136, 137–39  
Variable, 35  
Integrator, 27, 160  
Interconnect Board, 8  
Interconnect Module, 175  
ICM-1100, 18, 39, 151  
Interface  
Frequency, 6, 166–68  
Function, 38–39, 59, 74, 91–92, 104, 107, 111–16, 117,  
120, 127–32, 135–37  
Functions  
Arithmetic, 107, 120, 128, 130, 140  
Gain, 8, 135  
Terminal, 59  
Internal Variable, 120, 130  
Interrogation, 27, 64, 75, 81, 135, 137  
Interrupt, 110–12, 117, 123–25, 142, 175  
Invert, 156  
Jog, 72, 82, 88, 105, 117–18, 131, 149, 153  
Joystick, 73, 131, 148–49  
Proportional, 27, 160  
200 • Index  
DMC-3425  
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Jumper, 156  
Operand  
Jumpers, 43  
Keyword, 120, 128, 130, 131–32  
TIME, 132–33  
Label, 73–74, 78, 87, 94, 102, 105, 107–14, 116–25,  
131, 137, 140–43, 147, 149, 153  
LIMSWI, 152–54  
Internal Variable, 120, 130  
Operators  
Bit-Wise, 120, 127  
Optoisolation  
Home Input, 38, 101, 132  
Output  
POSERR, 152–53  
Special Label, 110, 154  
Latch, 64, 104  
Arm Latch, 105  
Data Capture, 133–34  
Amplifier Enable, 39, 151  
ICM-1100, 18, 39  
Motor Command, 21, 165  
Output of Data, 135  
Clear Bit, 140  
Position Capture, 104  
Set Bit, 140  
Record, 91, 93, 132, 134  
Teach, 93  
Limit  
Outputs  
Interconnect Module, 175  
PID, 21, 160, 170  
Torque Limit, 20  
Play Back, 135  
Limit Switch, 37–38, 110–12, 124, 132, 152–54, 156  
LIMSWI, 37, 110, 123–24, 152–54  
Linear Interpolation, 68, 73–75, 77, 89  
Clear Sequence, 73, 75, 79, 80  
Logical Operator, 119  
POSERR, 110, 123–24, 152–53  
Position Error, 110, 124, 131, 133–34, 143  
Position Capture, 104  
Latch, 64, 104  
Teach, 93  
Masking  
Bit-Wise, 120, 127  
Position Error, 18, 39, 110, 124, 131, 133–34, 143,  
151–53, 156, 159  
Math Function  
Absolute Value, 84, 121, 129, 152  
Bit-Wise, 120, 127  
Cosine, 69, 127–29, 133  
Logical Operator, 119  
Sine, 69, 87, 129  
Mathematical Expression, 120, 127, 129  
MCTIME, 110, 116, 124, 125  
Memory, 34, 59, 92, 107, 113, 119, 124, 131, 133  
Array, 4, 77, 91–93, 107, 113, 120, 128, 131–39, 140,  
172  
POSERR, 110, 123–24  
Position Follow, 142–43  
Position Latch, 175  
Position Limit, 152  
Program Flow, 109, 115  
Interrupt, 110–12, 117, 123–25, 142  
Stack, 123, 126, 142  
Programmable, 130–31, 140, 149, 152  
EEPROM, 4  
Programming  
Halt, 74, 112–16, 117–19  
Proportional Gain, 27, 160  
Protection  
Download, 59, 107, 133  
Upload, 108  
Message, 78, 102, 113, 124–25, 128, 135–36, 142, 153–  
54  
Error Limit, 18, 20, 39, 151–53  
Torque Limit, 20  
Modelling, 157, 160–61, 165  
Motion Complete  
MCTIME, 110, 116, 124, 125  
Motion Smoothing, 100  
S-Curve, 74, 100  
PWM, 5, 173–74, 173–74  
Quadrature, 6, 140, 145, 152, 163, 174  
Quit  
Abort, 73, 79, 151, 153, 171  
Stop Motion, 74, 79, 125, 154  
Record, 91, 93, 132, 134  
Latch, 64, 104  
Motor Command, 21, 165  
Moving  
Acceleration, 118, 140, 143–47, 194–95  
Begin Motion, 109–12, 117–18, 131, 135, 140, 142  
Circular, 78–80, 133, 146–47  
Slew Speed, 175  
Position Capture, 104  
Teach, 93  
Register, 131  
Reset, 37, 40, 119, 151, 153, 172, 173  
SB  
Multitasking, 111  
Halt, 74, 112–16, 117–19  
OE  
Set Bit, 140  
Scaling  
Off-On-Error, 151, 153  
Off-On-Error, 18, 39, 151, 153  
Offset Adjustment, 155  
Ellipse Scale, 80  
S-Curve, 74, 100  
Motion Smoothing, 100  
DMC-3425  
Index201  
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SDK, 27, 108  
Tell Code, 63  
Selecting Address, 133–34, 197  
Serial Port, 12  
Servo Design Kit, 8  
Tell Error, 64  
Position Error, 110, 124, 131, 133–34, 143  
Tell Position, 64  
SDK, 27, 108  
Tell Torque, 64  
Set Bit, 140  
Sine, 69, 87, 129  
Terminal, 37, 59, 108, 130, 136  
Theory, 27, 157  
Single-Ended, 6, 19, 21  
Slew, 69, 101, 116, 118, 145  
Slew Speed, 175  
Smoothing, 74, 75, 79, 80, 95–101  
Software  
Damping, 27, 156, 160  
Digital Filter, 59, 164–65, 167–69  
Modelling, 157, 160–61, 165  
PID, 21, 160, 170  
Stability, 155–56, 160, 166  
Time  
SDK, 27, 108  
Terminal, 59  
Clock, 132  
Special Label, 110, 154  
Specification, 74–75, 79  
Stability, 155–56, 160, 166  
Stack, 123, 126, 142  
Zero Stack, 126, 142  
Status, 59, 64, 75, 113–15, 131, 134  
Interrogation, 27, 64, 75, 81, 135, 137  
Stop Code, 64, 134, 156  
Tell Code, 63  
TIME, 132–33  
Time Interval, 89–91, 93, 133  
Timeout, 110, 116, 124, 125  
MCTIME, 110, 116, 124, 125  
Torque Limit, 20  
Trigger, 107, 115, 159  
Trippoint, 70, 74–75, 80, 91, 116, 122, 123  
Trippoints, 34  
Troubleshooting, 155  
TTL, 6, 39, 151  
Step Motor  
KS, Smoothing, 74, 75, 79, 80, 95–101  
Step Motors, 8–11  
Tuning  
SDK, 27, 108  
PWM, 173–74, 173–74  
Stop  
Stability, 155–56, 160, 166  
Upload, 108  
Abort, 73, 79, 151, 153, 171  
Stop Code, 64, 131, 134–35, 134, 145–47, 148–49, 156  
Stop Motion, 74, 79, 125, 154  
Stop Motion or Program, 175  
Subroutine, 37, 78, 110, 119–25, 142, 152–53, 175  
Automatic Subroutine, 123, 124  
Synchronization, 6, 83  
Syntax, 59–60  
Teach, 93  
Data Capture, 133–34  
Latch, 64, 104  
Play-Back, 135  
Position Capture, 104  
Record, 91, 93, 132, 134  
User Unit, 140  
Variable, 35  
Internal, 120, 130  
Vector Acceleration, 75–76, 80, 147  
Vector Deceleration, 75–76, 80  
Vector Mode  
Circle, 146–47  
Circular Interpolation, 78–80, 133, 146–47  
Clear Sequence, 73, 75, 79, 80  
Ellipse Scale, 80  
Feedrate, 75, 79, 80, 118, 146–47  
Vector Speed, 73–77, 80, 118, 147  
Wire Cutter, 145  
Zero Stack, 126, 142  
202 • Index  
DMC-3425  
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