Application Note #5436 Introduction Setup - Galil

Application Note #5436 

Connecting a Galil Optima Series controller to an Advanced Digital 

“Simple Servo” model SS-108AC 

Introduction 

This application note details the steps necessary to physically connect a DMC 

2100 (or any Galil Optima Series controller) to a Simple Servo SS-108AC “smart” 

digital amplifier. 

Parts List: 

Simple Servo SS108 Digital Servo Amplifier 

10’ Encoder Cable (supplied by Advanced Digital) 

10’ Motor Power Cable (supplied by Advanced Digital) 

Servo Motor (supplied by Advanced Digital) 

MotionView software CD-ROM 

Straight-thru serial cable, 9 pin 

Custom signal splitter OR Advanced Digital splitter, part no. CL15-00-DD-CMCM 

Custom cable for Molex connector to ICM-1900 

Galil DMC-21x0 Motion Controller 

ICM-1900-LAEN (Low Amp Enable) Interconnect Module 

Cable-100-1M 

Ethernet cables and hub OR Ethernet crossover cable 

Windows Servo Design Kit (WSDK) 

Windows-based PC with a COM port 

Setup 

1. Connecting the Simple Servo digital drive to the Simple Servo motor is 

seamless. Connect the motor wire to the correct phases. 

2. Connect encoder inputs. If the unit was to be run as a standalone, the 

user would connect the encoder cable to the provided D-sub. 

Unfortunately, both the Galil and the SS (Simple Servo drive) need to 

read the encoder feedback. This results in the need for a custom cable 

that “splits” the encoder and Hall-Effect signals and sends them to both 

1 

Galil Motion Control, Inc. • 3750 Atherton Road • Rocklin, CA 95765 USA • 800-377-6329 • Ph: 916-626-0101 • Fax: 916-626-0102 • www.galilmc.com

devices. Figure (1) shows a picture of the cable that was built at Galil. 

Figure (2) shows the wire pinouts. 

Figure (1)- Picture of Signal Splitter 

Figure (2)- Signal Splitter Schematic 

Advanced Digital can now provide a manufactured signal splitter. This is a 

cleaner solution than the handmade version shown above. 

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Figure (3)- Manufactured Signal Splitter 

3. Connect Enable/Motor Command cable from ICM 1900 to SS drive. This 

requires a cable with a 16-pin Molex connector on one end and flying 

leads on the other. Figure (3) shows the Enable/Motor Command cable 

attached to the ICM-1900. 

3 


Figure (4)- Enable/Motor Command Connector Cable 

4. Connect the SS drive to the PC using the serial cable. 

5. Install the MotionView software as per the instructions. 

6. Install WSDK if not already done. 

7. Connect to the DMC-2100 via Ethernet if not already done. 

8. Make the appropriate connections from the ICM-1900 to the SS drive. 

Figure (4) shows a general schematic. Figure (5) shows a photo of the 

entire system. Note that only the bare minimum connections are shown. 

Specific systems may require shielding, external sensors, or shared logic 

circuits. 

4 


DS2 

DS1 

DS1 

SS108 

CONNECTIONS 

N/C1 

TX2 

RX3 

NC4 

NC5 

NC6 

NC7 

NC8 

RES 

ENC A+1 

ENC A-2 

ENC B+3 

ENC B-4 

ENC Z+5 

ENC Z-6 

ENC COM 7 

ENC SHLD 8 

ENC PWR (+5) 9 

HALL A- 10 

HALL A+ 11 

HALL B+ 12 

HALL C+ 13 

HALL B- 14 

HALL C- 15 

TB2 +10 VDC 1 

ANALOG COM 2 

-10VDC 3 

AN REF IN+ 4 

AN REF IN- 5 

SHIELD 6 

AN OUT-1 7 

AN OUT-2 8 

ENABLE IN 9 

+5VDC OUT 10 

LOGIC COM 11 

SPARE 12 

SPARE 13 

SPARE 14 

SPARE 15 

FAULT OUTPUT 16 

DIAGNOSTIC 

LED 

EARTH GROUND SCREW 

TB1 

MOTOR OUTPUT PHASE U 

MOTOR OUTPUT PHASE V 

MOTOR OUTPUT PHASE W 

5 

110V AC IN 

TO 

CONTROLLER 

THREE PHASE BRUSHLESS MOTOR 

Figure (5)- ICM Wiring Schematic 

TO COM PORT FOR MOTIONVIEW 

ICM 1900/ICM 2900 

GND 

RP1 U6 

Galil Motion Control, Inc. • 3750 Atherton Road • Rocklin, CA 95765 USA • 800-377-6329 • Ph: 916-626-0101 • Fax: 916-626-0102 • www.galilmc.com 

7406 

MOCMD 

AMPEN 

GND 

GND 

+MAX 

-MAX 

+MBX 

-MBX 

+INX 

-INX 

LAEN CHIP (7406)

Figure (6)- System Layout 

9. Connect to the controller using WSDK. 

10. Set appropriate error conditions, such as Off-On-Error, Error Limit, 

Torque Limits, and low values for PID. Turn the motor off using MO. 

11. Power up the SS-108. 

12. Check for proper encoder feedback in both directions by rotating the 

motor shaft back and forth while issuing ‘TP’. 

13. With the motor off, the Simple Servo diagnostic LED should be blinking 

green. 

14. Connect to the SS using MotionView. You need to go on-line and 

connect using COM1. Note that using a Simple Servo motor, the amp 

will automatically configure parameters. 

15. Return to WSDK. Issue a SH. The diagnostic LED on the SS-108 

should turn solid green. If it does not, or a red LED state occurs, ensure 

the proper Hall-Effect transitions, check for overspeed conditions, and 

confirm proper motor phasing. 

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16. Check the motor shaft for servo. WARNING: Axis is live and can run 

away if not properly tuned. Use caution. 

17. If the axis maintains position, tune the axis in either Torque or Velocity 

mode. 

Tuning 

Torque Mode 

Torque mode is used when the system motion can be best described as point-topoint. 

The critical aspects of the motion are fastest settling time, minimum 

overshoot, and/or accurate profiling. Te enable torque mode, choose Torque 

mode in the MotionView software. Choose an appropriate amplifier gain, and 

tune the axis using WSDK. 

Several general tests were performed in torque mode. The following data 

represents results from using a SS-108 amplifier with a Simple Servo 100 Watt 

brushless servo, part number 524-20-516. Any other system will result in 

significantly different gains and bandwidths. 

No Load Current 

Test procedure: Tune the PID, FA, FV, and OF to within system tolerance. 

Issue JG commands to a constant velocity, and measure the average torque. 

Data: 

Speed (RPM) JG (cts/sec) TT (avg) 

60 8,000 0.15 

600 80,000 0.2 

1200 160,000 0.27 

3000 400,000 0.25 

4500 600,000 0.5 

-60 -8,000 -0.15 

-600 -80,000 -0.12 

-1200 -160,000 -0.25 

-3000 -400,000 -0.45 

-4500 -600,000 -0.3 

Analysis: The System required equivalent torque in the positive and negative 

direction. The amplifier exhibited no undesirable increases in no-load current 

throughout the speed range. 

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Smooth Motion 

Test procedure: Vary the PID and the Jog speed and query the min/max error 

Data: 

Speed (Cts/Sec) KP KD Min Error Max Error 

60,000 10 100 10 22 

60,000 10 150 10 19 

60,000 10 200 8 21 

60,000 20 200 1 15 

60,000 33 150 0 9 

60,000 5 80 24 35 

160,000 5 80 37 43 

-160,000 5 80 -35 -40 

400,000 5 80 50 62 

200,000 5 80 37 42 

300,000 5 80 47 51 

350,000 5 80 49 55 

450,000 5 80 50 53 

600,000 5 80 57 60 

-600,000 5 80 -45 -49 

Analysis: The first five data points show the effect of increasing KP and KD on 

the error range. Once adequately tuned, the remaining data points show a stable 

error range, neither increasing nor decreasing dramatically throughout the speed 

range. 

System frequency response 

Test procedure: Run the ‘System Response on Closed Loop’ test in WSDK. 

Vary the PID values and determine system bandwidth and maximum system 

gain. 

Data: 

KP KD KI Bandwidth (Hz) Max Gain 

5 80 0 90 1.3 

5 150 0 120 1.44 

12 150 0 100 1.5 

Analysis: A no-load system frequency response running in torque mode results 

in a bandwidth of up to 120 Hertz with a maximum gain of 1.44. A loaded system 

will produce drastically different results. 

8 


Point-to-point settling time 

Test procedure: Run the Point-to-Point tuning test in WSDK, and determine best 

settling time. 

Data: 

KP KD KI Settling time, Samples 

5 50 0 18 

5 50 1 13 

5 100 2 11 

15 50 0 13 

15 50 1 10 

15 100 2 10 

25 50 0 18 

25 50 1 12 

25 100 2 8 

Analysis: With TM (time constant) set to the default 1000 µsec, KP 25, KD 100, 

KI 2 resulted in a minimum settling time of 8 milliseconds. 

Velocity Mode 

Velocity mode is most often used if the system is typically commanded to slew at 

a constant RPM. In this mode, the user must choose Velocity Mode from the 

MotionView software. Nominal P gain and I gain must be set. Note that gains 

are cumulative. Any proportional gains on the controller are multiplied by the 

amplifier gains. For the tests performed here, the P gain was set to 400 and the I 

gain was set to 0. 

No load current 

Test Procedure: Set KP=19, KD=0, and KI=0. Jog at various speeds and record 

the average torque. 

Data: 

JG (cts/sec) TT 

-100,000 -1.56 

-60,000 -1.22 

-30,000 -0.78 

-10,000 -0.34 

-1,000 -0.06 

1,000 0.10 

10,000 0.35 

30,000 0.81 

60,000 1.30 

100,000 1.60 

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Analysis: Applied torque is essentially linear throughout the specified velocity 

range. 

Motion smoothness 

Test procedure: Jog at 100,000 counts/sec and vary the amplifier P gain, and 

controller KP and KD. View the error range. 

Data: 

P Gain KP KD Min Error Max Error Error Range 

20 6 64 217 226 9 

100 6 25 202 209 7 

400 6 0 174 180 6 

400 8 0 174 180 7 

Analysis: By relying on the P Gain and minimizing the Galil velocity loop gain 

(KD), the range of error was reduced. Note that for constant jog moves, FV 

provides an open-loop voltage bias to eliminate the error caused by the back- 

EMF of the motor. To determine the necessary FV, jog the axis at the desired 

speed, and increment FV until the error range is within system specifications. 

Tuning 

Test procedure: Tune the axis using General Tuning, Point-to-Point, and Curve 

Follower methods in WSDK. 

Data: 

Tuning Method P Gain I Gain KP KD KI FV FA 

Point-Point 400 0 4 0 0.12 0 0 

Curve Follow 400 0 9 10 0.25 0 0 

General 400 0 5 10 0 0 25 

Analysis: A combination of high P Gain, no I Gain, and moderately low PID 

values coupled with modest FV and FA values, led to fast, reliable, stable system 

behavior. Note that any system will have any combination of values. These 

values are for reference only. 

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Conclusion 

The Simple Servo model SS-108 is an effective, mid-cost solution to numerous 

motion applications. Several strengths and weaknesses are listed below. 

Strengths 

¥ If the consumer is interfacing to a Simple Servo motor, the setup and 

configuration is instant. The Amplifier communicates with the motor and 

draws it’s parameters from a database. This database contains several 

other makes and models of brushless motors. 

¥ The MotionView software is easy to learn and navigate. Error conditions 

are stored in an easily accessed location. 

¥ Connections and pin-outs are fully labeled on the drive. 

¥ Customer support was courteous and well-informed. 

Weaknesses 

¥ The drive requires the user to either enter a model number held in a 

database or fully specify the motor/encoder/Hall Effect parameters. If 

these properties are not known, the drive will not function. A motor selftest 

would be most helpful. 

¥ As per the manufacturer specifications, the encoder feedback rate is 

limited to 3.0 MHz. Galil Optima Series controllers can handle up to 12.0 

MHz encoder feedback, so the consumer must choose encoder 

resolutions wisely. 

¥ The troubleshooting section of the manual is extremely limited. 

Setup and tuning is of average complexity. The amplifier gains appear linear 

throughout. The packaging and connections are well done with the exceptions 

mentioned above. Support from Advanced Digital was very good. In conclusion, 

the Simple Servo SS-108 coupled with a Simple Servo motor can provide reliable 

motion in both torque and velocity mode. 

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Application Note #5436 Introduction Setup - Galil

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