ABB PCI2 User Manual

Contents

1General Information

2Introduction

2.1 NextMove PCI-2 features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2.2 Receiving and inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2.2.1 Identifying the catalog number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

2.3 Units and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

3 Basic Installation

3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3.1.1 Location requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3.1.2 Other requirements for installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

3.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

3.2.1 Installing the NextMove PCI-2 card. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

4 Input / Output

4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4.2 100-pin edge connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4.2.1 100-pin edge connector pin assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

4.3 Analog I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

4.3.1 Analog inputs - X6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 4.3.2 Analog outputs (Demands) - X7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

4.4 Digital I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

4.4.1 Digital inputs - overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 4.4.2 Digital inputs - X1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 4.4.3 Digital inputs - X2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11 4.4.4 Digital inputs - X3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12 4.4.5 Digital outputs - overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 4.4.6 Digital outputs - X4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14 4.4.7 Digital outputs - X5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16

4.5 Other I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17

4.5.1 Encoder inputs - X12, X13, X14, X15, X16 . . . . . . . . . . . . . . . . . . . . . . . . . 4-17 4.5.2 Power - X9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19 4.5.3 Relay and CAN power - X8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 4.5.4 Stepper control outputs - X10, X11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 4.5.5 Emulator connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21

4.6 CAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

4.6.1 CANopen connector - X17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 4.6.2 CANopen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 4.6.3 Baldor CAN connector - X18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

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4.6.4 Baldor CAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-25 4.6.5 CAN wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-27

4.7 Reset states . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-28

4.7.1 System watchdog. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-28

4.8 Connection summary - minimum system wiring . . . . . . . . . . . . . .4-29

5 Operation

5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.1.1 Installing the driver software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1 5.1.2 Installing Mint WorkBench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

5.2 Mint Machine Center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-2

5.2.1 Starting MMC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-3

5.3 Mint WorkBench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-5

5.3.1 Help file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-6 5.3.2 Starting Mint WorkBench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-7

5.4 Configuring an axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10

5.4.1 Selecting the axis type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-10 5.4.2 Selecting a scale . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-11 5.4.3 Setting the drive enable output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-12 5.4.4 Testing the drive enable output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-13

5.5 Servo axis - testing and tuning . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14

5.5.1 Testing the demand output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-14 5.5.2 An introduction to closed loop control . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-15

5.6 Servo axis - tuning for current control . . . . . . . . . . . . . . . . . . . . . .5-18

5.6.1 Selecting servo loop gains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-18 5.6.2 Underdamped response. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-20 5.6.3 Overdamped response. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-21 5.6.4 Critically damped response . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-22

5.7 Servo axis - eliminating steady-state errors . . . . . . . . . . . . . . . . .5-23

5.8 Servo axis - tuning for velocity control. . . . . . . . . . . . . . . . . . . . . .5-24

5.8.1 Calculating KVELFF. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-24 5.8.2 Adjusting KPROP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-27

5.9 Stepper axis - testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-29

5.9.1 Testing the output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-29

5.10 Digital input/output configuration . . . . . . . . . . . . . . . . . . . . . . . . . .5-30

5.10.1 Digital input configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-30 5.10.2 Digital output configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-31

5.11 Saving setup information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-32

5.11.1 Loading saved information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-33

6 Troubleshooting

6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

6.1.1 Problem diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1 6.1.2 SupportMe feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-1

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6.2 NextMove PCI-2 indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6.2.1 Status LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 6.2.2 CAN LEDs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 6.2.3 Reset LED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

6.3 Problem solving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

6.3.1 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3 6.3.2 Motor control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

7 Specifications

7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

7.1.1 Input power and mechanical specifications. . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7.1.2 Analog inputs (X6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7.1.3 Analog outputs (X7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 7.1.4 Digital inputs (X1 & X2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 7.1.5 Digital inputs (X3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 7.1.6 Digital outputs (X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 7.1.7 Relay output (X8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3 7.1.8 Encoder inputs (X12 - X16). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 7.1.9 Stepper control outputs (X10 & X11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 7.1.10 CANopen interface (X17) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 7.1.11 Baldor CAN interface (X18). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 7.1.12 Environmental . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

Appendices

A Accessories

A.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1

A.1.1 NextMove PCI-2 breakout module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 A.1.2 NextMove PC system adapter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2 A.1.3 Encoder splitter/buffer board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2 A.1.4 Spares. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2 A.1.5 Feedback cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3 A.1.6 Baldor CAN nodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4 A.1.7 HMI panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5 A.1.8 Mint NC (CAD to motion software) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5

B Mint Keyword Summary

B.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

B.1.1 Keyword listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1

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Contents iii

iv Contents

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General Information 1

LT0226A05EN Copyright ABB (c) 2012. All rights reserved.

This manual is copyrighted and all rights are reserved. This document or attached software may not, in whole or in part, be copied or reproduced in any form without the prior written consent of ABB. ABB makes no representations or warranties with respect to the contents hereof and specifically disclaims any implied warranties of fitness for any particular purpose. The information in this document is subject to change without notice. ABB assumes no responsibility for any errors that may appear in this document.

Mint™ is a registered trademark of Baldor, a member of the ABB group.

Windows XP, Windows Vista and Windows 7 are registered trademarks of the Microsoft Corporation.

ABB Ltd

Motion Control

6 Bristol Distribution Park

Hawkley Drive
Bristol, BS32 0BF
Telephone:	[phone]
Fax:	[phone]
E-mail:	[e-mail]
Web site:	www.abbmotion.com

See rear cover for other international offices.

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General Information 1-1

Safety Notice

Only qualified personnel should attempt to start-up, program or troubleshoot this equipment. This equipment may be connected to other machines that have rotating parts or parts that are controlled by this equipment. Improper use can cause serious or fatal injury.

	Precautions
!	Do not touch any circuit board, power device or electrical connection before you first
	ensure that no high voltage is present at this equipment or other equipment to which it is
WARNING	connected. Electrical shock can cause serious or fatal injury. Only qualified personnel
	should attempt to start-up, program or troubleshoot this equipment.
!	Be sure that you are completely familiar with the safe operation and programming of this
	equipment. This equipment may be connected to other machines that have rotating parts
WARNING	or parts that are controlled by this equipment. Improper use can cause serious or fatal
	injury.
!	MEDICAL DEVICE / PACEMAKER DANGER: Magnetic and electromagnetic fields in the
	vicinity of current carrying conductors and industrial motors can result in a serious health
WARNING	hazard to persons with cardiac pacemakers, internal cardiac defibrillators,
	neurostimulators, metal implants, cochlear implants, hearing aids, and other medical
	devices. To avoid risk, stay away from the area surrounding a motor and its current
	carrying conductors.

The stop input to this equipment should not be used as the single means of achieving a

!safety critical stop. Drive disable, motor disconnect, motor brake and other means should be used as appropriate.

CAUTION

Improper operation or programming may cause violent motion of the motor shaft and

!driven equipment. Be certain that unexpected motor shaft movement will not cause injury to personnel or damage to equipment. Peak torque of several times the rated motor

CAUTION

torque can occur during control failure.

	i	The safe integration of this equipment into a machine system is the responsibility of the
		machine designer. Be sure to comply with the local safety requirements at the place
	NOTICE	where the machine is to be used. In Europe these are the Machinery Directive, the
		ElectroMagnetic Compatibility Directive and the Low Voltage Directive. In the United
		States this is the National Electrical code and local codes.

i

Electrical components can be damaged by static electricity. Use ESD (electrostatic discharge) procedures when handling this equipment.

NOTICE

1-2 General Information

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Introduction 2

2.1 NextMove PCI-2 features

NextMove PCI-2 is a high speed multi-axis intelligent motion controller for use in PCI bus based PC systems.

NextMove PCI-2 features the Mint motion control language. Mint is a structured form of Basic, custom designed for stepper or servo motion control applications. It allows you to get started very quickly with simple motion control programs. In addition, Mint includes a wide range of powerful commands for complex applications.

Standard features include:

Control of up to eight axes.

Point to point moves, software cams and gearing.

20 opto-isolated digital inputs, software configurable as level or edge triggered.

12 opto-isolated digital outputs. Models with PNP or NPN outputs are available.

4 differential analog inputs with 12-bit resolution.

4 single-ended analog drive demand outputs with 16-bit resolution.

CANopen or proprietary Baldor CAN protocol for communication with Mint controllers and other third party devices.

Programmable in Mint.

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Introduction 2-1

The Mint WorkBench software application can be installed from the Mint Motion Toolkit CD (OPT-SW-001), or downloaded from www.abbmotion.com. Mint WorkBench provides:

Mint WorkBench

Provides everything you need to quickly get your NextMove PCI-2 up and running. Mint WorkBench allows configuration, commissioning, parameterisation, programming, debugging and monitoring capabilities.

Mint Machine Center

Provides a network view of all connected controllers and allows quick access to Mint WorkBench for a selected device.

ActiveX control

The ActiveX control allows PC applications to communicate with the NextMove PCI-2.

This manual is intended to guide you through the installation of NextMove PCI-2.

The chapters should be read in sequence.

The Basic Installation section describes the mechanical installation of the NextMove PCI-2. The following sections require knowledge of the low level input/output requirements of the installation and an understanding of computer software installation. If you are not qualified in these areas you should seek assistance before proceeding.

2-2 Introduction

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2.2 Receiving and inspection

When you receive your NextMove PCI-2, there are several things you should do immediately:

1.Check the condition of the packaging and report any damage immediately to the carrier that delivered your NextMove PCI-2.

2.Remove the NextMove PCI-2 from the shipping container but do not remove its antistatic bag until you are ready to install it. The packing materials may be retained for future shipment.

3.Verify that the catalog number of the NextMove PCI-2 you received is the same as the catalog number listed on your purchase order. The catalog/part number is described in the next section.

4.Inspect the NextMove PCI-2 for external damage during shipment and report any damage to the carrier that delivered it.

5.If the NextMove PCI-2 is to be stored for several weeks before use, be sure that it is stored in a location that conforms to the storage humidity and temperature specifications shown in section 3.1.1.

2.2.1Identifying the catalog number

NextMove PCI-2 cards are available with different specifications. As a reminder of which card has been installed, it is a good idea to write the catalog number in the space provided below.

Catalog number: PCI201- _____________________________

Installed in: ______________________________________ Date: _____________

A description of a catalog number is shown here, using the example PCI201-504:

Catalog	Meaning
number
PCI201	NextMove PCI-2 family
50	PNP digital outputs; 51 indicates NPN digital outputs.
4	Number of physical axes (up to a maximum of 8).

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Introduction 2-3

2.3 Units and abbreviations

The following units and abbreviations are used in this manual:

V. . . . . . . . . . . . . . . . Volt (also V AC and V DC) W . . . . . . . . . . . . . . . Watt

A. . . . . . . . . . . . . . . . Ampere Ω . . . . . . . . . . . . . . . Ohm mΩ. . . . . . . . . . . . . . milliohm

μF. . . . . . . . . . . . . . . microfarad pF. . . . . . . . . . . . . . . picofarad mH . . . . . . . . . . . . . . millihenry

Φ . . . . . . . . . . . . . . .	phase
ms . . . . . . . . . . . . . .	millisecond
μs . . . . . . . . . . . . . . .	microsecond
ns . . . . . . . . . . . . . . .	nanosecond

mm. . . . . . . . . . . . . . millimeter m . . . . . . . . . . . . . . . meter

in . . . . . . . . . . . . . . . inch ft . . . . . . . . . . . . . . . . feet

lbf-in . . . . . . . . . . . . . pound force inch (torque) N·m . . . . . . . . . . . . . Newton meter (torque)

ADC . . . . . . . . . . . . . Analog to Digital Converter

ASCII . . . . . . . . . . . . American Standard Code for Information Interchange AWG . . . . . . . . . . . . American Wire Gauge

CAL . . . . . . . . . . . . . CAN Application Layer

CAN . . . . . . . . . . . . . Controller Area Network

CDROM . . . . . . . . . . Compact Disc Read Only Memory

CiA . . . . . . . . . . . . . . CAN in Automation International Users and Manufacturers Group e.V. CTRL+E . . . . . . . . . . on the PC keyboard, press Ctrl then E at the same time.

DAC . . . . . . . . . . . . . Digital to Analog Converter

DS301 . . . . . . . . . . . CiA CANopen Application Layer and Communication Profile DS401 . . . . . . . . . . . CiA Device Profile for Generic I/O Devices

DS403 . . . . . . . . . . . CiA Device Profile for HMIs EDS . . . . . . . . . . . . . Electronic Data Sheet

EMC. . . . . . . . . . . . . Electromagnetic Compatibility HMI . . . . . . . . . . . . . Human Machine Interface

ISO. . . . . . . . . . . . . . International Standards Organization

Kbaud. . . . . . . . . . . . kilobaud (the same as Kbit/s in most applications) LCD . . . . . . . . . . . . . Liquid Crystal Display

MB . . . . . . . . . . . . . . megabytes Mbps . . . . . . . . . . . . megabits/s (NC) . . . . . . . . . . . . . Not Connected

RF . . . . . . . . . . . . . . Radio Frequency

2-4 Introduction

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Basic Installation 3

3.1 Introduction

You should read all the sections in Basic Installation.

It is important that the correct steps are followed when installing the NextMove PCI-2. This section describes the mechanical and electrical installation of the NextMove PCI-2.

3.1.1 Location requirements

It is essential that you read and understand this section before beginning the installation.

i

To prevent equipment damage, be certain that input and output signals are powered and referenced correctly.

	NOTICE	To ensure reliable performance of this equipment be certain that all signals to/
	i
		from the NextMove PCI-2 are shielded correctly.
	NOTICE	Avoid locating the NextMove PCI-2 or host PC immediately above or beside heat
	i
		generating equipment, or directly below water steam pipes.
	NOTICE	Avoid locating the NextMove PCI-2 or host PC in the vicinity of corrosive
	i
		substances or vapors, metal particles and dust.
	NOTICE

The safe operation of this equipment depends upon its use in the appropriate environment. The following points must be considered:

The NextMove PCI-2 must be installed in an enclosed cabinet located so that it can only be accessed by service personnel using tools.

The maximum suggested operating altitude is 2000 m (6560 ft).

The NextMove PCI-2 must be installed in an ambient temperature of 0 °C to 45 °C (32 °F to 113 °F).

The NextMove PCI-2 must be installed in relative humidity levels of less than 93% for temperatures up to 31 °C (87 °F) decreasing linearly to 50% relative humidity at 45 °C (113 °F) (non-condensing).

The NextMove PCI-2 must be installed where the pollution degree according to IEC664 shall not exceed 2.

Power is supplied to the card from the host PC power supply bus.

The atmosphere shall not contain flammable gases or vapors.

There shall not be abnormal levels of nuclear radiation or X-rays.

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Basic Installation 3-1

3.1.2 Other requirements for installation

The components you will need to complete the basic installation are described below:

A PC that fulfills the following specification:

	Minimum specification
Processor	1 GHz
RAM	512 MB
Hard disk space	2 GB
CD-ROM	A CD-ROM drive
PCI slot	One spare PCI slot
Screen	1024 x 768, 16-bit color
Mouse	A mouse or similar pointing device
Operating	Windows XP or newer, 32-bit or 64-bit
system

3-2 Basic Installation

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3.2 Installation

NextMove PCI-2 can be installed into an AT style personal computer that has a free 7 inch PCI card slot. You will need a small cross-head screwdriver to fit the card.

3.2.1	Installing the NextMove PCI-2 card
	i	Before touching the card, be sure to discharge static electricity from your body
		and clothing by touching a grounded metal surface. Alternatively, wear an earth
	NOTICE	strap while handling the card.

1.Exit any applications that are running and close all windows. Shutdown Windows.

2.Turn off the power (if not automatically done by Windows) and unplug all power cords.

3.Remove the cover from the computer system unit.

4.Locate an unused PCI slot.

5.Remove the backplate cover from the slot, and save the screw for later use.

6.Discharge any static electricity from your body and clothing.

7.Remove the card from its protective wrapper. Do not touch the gold contacts at the bottom of the card.

8.Align the bottom of the card (gold contacts) with the slot and press the card firmly into the socket. When correctly installed, the card locks into place.

9.Make sure that the top of the card is level (not slanted) and that the slot on top of the card’s metal bracket lines up with the screw hole in the PC case.

10.Insert the screw and tighten to secure the card.

11.Replace the computer cover and screws.

12.Reconnect any cables and power cords that were disconnected or unplugged.

13.Attach the optional 100-pin cable assembly to the NextMove PCI-2. It is advisable to provide additional support for the cable to prevent mechanical forces on the connector.

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Basic Installation 3-3

3-4 Basic Installation

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Input / Output 4

4.1 Introduction

This section describes the digital and analog input and output capabilities of the NextMove PCI-2.

The following conventions will be used to refer to the inputs and outputs:

I/O . . . . . . . . . . . . . . Input / Output

DIN . . . . . . . . . . . . . Digital Input

DOUT . . . . . . . . . . . Digital Output

AIN . . . . . . . . . . . . . Analog Input

AOUT . . . . . . . . . . . Analog Output

Connections to the NextMove PCI-2 card are made using the 100-way cable assembly and DIN rail mounted NextMove PCI-2 breakout module (supplied as options, see Appendix A). All connector numbers in the following sections refer to the breakout module. It is advisable to provide additional support for the cable to prevent mechanical forces on the connector.

4.2 100-pin edge connector

100 50

The pin assignment for the 100-pin D-type connector is shown in Table 1.

51 1

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Input / Output 4-1

4.2.1 100-pin edge connector pin assignment

Pin	Signal	Pin	Signal
100	Relay NO	50	Relay COM
99	Relay NC	49	Common1
98	DIN0	48	DIN2
97	DIN1	47	DIN3
96	DIN4	46	DIN6
95	DIN5	45	DIN7
94	DIN8	44	DIN10
93	DIN9	43	DIN11
92	DIN12	42	DIN14
91	DIN13	41	DIN15
90	DIN16	40	DIN18
89	DIN17	39	DIN19
88	Common2	38	DOUT0
87	CGND	37	DOUT1
86	DOUT2	36	DOUT3
85	CGND	35	DOUT4
84	DOUT5	34	DOUT6
83	USR V+	33	DOUT7
82	DOUT8	32	DOUT9
81	USR V+	31	DOUT10
80	DOUT11	30	STEP3
79	DIR3	29	DIR1
78	DIR2	28	STEP1
77	DIR0	27	STEP2
76	+5 V out	26	STEP0
75	Master encoder CHZ+	25	Master encoder CHZ-
74	Master encoder CHB+	24	Master encoder CHA+
73	Master encoder CHB-	23	Master encoder CHA-
72	Encoder 1 CHZ+	22	Encoder 3 CHZ+
71	Encoder 1 CHZ-	21	Encoder 3 CHZ-
70	Encoder 1 CHB+	20	Encoder 3 CHB+
69	Encoder 1 CHB-	19	Encoder 3 CHB-

4-2 Input / Output

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Pin	Signal	Pin	Signal
68	Encoder 1 CHA+	18	Encoder 3 CHA+
67	Encoder 1 CHA-	17	Encoder 3 CHA-
66	Encoder 0 CHZ+	16	Encoder 2 CHZ+
65	Encoder 0 CHZ-	15	Encoder 2 CHZ-
64	Encoder 0 CHB+	14	Encoder 2 CHB+
63	Encoder 0 CHB-	13	Encoder 2 CHB-
62	Encoder 0 CHA+	12	Encoder 2 CHA+
61	Encoder 0 CHA-	11	Encoder 2 CHA-
60	CAN2 receive	10	CAN1 receive
59	CAN2 transmit	9	CAN1 transmit
58	+5 V out	8	GND
57	GND	7	Analog GND
56	Demand3	6	Demand2
55	Demand1	5	Demand0
54	AIN3-	4	AIN2-
53	AIN3+	3	AIN2+
52	AIN1-	2	AIN0-
51	AIN1+	1	AIN0+

Table 1: 100-pin edge connector pin assignment

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Input / Output 4-3

4.3 Analog I/O

The NextMove PCI-2 provides:

Two 12-bit resolution analog inputs.

Four 16-bit resolution analog outputs.

4.3.1Analog inputs - X6

	12	Location	Breakout module, connector X6
		Pin	Name	Description
		1	AGND	Analog ground
		2	AIN0+	Analog input 0
		3	AIN0-
	1	4	AIN1+	Analog input 1
		5	AIN1-
		6	Shield	Shield connection
		7	AGND	Analog ground
		8	AIN2+	Analog input 2
		9	AIN2-
		10	AIN3+	Analog input 3
		11	AIN3-
		12	Shield	Shield connection

The analog inputs are available on breakout module connector X6. Shielded twisted pairs should be used and connected as shown in Figure 1. The shield connection should be made at one end only.

Single ended or differential inputs.

Voltage range: software selectable 0-5 V, ± 5 V, 0-10 V, ±10 V

Resolution: 12-bit with sign (accuracy ±4.9 mV @ ±10 V input).

Input impedance: >5 kΩ.

Sampling frequency: 2.5 kHz

The analog inputs pass through a differential buffer and second order low-pass filter with a cut-off frequency of approximately 1 kHz. Four input voltage ranges can be selected in Mint using the ADCMODE keyword. Analog inputs can be read using the ADC keyword. See the Mint help file for full details of ADC, ADCMODE and other related ADC... keywords.

4-4 Input / Output

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Breakout

module

‘X6’

AIN0- 3

AIN0+ 2

AGND 1

		NextMove PCI-2
		+12V
	100 way	10k	120k
	cable			-	Mint
				-	ADC(0)
				+
			120k	+
		10k		TL084
		-12V

Figure 1: Analog input wiring, AIN0 shown

For differential inputs connect input lines to AIN+ and AIN-. Leave AGND unconnected. For single ended inputs, connect signal to AIN+. Connect signal ground to AINand AGND.

+24 V DC

1.5 kΩ, 0.25 W

		X6
	1 kΩ, 0.25 W	2
	potentiometer
			AIN0
0 V		3
			(ADC(0)

1

Figure 2: Typical input circuit to provide 0-10 V (approx.) input from a 24 V source

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Input / Output 4-5

4.3.2 Analog outputs (Demands) - X7

	Location	Breakout module, connector X7
12
	Pin	Name	Description
	1	Demand0	Demand output signal 0
	2	AGND	Analog ground
	3	Shield	Shield connection
	4	Demand1	Demand output signal 1
1
	5	AGND	Analog ground
	6	Shield	Shield connection
	7	Demand2	Demand output signal 2
	8	AGND	Analog ground
	9	Shield	Shield connection
	10	Demand3	Demand output signal 3
	11	AGND	Analog ground
	12	Shield	Shield connection

The analog outputs are available on breakout module connector X7.

Four independent demand outputs.

Output range: ±10 V DC (±0.1%).

Resolution: 12-bit, 14-bit or 16-bit (software selectable).

Output current: 1 mA maximum.

Update frequency: 200 μs - 2000 ms (determined by LOOPTIME).

Mint uses the analog outputs Demand0 to Demand3 to control drive amplifiers. The Mint WorkBench Axis Config Wizard (or Mint CONFIG and AXISCHANNEL keywords) can be used to assign outputs to axes; see section 5.4.1). The output resolution can be selected as either 12-bit, 14-bit or 16-bit using the Mint DACMODE keyword. The analog outputs may be used to drive loads of 10 kΩ or greater. The outputs are referenced to PC system ground.

Shielded twisted pair cable should be used. The shield connection should be made at one end only.

4-6 Input / Output

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NextMove PCI-2		Breakout
	+12 V	module	‘X7’
Demand		100
±100%	47R	way
-		cable	Demand0
TL084		1
+
	-12 V
		2	AGND

Figure 3: Analog output circuit - Demand0 shown

	Breakout module		MicroFlex / drive amplifier
		‘X7’	‘X3’
100
way
cable	Demand0	1	13	AIN0+	Drive
					amplifier
	AGND				±10 VDC
		2	12	AIN0-	demand
					Input
	Shield 3		Connect overall shield
			at one end only

Figure 4: Analog output - typical connection to an ABB MicroFlex

	Breakout module	‘X7’	‘X1’	FlexDriveII / drive amplifier
100
way
cable	Demand0	1	1	AIN0+	Drive
					amplifier
	AGND				±10 VDC
		2	2	AIN0-	demand
					Input
	Shield 3		Connect overall shield
			at one end only

Figure 5: Analog output - typical connection to a Baldor FlexDriveII, Flex+DriveII or MintDriveII

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Input / Output 4-7

4.4 Digital I/O

The NextMove PCI-2 provides:

20 general purpose digital inputs.

12 general purpose digital outputs.

4.4.1Digital inputs - overview

There are a total of 20 general purpose digital inputs. Inputs can be configured in Mint for any of the following functions:

Forward limit (end of travel) input on any axis.

Reverse limit (end of travel) input on any axis.

Home input on any axis.

Drive error input on any axis.

Inputs can be shared between axes, and are programmable in Mint (using the keywords

INPUTACTIVELEVEL, INPUTDEBOUNCE, INPUTMODE, INPUTNEGTRIGGER and

INPUTPOSTRIGGER) to determine their active level and if they should be edge triggered. Four of the inputs, DIN0-DIN3, are fast position latch inputs.

The inputs use two separate common connections. This can be useful for separating inputs which are active low from others which are active high. If all inputs are similar then the commons can be connected together to form one common connection. The arrangement of the inputs, their common power connection and the connectors on which they are available are described in Table 2 :

4-8 Input / Output

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Input	Common	Breakout module connector
DIN0
DIN1		X3 - Fast position inputs
DIN2
DIN3	Common1
DIN4
DIN5
DIN6
DIN7		X2 - General purpose inputs
DIN8
DIN9
DIN10
DIN11
DIN12
DIN13	Common2
DIN14
DIN15		X1 - General purpose inputs
DIN16
DIN17
DIN18
DIN19

Table 2: Digital input arrangement

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Input / Output 4-9

4.4.2 Digital inputs - X1

12	Location	Breakout module, connector X1
	Pin	Name	Mint keyword / description	Common
	1	Shield	Shield connection
	2	DIN12	INX(12)
	3	DIN13	INX(13)
1	4	DIN14	INX(14)
	5	DIN15	INX(15)	Common2
	6	DIN16	INX(16)
	7	DIN17	INX(17)
	8	DIN18	INX(18)
	9	DIN19	INX(19)
	10	Shield	Shield connection
	11	-	(NC)
	12	Common2	Common connection

Digital inputs DIN12 to DIN19 have a common specification:

General purpose opto-isolated digital inputs.

Sampling frequency 1 kHz.

The inputs are conditioned using low pass RC filters and Schmitt trigger buffers. If an input is configured as edge triggered, the triggering pulse must have a duration of at least 1ms (one software scan) to guarantee acceptance by Mint. Voltages below 2 V are considered as 0 V. The use of shielded cable for inputs is recommended.

Active high: The digital inputs will be active when a voltage of +24 V DC (±20%) is applied to them and will sink a maximum of 8 mA each.

Active low: The digital inputs will be active when grounded (< 2 V) and will source a maximum of 8 mA each.

Note: Sustained input voltages above 30 V will damage the inputs.

4-10 Input / Output

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‘X1’

Breakout

NextMove PCI-2

Vcc

module

100

way

3k3

DIN12

2

cable

Mint

INX(12)

TLP280

Common2

12

DGND

Active high:

Active low:

DINx = 12-24 V DC (±20%)

DINx = 0 V

Common2 = 0V

Common2 = 12-24 V DC (±20%)

Figure 6: Digital input circuit - DIN12 shown

4.4.3 Digital inputs - X2

	12	Location	Breakout module, connector X2
		Pin	Name	Mint keyword / description	Common
		1	Shield	Shield connection
		2	DIN4	INX(4)
		3	DIN5	INX(5)	Common1
	1	4	DIN6	INX(6)
		5	DIN7	INX(7)
		6	DIN8	INX(8)
		7	DIN9	INX(9)	Common2
		8	DIN10	INX(10)
		9	DIN11	INX(11)
		10	Shield	Shield connection
		11	Common1	Common connection
		12	Common2	Common connection

Digital inputs DIN4 to DIN11 are electrically identical to inputs DIN12 to DIN19, described in section 4.4.2.

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Input / Output 4-11

4.4.4 Digital inputs - X3

	12	Location	Breakout module, connector X3
		Pin	Name	Mint keyword / description
		1	DIN0	INX(0)
		2	Common1	Common connection
		3	Shield	Shield connection
	1	4	DIN1	INX(1)
		5	Common1	Common connection
		6	Shield	Shield connection
		7	DIN2	INX(2)
		8	Common1	Common connection
		9	Shield	Shield connection
		10	DIN3	INX(3)
		11	Common1	Common connection
		12	Shield	Shield connection

Digital inputs DIN0 to DIN3 have a common specification:

Opto-isolated high-speed digital inputs.

Sampling frequency 1 kHz.

Note: Digital inputs DIN0 to DIN3 are particularly sensitive to noise, so inputs must use shielded twisted pair cable.

Digital inputs DIN0 to DIN3 can be used as high speed position latches. A fast position input can cause the position of any combination of axes to be captured (by the hardware) within 1 μs. Special Mint keywords (beginning with the letters FAST...) allow specific functions to be performed as a result of fast position inputs becoming active.

Active high: The high speed digital inputs will be active when a voltage of +24 V DC (±20%) is applied to them and will sink a maximum of 7 mA each.

Active low: The digital inputs will be active when grounded (< 2 V) and will source a maximum of 7 mA each.

Note: Sustained input voltages above 30 V will damage the inputs.

4-12 Input / Output

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‘X3’	Breakout	NextMove PCI-2	Vcc
	module
	100
	way	3k3
DIN0	cable		Mint
	1		INX(0)
			TLP115A
Common1	2
			DGND
	Active high:		Active low:
	DINx = 12-24 V DC (±20%)		DINx = 0 V
	Common1 = 0V		Common1 = 12-24 V DC (±20%)

Figure 7: Digital input circuit - fast interrupts - DIN0 shown

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Input / Output 4-13

4.4.5 Digital outputs - overview

There are a total of 12 general purpose digital outputs. An output can be configured in Mint as a general purpose output, a drive enable output or a general error output. Outputs can be shared between axes and are programmable, using the Mint keyword OUTPUTACTIVELEVEL, to determine their active level.

Two types of output are available, depending on the NextMove PCI-2 model:

Current sourcing PNP (PCI201-50x).

Current sinking NPN (PCI201-51x).

On all models, the entire group of outputs is protected by a 1.5 A self resetting fuse. The fuse may take a few seconds to reset after the load has been removed.

Unused stepper channels can have their pulse and direction output pins used as outputs. See the Mint keywords CONFIG and STEPPERIO.

4.4.6 Digital outputs - X4

	12	Location	Breakout module, connector X4
		Pin	Name	Mint keyword / description
		1	Shield	Shield connection
		2	DOUT6	OUTX(6)
		3	DOUT7	OUTX(7)
	1	4	DOUT8	OUTX(8)
		5	DOUT9	OUTX(9)
		6	DOUT10	OUTX(10)
		7	DOUT11	OUTX(11)
		8	-	(NC)
		9	-	(NC)
		10	Shield	Shield connection
		11	USR V+	Customer power supply
		12	CGND	Customer power supply ground

Digital outputs DOUT6 to DOUT11 have a common specification:

General purpose opto-isolated digital outputs.

Output current: 50 mA maximum each output.

Update frequency: Immediate.

4-14 Input / Output

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