Baldor BXII User Manual

MOTION CONTROL

NextMove BX

II

Motion Controller

Installation Manual

9/02 MN1904

Contents

1 General Information 1-1.................................

2 Introduction 2-1........................................

2.1 NextMove BXIIfeatures 2-1.................................

2.2 Receiving and inspection 2-2................................

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

2.3 Units and abbreviations 2-3..................................

3 Basic Installation 3-1....................................

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

3.1.1 Power sources 3-1................................................

3.1.2 PC Hardware requirements 3-1......................................

3.1.3 Tools and miscellaneous hardware 3-2................................

3.1.4 Other information needed for installation 3-2...........................

3.2 Mechanical installation and location requirements 3-3...........

3.2.1 Mounting the NextMove BX

4 Input / Output 4-1......................................

4.1 Introduction 4-1............................................

II

3-4.....................................

4.2 Connector locations - top panel 4-1...........................

4.3 Connector locations - front panel 4-2..........................

4.4 Power connections 4-3......................................

4.4.1 Power - X8 4-3....................................................

4.5 Analog I/O 4-4.............................................

4.5.1 Analog inputs - X3 4-4..............................................

4.5.2 Analog outputs (Demands) - X7 4-6..................................

4.6 Digital I/O 4-7..............................................

4.6.1 Digital inputs - X1 4-8..............................................

4.6.2 Digital inputs - X2 4-9..............................................

4.6.3 Digital inputs (Interrupts) - X6 4-10....................................

4.6.4 Digital outputs - X4 4-11.............................................

4.7 Other I/O 4-12..............................................

4.7.1 Encoder interfaces - X9, X10, X11, X12, X13 4-12.......................

4.7.2 Encoder input frequency 4-13........................................

4.7.3 Relay and user power - X5 4-14.......................................

4.7.4 RS232 - X15 4-15..................................................

MN1904

Contents i

4.7.5 Connecting Baldor HMI Operator Panels 4-17...........................

4.7.6 RS422 / RS485 - X14 4-18...........................................

4.7.7 CAN connectors - X16 & X17 4-20....................................

4.7.8 CANopen 4-21.....................................................

4.7.9 Baldor CAN 4-21...................................................

4.8 Reset states 4-22...........................................

4.8.1 System watchdog 4-22..............................................

4.9 Connection summary - minimum system wiring 4-23.............

5 Operation 5-1..........................................

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

5.1.1 Connecting the NextMove BXIIto the PC 5-1..........................

5.1.2 Installing the software 5-1...........................................

5.1.3 Starting the NextMove BX

5.1.4 Preliminary checks 5-1.............................................

5.1.5 Power on checks 5-2...............................................

5.2 WorkBench v5 5-3..........................................

5.2.1 Help file 5-3......................................................

5.2.2 Starting WorkBench v5 5-4..........................................

5.3 Configuring an axis 5-6.....................................

5.3.1 Selecting a scale 5-6...............................................

5.3.2 Setting the drive enable output 5-7...................................

5.3.3 Testing the drive enable output 5-8...................................

5.4 Testing and tuning 5-9......................................

5.4.1 Testing the drive command output 5-9.................................

5.5 An introduction to closed loop control 5-11......................

II

5-1......................................

5.6 Tuning an axis for current control 5-14.........................

5.6.1 Selecting servo loop gains 5-14.......................................

5.6.2 Underdamped response 5-16.........................................

5.6.3 Overdamped response 5-17..........................................

5.6.4 Critically damped response 5-18......................................

5.7 Eliminating steady-state errors 5-19............................

5.8 Tuning an axis for velocity control 5-20.........................

5.8.1 Calculating KVELFF 5-20............................................

5.8.2 Adjusting KPROP 5-23..............................................

5.9 Digital input/output configuration 5-25..........................

5.9.1 Digital input configuration 5-25........................................

5.9.2 Digital output configuration 5-26.......................................

5.10 Saving setup information 5-27.................................

5.11 Loading saved information 5-28...............................

ii Contents

MN1904

6 Troubleshooting 6-1....................................

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

6.1.1 Problem diagnosis 6-1..............................................

6.1.2 SupportMet feature 6-1............................................

6.2 NextMove BXIIindicators 6-2................................

6.2.1 Status display 6-2.................................................

6.2.2 Motor control 6-4..................................................

6.2.3 Communication 6-5................................................

6.2.4 Axis LED is red or Status LED shows a flashing symbol 6-5..............

7 Specifications 7-1......................................

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

7.1.1 Input power 7-1...................................................

7.1.2 Analog inputs (X3) 7-1..............................................

7.1.3 Analog outputs (Demands - X7) 7-2..................................

7.1.4 Digital inputs (X1 & X2) 7-2.........................................

7.1.5 Digital inputs (Interrupts) (X6) 7-2....................................

7.1.6 Digital outputs (X4) 7-3.............................................

7.1.7 Relay output (X5) 7-3..............................................

7.1.8 Encoder interfaces (X9 - X13) 7-3....................................

7.1.9 CAN interfaces (X16 & X17) 7-3.....................................

7.1.10 Environmental 7-4.................................................

7.1.11 Weights and dimensions 7-4........................................

Appendices

A Accessories A-1........................................

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

A.1.1 Baldor CAN nodes A-1.............................................

A.1.2 Encoder Splitter/Buffer board A-2.....................................

MN1904

Contents iii

iv Contents

MN1904

Teleph

61296745455

1 General Information

LT0158A01 Copyright Baldor (c) 2002. 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 BALDOR.
BALDOR makes no representations or warranties with respect to the contents hereof and specifically dis ­claims any implied warranties of fitness for any particular purpose. The information in this document is
subject to change without notice. BALDOR assumes no responsibility for any errors that may appear in
this document.

Mintt is a registered trademark of Baldor.
Windows 95, Windows 98, Windows ME, Windows NT, Windows 2000 and Windows XP are registered
trademarks of the Microsoft Corporation.
UL and cUL are registered trademarks of Underwriters Laboratories.

Limited Warranty:
For a period of two (2) years from the date of original purchase, BALDOR will repair or replace without
charge controls and accessories which our examination proves to be defective in material or workman­ship. This warranty is valid if the unit has not been tampered with by unauthorized persons, misused,
abused, or improperly installed and has been used in accordance with the instructions and/or ratings sup­plied. This warranty is in lieu of any other warranty or guarantee expressed or implied. BALDOR shall
not be held responsible for any expense (including installation and removal), inconvenience, or conse­quential damage, including injury to any person or property caused by items of our manufacture or sale.
(Some countries and U.S. states do not allow exclusion or limitation of incidental or consequential dam­ages, so the above exclusion may not apply.) In any event, BALDOR’s total liability, under all circum­stances, shall not exceed the full purchase price of the control. Claims for purchase price refunds, repairs,
or replacements must be referred to BALDOR with all pertinent data as to the defect, the date purchased,
the task performed by the control, and the problem encountered. No liability is assumed for expendable
items such as fuses. Goods may be returned only with written notification including a BALDOR Return
Authorization Number and any return shipments must be prepaid.

1

Baldor UK Ltd
Mint Motion Centre
6 Bristol Distribution Park
Hawkley Drive
Bristol, BS32 0BF
Telephone: [phone]
Fax: [phone]
Email: [e-mail]
Web site: www.baldor.co.uk

Baldor Electric Company
Telephone: [phone]
Fax: [phone]
Email: [e-mail]
Web site: www.baldor.com

Baldor ASR GmbH
Telephone: [phone]
Fax: [phone]

Baldor ASR AG
Telephone: [phone]
Fax: [phone]

Australian Baldor Pty Ltd

one: +

Fax: [phone]

Baldor Electric (F.E.) Pte Ltd
Telephone: [phone]
Fax: [phone]

Baldor Italia S.R.L
Telephone: [phone]
Fax: [phone]

General Information 1-1MN1904

Safety Notice

Only qualified personnel should attempt the start-up procedure 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. Only qualified personnel
should attempt to start-up, program or troubleshoot this equipment.

Precautions

WARNING: Be sure that you are completely familiar with the safe operation and programming

WARNING: The stop input to this equipment should not be used as the single means of

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

WARNING: When operating a motor with no load coupled to its shaft, remove the shaft key to

CAUTION: The safe integration of this equipment into a machine system is the responsibility

CAUTION: To prevent equipment damage, be certain that the input power has correctly sized

CAUTION: To prevent equipment damage, be certain that input and output signals are

of 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. Only qualified personnel should attempt to program,
start-up or troubleshoot this equipment.

achieving a safety critical stop. Drive disable, motor disconnect, motor brake and
other means should be used as appropriate. Only qualified personnel should
attempt to program, start-up or troubleshoot this equipment.

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 torque can occur during control failure.

prevent it flying out when the shaft rotates.

of the machine designer. Be sure to comply with the local safety requirements at
the place 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.

protective devices installed.

powered and referenced correctly.

CAUTION: To ensure reliable performance of this equipment be certain that all signals to/from

the NextMove BX

CAUTION: Avoid locating this equipment immediately above or beside heat generating

equipment, or directly below water or steam pipes.

CAUTION: Avoid locating this equipment in the vicinity of corrosive substances or vapors,

metal particles and dust.

II

are shielded correctly.

1-2 General Information MN1904

2 Introduction

2.1 NextMove BXIIfeatures

NextMove BXIIis a high speed multi-axis intelligent motion controller, supporting up to four
servo axes.

NextMove BX
custom designed for 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 of the NextMove BX

H Control of up to four axes

H Point to point moves, software cams and gearing

H 16 general purpose digital inputs, software configurable as level or edge triggered

H 4 fast position latch inputs

H 8 digital outputs

H 8 analog inputs with 12-bit resolution, configurable as single ended inputs or differential

pairs

H CANopen protocol for peer-to-peer communications with Mint controllers and other third

party devices

H Proprietary CAN protocol for control of Baldor remote I/O devices

H Programmable in Mint.

Included with NextMove BX
utilities and useful resources to get the most from your Mint controller. These include:

II

features the Mint motion control language. Mint is a structured form of Basic,

II

include:

II

is the Baldor Motion Tookit CD. This contains a number of

2

H Mint WorkBench v5

This is the user interface for communicating with the NextMove BX
WorkBench v5 will also install firmware for NextMove BX

H PC Developer Libraries

These include ActiveX interfaces that allow PC applications to be written that
communicate with the NextMove BX

H Embedded Developer Libraries

Allows embedded C31 applications to be developed using the Texas Instruments
TMS320C3x compiler.

This manual is intended to guide you through the installation of NextMove BX

The chapters should be read in sequence.

The Basic Installation section describes the mechanical installation of the NextMove BX
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.

II

.

II

.

II

. Installing

II

.

II

.

Introduction 2-1MN1904

2.2 Receiving and inspection

When you receive your NextMove BXII, 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 BX

2. Remove the NextMove BX
retained for future shipment.

3. Verify that the catalog number of the NextMove BX
number listed on your purchase order. The catalog/part number is described in the next
section.

4. Inspect the NextMove BX
the carrier that delivered it.

5. If the NextMove BX
a location that conforms to the storage humidity and temperature specifications shown in
section 7.1.10.

II

II

.

II

from the shipping container. The packing materials may be

II

you received is the same as the catalog

II

for external damage during shipment and report any damage to

is to be stored for several weeks before use, be sure that it is stored in

2.2.1 Identifying the catalog number

NextMove BXIIis available with different specifications. As a reminder of which model has
been installed, it is a good idea to write the catalog number in the space provided below.

Catalog number:

Installed in: ________________________

A description of the catalog numbers are shown in the following table:

Catalog
number

NMX004-501 NextMove BXII, for control of 2 axes

NMX004-502 NextMove BXII, for control of 3 axes

NMX004-503 NextMove BXII, for control of 4 axes

NMX004-_______

Date: ______

Description

2-2 Introduction MN1904

2.3 Units and abbreviations

The following units and abbreviations may appear in this manual:

V Volt (also VAC and VDC)...............

WWatt..............

A Ampere...............

Ω Ohm...............

µF microfarad..............

pF picofarad..............

mH millihenry.............

Φ phase...............

ms millisecond..............

µs microsecond..............

ns nanosecond..............

Kbaud kilobaud (the same as Kbit/s in most applications)...........

MB megabytes.............

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

CTRL+E on the PC keyboard, press Ctrl then E at the same time..........

mm millimeter.............

m meter...............

in inch...............

ft feet...............

lb-in pound-inch (torque).............

Nm Newton-meter (torque).............

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

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

AWG American Wire Gauge............

(NC) Not Connected............

PC Personal Computer (IBM compatible).............

Introduction 2-3MN1904

2-4 Introduction MN1904

3.1 Introduction

3 Basic Installation

3

You should read all the sections in Basic Installation.

It is important that the correct steps are followed when installing the NextMove BX
section describes the mechanical installation and power requirements of the NextMove BX

3.1.1 Power sources

An external (customer supplied) 24VDC logic supply is required. This must be a regulated
power supply capable of providing:

H 24VDC ±20% at approximately 700mA (max) for the logic power supply

H 12 to 24VDC ±20% at approximately 400mA (max) for the isolated outputs

H 12 to 24VDC ±20% at approximately 200mA for the isolated digital inputs and fast

interrupts.

A 24V filter may be required to comply with the CE directive for which the NextMove BX
tested.

3.1.2 PC Hardware requirements

A PC that fulfills the following specification will be required:

Minimum specification Recommended specification

Processor Intel Pentium 133MHz Intel Pentium 200MHz or faster

RAM 32MB 64MB

Hard disk space 40MB 60MB

CD-ROM ACD-ROMdrive

Screen 800 x 600, 256 colors 1024 x 768, 256 colors

Mouse A mouse or similar pointing device

Operating system Windows 95, Windows 98, Windows ME,

Windows NT, Windows 2000 or Windows XP

II

.This

II

.

II

was

Basic Installation 3-1MN1904

3.1.3 Tools and miscellaneous hardware

H Your PC operating system user manual might be useful if you are not familiar with

Windows

H A small screwdriver (supplied) with a blade width less than 2.5mm (1/10 in).

H M5 screws or bolts for mounting the NextMove BX

H Crimping tool.

A connector kit is supplied with your NextMove BX
and accessories.

II

II

, containing a number of useful connectors

3.1.4 Other information needed for installation

This information is useful (but not essential) to complete the installation:

H The data sheet or manual provided with the servo drive controlling the motor, describing

the wiring information of the cables/connectors

H Knowledge of which digital inputs/outputs will be ‘Active Low’, ‘Active High’ or edge

triggered.

3-2 Basic Installation MN1904

3.2 Mechanical installation and location requirements

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

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

H The NextMove BX

H The maximum suggested operating altitude is 2000m (6562ft).

H The NextMove BX

H The NextMove BX

H The NextMove BX

H The external customer supplied 24VDC for the logic supply must be installed so that the

H The inputs and outputs of the control circuit must be limited to Safety Extra Low Voltage

H The atmosphere must not contain flammable gases or vapors.

H There must not be abnormal levels of nuclear radiation or X-rays.

H The NextMove BX

H The external customer supplied 24VDC logic supply might require a 24V filter.

H Each D-type connector on the front panel of the NextMove BX

H The two D-type connectors on the top panel of the NextMove BX

.

II

must be installed indoors, permanently fixed and located so that it can

only be accessed by service personnel using tools.

II

must operate in an ambient temperature of 0°C to 40°C (32°F to

104°F).

II

must operate in relative humidity levels of less than 80% for
temperatures up to 31°C (87°F) decreasing linearly to 50% relative humidity at 40°C
(104°F) (non-condensing).

II

must be installed where the pollution degree according to IEC664
shall not exceed 2.

24VDC supplied to the unit is isolated from the AC supply using double or reinforced
insulation.

circuits.

II

must be secured by the slots in the flange, with the protective
earth/ground stud bonded to a safety earth/ground by a 25A conductor.

II

is secured using two
hexagonal jack screws (sometimes known as “screwlocks”). If a jack screw is removed
accidentally or lost it must be replaced with an identical jack screw with an external male
threaded section of 5mm (0.2 in).
Jack screws with longer threads might result in loose connections.

II

are each secured using
two hexagonal jack screws (sometimes known as “screwlocks”). If a jack screw is
removed accidentally or lost it must be replaced with an identical jack screw with an
external male threaded section of 7mm (0.28 in). Jack screws with shorter threads might
result in loose connections.

See also page 1-2.

Basic Installation 3-3MN1904

3.2.1 Mounting the NextMove BX

Ensure you have read and understood the Mechanical installation and location requirements in
section 3.2. Mount the NextMove BX
The NextMove BX
should be used.

II

must be mounted upright to ensure adequate cooling. M5 bolts or screws

II

II

on its rear side, the side opposite the front panel.

194 (7.6)

All dimensions shown as mm (inches)

203 (8.0)

(Allow additional depth to accommodate wiring)

Figure 1 - Package dimensions

58.5 (2.3)

40 (1.6)

302 (11.9)

312 (12.3)

This completes the basic installation.

You should read the following sections in

sequence before using the NextMove BX

3-4 Basic Installation MN1904

II

.

4 Input / Output

4.1 Introduction

This section describes the location and purpose of each connector on the NextMove BXII.

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...........

4.2 Connector locations - top panel

4

Jumpers

P Power
1CAN1
2CAN2

X16 / X17 CAN

1CAN1+
2CAN1­3 (NC)
4CAN0V
5 CAN V+
6 (NC)
7CAN2+
8CAN2-

X15 RS232

X14 RS485

1 Shield
2RX+
3TX+
4 (NC)
50VGND
6 (NC)
7TX­8RX­90VGND

1 Shield
2RXD
3TXD
4DTR
50VGND
6DSR
7RTS
8CTS
90VGND

Input / Output 4-1MN1904

4.3 Connector locations - front panel

X1 Digital Inputs 8-15

1DIN8
2DIN9
3DIN10
4DIN11
5DIN12
6DIN13
7DIN14
8DIN15
9 CREF
10 Shield

X3 Analog Inputs

1AIN0
2AIN1
3AIN2
4AIN3
5AIN4
6AIN5
7AIN6
8AIN7
9AGND
10 Shield

X5 Relay & User Power

1 Relay COM
2 Relay NC
3 Relay NO
4 Relay COM
5 USR V+
6 USR V+
7 CREF
8 CREF
9CGND
10 CGND

X6 Interrupts

1 FASTIN0
2 Shield
3 CREF
4 FASTIN1
5 Shield
6 CREF
7 FASTIN2
8 Shield
9 CREF
10 FASTIN3

X8 Power

1 +24V
20V
3 Shield
4 +5V out
5GND
6 +12V out
7GND
8 -12V out
9 Shield
10 Shield

Tightening torque for terminal block

connections is 0.25Nm (2.2 lb-in)

X2 Digital Inputs 0-7

1DIN0
2DIN1
3DIN2
4DIN3
5DIN4
6DIN5
7DIN6
8DIN7
9 CREF
10 Shield

X4 Digital Outputs 0-7

1DOUT0
2DOUT1
3DOUT2
4DOUT3
5DOUT4
6DOUT5
7DOUT6
8DOUT7
9 USR V+
10 CGND

X7 Demands

1AOUT0
2AGND
3AOUT1
4AGND
5AOUT2
6AGND
7AOUT3
8AGND
9AGND
10 Shield

X9 Encoder 0
X10 Encoder 1
X11 Encoder 2
X12 Encoder 3
X13 Aux Encoder

1 CHA+
2 CHB+
3 CHZ+
4 (NC)
5DGND
6 CHA­7 CHB­8 CHZ­9 +5V out

4-2 Input / Output MN1904

4.4 Power connections

24V

logi

lyi

t(1

8-30V

)

5

Voutput

p

A 24VDC, 2A supply must be provided to power the control electronics. It is recommended
that a separate fused 24V supply is provided for the NextMove BX
maximum. If other devices are to be powered from the same 24V supply, a filter (Baldor
catalog number FI0014A00) should be installed to isolate the NextMove BX
the system.

II

, with the fuse rated at 4A

4.4.1 Power - X8

Location Connector X8

Description

Connection point for 24V logic power supply input,
5V output and 12V output.

(Mating connector: Weidmüller BL 3.5/10, 3.5mm pitch)

Pin Name Description

1 +24V

2 GND

3 Shield Shield connection

4 +5V

5 GND

6 +12V

7 GND

8 -12V

9 Shield Shield connection

10 Shield Shield connection

+

+

±12V output

c supp

II

from the rest of

npu

Tightening torque for terminal block connections is 0.25Nm (2.2 lb-in). Use 60/75 or 75°C
copper (Cu) wire only.

The power connector X8 provides a connection point for the main customer supplied 24V logic
power supply. From this supply, the NextMove BX
and external use.

The 5V supply can be used to supply encoders and external circuits, to a maximum of 650mA.
The +5V and GND connections on pins 4 and 5 are connected internally to the +5V and GND
pins on connectors X9 to X13.

CAUTION: Encoder power must be connected before operating the system. If the

encoders are not powered when the system is enabled, there will be no
position feedback. This could cause violent motion of the motor shaft.

The 12V supply can be used to power external circuits, to a maximum of 200mA. However,
this supply must not be used to provide power for the digital outputs. For this, a separate
supply must be used (see sections 4.6.4 and 4.7.3).

II

creates 5V and 12V supplies for internal

Input / Output 4-3MN1904

4.5 Analog I/O

The NextMove BXIIprovides:

H Eight 12-bit resolution analog inputs, available on connector X3.

H Four 14-bit resolution analog outputs, available on connector X7.

Sections 4.5.1 to 4.5.2 describe each analog input and output.

4.5.1 Analog inputs - X3

Location Connector X6

Description

Single ended or differential inputs
Voltage range: software selectable 0-5V, ±2.5V, ±10V
Resolution: 12-bit with sign (accuracy ±4.9mV @ ±10V input)
Input impedance: >20kΩ
Sampling interval: 222µs - 2ms

The Mint keyword ADCMODE can be used to setup various configurations for the analog inputs.
H Single ended (ADCMODE 0): This is the default configuration. Each input behaves as a

single ended, unipolar input with an input range of 0-5V. The input’s 0V connection is
connected to pin 9, AGND.

H Single ended, bipolar (ADCMODE 2): Each input is a single ended, bi-polar input with an

input range of ±5V. The input’s 0V connection is connected to pin 9, AGND.

H Pseudo differential (ADCMODE 1): Inputs are used in pairs (0 and 1, 2 and 3, 4 and 5, 6 and

7) to create four differential inputs. Within each pair, the odd numbered input is the
negative input, and the even numbered input is the positive input. The input range is 0 ­5V.

(Mating connector: Weidmüller BL 3.5/10, 3.5mm pitch)

Pin Name MintMT keyword / description

1 AIN0 ADC.0
2 AIN1 ADC.1
3 AIN2 ADC.2
4 AIN3 ADC.3
5 AIN4 ADC.4
6 AIN5 ADC.5
7 AIN6 ADC.6
8 AIN7 ADC.7

9 AGND Analog ground

10 Shield Shield connection

4-4 Input / Output MN1904

H Pseudo differential, bipolar (ADCMODE 3): Inputs are used in pairs (0 and 1, 2 and 3, 4 and

5, 6 and 7) to create four differential inputs. Within each pair, the odd numbered input is the
negative input, and the even numbered input is the positive input. The input range is
±2.5V.

H True differential (ADCMODE 5): Inputs are used in pairs (0 and 1, 2 and 3, 4 and 5, 6 and 7)

to create four differential inputs. Within each pair, the odd numbered input is the negative
input, and the even numbered input is the positive input. The input range is ±10V.

When an input is selected to operate in any of the paired modes (1, 3 or 5), the other input of
the pair is automatically configured to the same mode. The differential input is referenced
using the name of the odd numbered input.

ADCMODE 4 can be used to turn off an input. When an input is turned off, the sampling
frequency for the other inputs increases proportionately, to a maximum of 4.5kHz for a single
active input.

See the Mint help file for full information about ADCMODE and analog input configuration.

AIN0
Pin 1

AIN1
Pin 2

NextMove BX

II

+12V

10k

10k 10k

-12V

10k

20k

-

+

20k

-

+

10k

56k

56k

10k

14k

10k

-

+

14k

-

+

10k

-

+

Mint

ADC.0

Mint

ADC.0

(differential
mode)

Mint

ADC.1

Figure 2 - Analog input circuit, AIN0/AIN1 pair shown

Input / Output 4-5MN1904

4.5.2 Analog outputs (Demands) - X7

1

Location Connector X7

(Mating connector: Weidmüller BL 3.5/10, 3.5mm pitch)

Pin Name MintMT keyword / description

1 Demand0 DAC.0

2 AGND Analog ground

10

3 Demand1 DAC.1

4 AGND Analog ground
5 Demand2 DAC.2

6 AGND Analog ground
7 Demand3 DAC.3

8 AGND Analog ground

9 AGND Analog ground

10 Shield Shield connection

Description

Four independent command outputs
Output range: ±10VDC (±10mV).
Resolution: 14-bit (accuracy ±1.22mV).
Output current: 1mA maximum
Update interval: Immediate

Mint and the Mint Motion Library use the analog outputs to control servo drives.
Demand outputs 0 to 3 correspond to axes 0 to 3. The analog outputs may be used to drive
loads of 10kΩ or greater. The outputs are referenced to the internal ground and are not
opto-isolated. Shielded twisted pair cable should be used. The shield connection should be
made at one end only.

NextMove BX

Demand

±100%

II

12k

1nF

14k7

-

TL084

+

+12V

-12V

Demand0
Pin 1

AGND

Figure 3 - Analog output circuit - Demand0 shown

4-6 Input / Output MN1904

4.6 Digital I/O

There are a total of 20 digital inputs. Inputs DIN0 to DIN15 are general purpose inputs, which
can be configured in Mint for any of the following functions:

H forward limit (end of travel) input on any axis

H reverse limit (end of travel) input on any axis

H home input on any axis

H drive error input on any axis

H controlled stop input on any axis.

Inputs DIN16 to DIN19 are known as fast position interrrupts and can only be used to latch
position. They cannot be used as general purpose inputs and their states cannot be read in
Mint.

Inputs can be shared between axes, and are programmable in Mint (using the keywords
INPUTACTIVELEVEL, INPUTMODE, INPUTPOSTRIGGER and INPUTNEGTRIGGER)to
determine their active level and if they should be edge triggered.

There are a 8 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.

The outputs are driven by a current sourcing, PNP Darlington type driver, with overcurrent and
short circuit protection. Power for the outputs is derived from a customer supplied 12-24V
supply.

Input / Output 4-7MN1904

4.6.1 Digital inputs - X1

Location Connector X1

(Mating connector: Weidmüller BL 3.5/10, 3.5mm pitch)

Pin Name Mint keyword / description

1 DIN8 INX.8
2 DIN9 INX.9
3 DIN10 INX.10
4 DIN11 INX.11
5 DIN12 INX.12
6 DIN13 INX.13
7 DIN14 INX.14
8 DIN15 INX.15

9 CREF Common connection

10 Shield Shield connection

Description

Eight general purpose optically isolated AC digital inputs.
Sampling interval: 1ms

NextMove BX

II

Vcc

DINx

CREF

2k2

Active high:

DINx = 12-24VDC (±20%)
CREF =0V

TLP120

Active low:

DINx =0V
CREF = 12-24VDC (±20%)

Mint

INX.x

Figure 4 - Digital input circuit

4-8 Input / Output MN1904

The inputs are conditioned using 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. The use of shielded cable for inputs is recommended.

Active high: connect +24VDC to the input and 0V to pin 9 (CREF).
The digital inputs will be active when a voltage of +24VDC (greater than 12VDC) is applied to
them and will sink a current of approximately 11mA each.

Active low: connect +24VDC to pin 9 (CREF) and 0V to the input.
The digital inputs will be active when grounded (<2V) and will source a maximum of 11mA
each.

Note: Sustained input voltages above 28V will damage the inputs.

4.6.2 Digital inputs - X2

1

10

The inputs are electrically identical to inputs DIN8 to DIN15 described in section 4.6.1.

Location Connector X2

(Mating connector: Weidmüller BL 3.5/10, 3.5mm pitch)

Pin Name Mint keyword / description

1 DIN0 INX.0
2 DIN1 INX.1
3 DIN2 INX.2
4 DIN3 INX.3
5 DIN4 INX.4
6 DIN5 INX.5
7 DIN6 INX.6
8 DIN7 INX.7

9 Common Common connection

10 Shield Shield connection

Description

Eight general purpose optically isolated AC digital inputs.
Sampling interval: 1ms

Input / Output 4-9MN1904

4.6.3 Digital inputs (Interrupts) - X6

Digital inputs FASTIN0 to FASTIN3 can be used as high speed position latches, allowing any
combination of axes to be captured by the hardware. Using FASTIN0, the latency between
input triggering and capture is 30µs. Using FASTIN1 to FASTIN3, latency is 1ms. Special Mint
keywords (beginning with the letters FAST...) allow specific functions to be performed as a
result of fast position inputs becoming active. See the Mint help file for details.

1

Location

Connector X6
(Mating connector: Weidmüller BL 3.5/10, 3.5mm pitch)

Pin Name Mint keyword / description

1 FASTIN0 FASTSELECT.0

2 Shield Shield connection

10

3 CREF Common connection
4 FASTIN1 FASTSELECT.1

5 Shield Shield connection

6 CREF Common connection
7 FASTIN2 FASTSELECT.2

8 Shield Shield connection

9 CREF Common connection

10 FASTIN3 FASTSELECT.3

Description

Four fast position digital inputs.

Note: The fast inputs are particularly sensitive to noise, so inputs must use shielded

twisted pair cable. Do not connect mechanical switches, relay contacts or other
sources liable to signal ‘bounce’ directly to the fast inputs. This could cause
unwanted multiple triggering.

NextMove BX

FASTIN x

CREF

II

Vcc

2k2

Mint

100pF

TLP115

Active high:

FASTIN x = 12-24VDC (±20%)
CREF =0V

Active low:

FASTIN x =0V
CREF = 12-24VDC (±20%)

Figure 5 - Digital input circuit - fast interrupts

4-10 Input / Output MN1904

4.6.4 Digital outputs - X4

1

Location Connector X4

(Mating connector: Weidmüller BL 3.5/10, 3.5mm pitch)

Pin Name Mint keyword / description

1 DOUT0 OUTX.0
2 DOUT1 OUTX.1

10

3 DOUT2 OUTX.2
4 DOUT3 OUTX.3
5 DOUT4 OUTX.4
6 DOUT5 OUTX.5
7 DOUT6 OUTX.6
8 DOUT7 OUTX.7

9 USR V+ Customer power supply V+

10 CGND Customer power supply ground

Description

Eight general purpose optically isolated digital outputs.
Output current: 50mA maximum (continuous) each output
Update interval: Immediate

Each optically isolated output is designed to source current from the customer supplied
12-24V supply (USR V+) as shown in Figure 6. The outputs can be written to directly using
the Mint keyword OUTX (for example OUTX.2=1).
The sense of the outputs can be configured in WorkBench v5, and their states are displayed in
the Spy window. The use of shielded cable is recommended.

NextMove BX

OUTX.x

II

UDN2987
Output

TLP121

module

USR V+

DOUTx

Output
load

CGND

Figure 6 - Digital output circuit

The USR V+ and CGND connections on pins 9 and 10 are connected internally to the USR V+
and CGND pins on connector X5. See section 4.7.3.

Input / Output 4-11MN1904

4.7 Other I/O

4.7.1 Encoder interfaces - X9, X10, X11, X12, X13

Location Connectors X9, X11, X11, X12, X13

Pin Name Description

1 CHA+ Channel A signal

2 CHB+ Channel B signal

3 CHZ+ Index channel signal

4 (NC) Not connected

5

9

6

1

Description

Five identical encoder inputs, each with complementary A, B and Z
channel inputs on a 9-pin female D-type connector

Up to five incremental encoders may be connected to NextMove BXII. The auxiliary (master)
encoder (X13) is labeled Aux Encoder. Each input channel enters an AM26LS32AM differential
line receiver with pull up resistors and terminators. Encoders must provide 5V single ended or
differential signals, or RS422/RS485 differential signals. The use of individually shielded
twisted pair cable is recommended. See section 4.4.1 for details of the encoder power supply.

5 DGND Power supply ground

6 CHA- Channel A signal complement

7 CHB- Channel B signal complement

8 CHZ- Index channel signal complement

9 +5V out Power supply to encoder

II

2k2

120R

2k2

Vcc

AM26LS32
Differential
line receiver

to CPU

CHA+

Pin 1

CHA­Pin 6

NextMove BX

22R

22R

Figure 7 - Encoder channel input circuit - Channel A shown

4-12 Input / Output MN1904

4.7.2 Encoder input frequency

Encoder

The maximum encoder input frequency is affected by the length of the encoder cables. The
theoretical maximum frequency is 7.5 million quadrature counts per second. This is equivalent
to a maximum frequency for the A and B signals of 1.87MHz. However, the effect of cable
length is shown in the Table 1:

Encoder

Frequency

1.3MHz 2 6.56

500kHz 10 32.8

250kHz 20 65.6

100kHz 50 164.0

50kHz 100 328.1

20kHz 300 984.2

10kHz 700 2296.6

7kHz 1000 3280.8

Table 1 - Effect of cable length on maximum encoder frequency

The maximum recommended cable length is 30.5m (100ft).

meters feet

Maximum cable length

Input / Output 4-13MN1904

4.7.3 Relay and user power - X5

Location Connector X5

(Mating connector: Weidmüller BL 3.5/10, 3.5mm pitch)

Pin Name Description

1 Relay COM Common relay connection

2 Relay NC Normally closed relay connection

3 Relay NO Normally open relay connection

4 Relay COM Common relay connection

5 USR V+ Digital output customer power supply

6 USR V+ Digital output customer power supply

7 CREF Digital input common connection

8 CREF Digital input common connection

9 CGND Digital output customer power supply ground

10 CGND Digital output customer power supply ground

Description

Connection point for the digital outputs’ customer power supply and the
relay contacts. Relay rated at 1A, 24VDC

The relay and user power connector X5 provides a connection point for the internal relay, the
customer power supply used to power the digital outputs, and the digital input’s common
connection. Power connections are assigned two pins to provide increased wiring capacity.
The USR V+ and CGND connections on pins 5/6 and 9/10 are connected internally to the
USR V+ and CGND pins on connector X4 - see section 4.6.4.

The relay outputs are isolated from any internal circuits in the NextMove BX
controlled by a latch, which is cleared when the NextMove BX

II

resets. Reset can occur due to

II

.Therelayis

power-down, a watchdog error or when deliberately caused by the host PC. In normal
operation the relay is energized and the Relay NC contact is connected to Relay COM. In the
event of an error or power loss, the relay is de-energized and the Relay NO contact is
connected to Relay COM.

The relay can be configured as a global error output using the Mint keyword
GLOBALERROROUTPUT.

Mint

II

Relay

Relay NC
Pin 2

Relay NO
Pin 3

Relay COM
Pin 1

NextMove BX

Figure 8 - Relay connections

4-14 Input / Output MN1904

4.7.4 RS232 - X15

Location Top panel, connector X15

Pin Name

1 Shield

2 RXD

1

6

9

5

Description

RS232 connections on a single 9-pin male D-type connector

The NextMove BXIIhas a full-duplex RS232 serial port with the following preset configuration:

H 9600 baud

H 1startbit

H 8 data bits

H 1stopbit

H No parity

H Hardware handshaking lines (RS232) RTS and CTS must be connected.

3 TXD

4 DTR (internally connected to pin 6)

5 0V

6 DSR (internally connected to pin 4)

7 RTS

8 CTS

9 0V

The configuration can be changed using the Mint keyword SERIALBAUD.Itisstoredin
EEPROM and restored at power up.

The port is configured as a DTE (Data Terminal Equipment) unit so it is possible to operate the
controller with any DCE (Data Communications Equipment) or DTE equipment. Full duplex
transmission with hardware handshaking is supported.

Only the TXD, RXD and 0V GND connections are essential for communication, although
hardware handshaking will not be supported unless the other connections are made.

Both the output and input circuitry are single ended and operate between ±12V. The port is
capable of operation at up to 57.6Kbaud.

Input / Output 4-15MN1904

NextMove BX

(DTE)

RS232

RXD 2

TXD 3

II

GND 5

RTS 7
CTS 8

Connect overall

shield to connector

backshell.

COM

2RXD
3TXD
5GND
7RTS
8CTS

9--pin
Computer
COM Port

(DCE / DTE)

Figure 9 - RS232 serial port connections

The maximum recommended cable length is 3m (10ft) at 57.6Kbaud. When using lower baud
rates, longer cable lengths may be used up to maximum of 15m (49ft) at 9600 baud.

4-16 Input / Output MN1904

4.7.5 Connecting Baldor HMI Operator Panels

Baldor HMI Operator Panels use a 15-pin male D-type connector (marked PLC PORT), but
the NextMove BX
hardware handshaking then use the connections shown in Figure 10:

II

RS232 connector is a 9-pin male D-type connector. If you do not require

Baldor HMI

PLC PORT

RXD 2

TXD 3

GND 5

NextMove BX

Twist ed pa ir

1

RS232

7RTS

8CTS

3TXD

2RXD

5GND

II

Figure 10 - Cable wiring if hardware handshaking is not required

If hardware handshaking is required then use the connections shown in Figure 11:

Baldor HMI
PLC PORT

CTS 11

RTS 10

RXD 2

TXD 3

GND 5

Twisted pair

1

NextMove BX

RS232

7RTS

8CTS

3TXD

2RXD

5GND

II

Figure 11 - Cable wiring if hardware handshaking is required

Input / Output 4-17MN1904

4.7.6 RS422 / RS485 - X14

If you will be using RS422 / RS485 and your PC does not have an RS422 / RS485 connector,
an RS232 to 4-wire RS422 / RS485 converter will be required. These commercially available
devices convert the signals from the PC RS232 port to the signals necessary for RS422 /
RS485 communications. Special care must be taken with the pin assignment on all RS422 /
RS485 devices, as this can differ between products. Connectors might need to be rewired to
provide the correct pin assignment.

Location

Top panel, connector X14

Pin Name

1 Shield

2 RX+ (input)

3 TX+ (output)

1

6

9

5

4 (NC)

5 GND

6 (NC)

7 TX- (output)

8 RX- (input)

9 GND

Description

RS422 / RS485 connections on a 9-pin male D-type connector

This port provides 4-wire RS422 / RS485 connections. The port can be used for multidrop
applications operating at 9600 or 19200 baud. The configuration can be changed using the
Mint keyword SERIALBAUD. It is stored in EEPROM and restored at power up.

Both the output and input circuitry are differential and operate between 0 and 5V.

Multidrop systems allow one device to act as a ‘network master’, controlling and interacting
with the other (slave) devices on the network. The network master can be a controller such as
a NextMove BX

II

, a host application such as WorkBench v5 (or other custom application), or a

programmable logic controller (PLC).

The NextMove BX
uniquely identify it on the network. The address of the NextMove BX

II

supports up to 15 devices, each having its own address (node) number to

II

can be configured using

the Mint keyword NODE. It is stored in EEPROM and restored at power up.

4-18 Input / Output MN1904

Network

master

TX+

TX-

RX+

RX-

DGND

T

R

Twisted pairs

Final slave shown with
terminating resistor, TR,
typical value 120Ω.

Network slave

RX+

RX-

TX+

TX-

DGND

Network slave

T

R

RX+

RX-

TX+

TX-

DGND

Connect overall shield
to connector backshell.

Figure 12 - 4-wire RS485 multi-drop connections

Each TX/RX network requires a termination resistor at the final RX connection, but
intermediate devices must not be fitted with termination resistors. An exception is where
repeaters are being used which may correctly contain termination resistors.

Termination resistors are used to match the impedance of the load to the impedance of the
transmission line (cable) being used. Unmatched impedance causes the transmitted signal to
not be fully absorbed by the load. This causes a portion of the signal to be reflected back into
the transmission line as noise. If the source impedance, transmission line impedance, and
load impedance are all equal, the reflections (noise) are eliminated. T ermination resistors
increase the load current and sometimes change the bias requirements and increase the
complexity of the system.

Input / Output 4-19MN1904

4.7.7 CAN connectors - X16 & X17

CAN (Controller Area Network) offers very reliable serial communications over a two wire
twisted pair cable. In an industrial environment, the probability of an undetected error is

-11

4.7x10
and low cost multiplex wiring schemes. CAN is optimized for the transmission of small data
packets and therefore offers fast update of I/O devices (peripherals) connected to the bus.
The CAN network allows several CAN peripheral devices to be attached to the same
controller.

The CAN connectors provide access to CANopen (CAN1) and Baldor CAN (CAN2) busses on
two separate connectors. Both busses are available on both connectors to simplify
“daisy-chaining” of peripherals.

. CAN also offers high speed data transfer (up to 1Mbit/s, dependent on bus length)

Location

Top panel, connectors X16 & X17

Pin Name Description

1 CAN1+ CANopen

2 CAN1- CANopen

3 (NC) Not connected

4 CAN 0V Ground/earth reference for CAN signals

5 CAN V+ CAN remote node power V+ (12-24V)

1

8

6 (NC) Not connected

7 CAN2+ Baldor CAN

8 CAN2- Baldor CAN

Description

CAN interfaces using RJ45 connectors.

Correct operation of CAN can only be achieved with screened/shielded twisted-pair cabling.
CAN1+ / CAN1- and CAN2+ / CAN2- must form twisted pairs with the shield connected to the
connector backshell, as shown in Figure 13. A range of suitable CAN cables are available
from Baldor, with catalog numbers beginning CBL004-5...

Baldor HMI

Operator Panel

2

7

T

R

NextMove BX

Twisted pair Twisted pairs

II

1

2

2

1

1

5

5

4

4

NextMove BX

II

T

R

End node

2

1

5

4

2

2

2

1

1

5

5

4

4

Figure 13 - Typical CAN network connections

4-20 Input / Output MN1904

4.7.8 CANopen

CANopen is a networking system based on the serial bus CAN. It uses the international CAN
standard ISO 11898 as the basis for communication. The Mint firmware implements a
CANopen protocol on CAN bus 1, based on the ‘Communication Profile’ CiA DS-301, which
supports both direct access to device parameters and time-critical process data
communication. This provides support for a range of Baldor and third-party devices.

The CANopen channel is available on both CAN connectors.

The default baud rate is 500Kbit/s, but this can be changed using the Mint
keyword BUSBAUD (previously CANBAUD). It is stored in EEPROM and
restored at power up.

CAN1 must be terminated by a 120Ω resistor connected between CAN1+

and CAN1- at both ends of the network and nowhere else. If the
NextMove BX
top panel) is fitted.

II

is at the end of the network then ensure that CAN jumper 1 (accessible on the

4.7.9 Baldor CAN

Baldor CAN is also a networking system based on the serial bus CAN. It uses the
international CAN standard ISO 11898 as the basis for communication. The Mint firmware
implements a proprietary Baldor protocol on CAN bus 2, based on CAL, which supports both
direct access to device parameters and time-critical process data communication. This
provides support for the full range of Baldor ioNode CAN peripherals.

The Baldor CAN channel is available on both CAN connectors.

The default baud rate is 125Kbit/s, but this can be changed using the Mint

keyword BUSBAUD (previously CANBAUD). It is stored in EEPROM and

restored at power up.

CAN2 must be terminated by a 120Ω resistor connected between CAN2+

and CAN2- at both ends of the network and nowhere else. If the
NextMove BX
the top panel) is fitted.

On the ioNode peripheral, jumpers JP1 and JP2 must be in the CAN Bus 2 position to select
pins 7 & 8 for CAN traffic.

II

is at the end of the network then ensure that the CAN jumper 2 (accessible on

Input / Output 4-21MN1904

4.8 Reset states

During power up, NextMove BXIIis held in a safe non-operational state known as hardware
reset. It will also go into hardware reset if the 24V logic supply drops below approximately
18V. This prevents uncontrolled operation due to the electronics losing power. When
NextMove BX
known states.

It is also possible for NextMove BX
operational state where only the bootloader present on NextMove BX
valid firmware has been found. This can happen if a firmware download is cancelled before it
has finished. Use WorkBench v5 to download new firmware, allowing the process to finish.
This might take 1-2 minutes.

Hardware and software reset states should not be confused with the Mint keyword RESET
whichisusedtoclearaxiserrors.

Communications

At power up the CAN controllers will be held in reset and will have no effect on the CAN
buses. If a reset occurs during the transmission of a message CAN errors are likely to occur.

Digital Outputs

All of the digital outputs are inactive on power up regardless of their polarity. They will return
to the inactive state whenever a reset occurs.

Analog Outputs

All analog outputs are set to 0V by hardware during power up and will return to 0V on a reset.

Encoders

The encoder interfaces will not register any encoder input during reset. If the unit goes into
reset all position data will be lost.

II

is in hardware reset for any reason, most of the controlled interfaces fall into

II

to be in a state known as software reset. This is a safe

II

is running, because no

4.8.1 System watchdog

The system watchdog provides hardware protection in the event of a firmware or ‘C’ program
malfunction. If the system watchdog is not updated, the controller will be reset.

4-22 Input / Output MN1904

4.9 Connection summary - minimum system wiring

As a guide, Figure 14 shows an example of the typical minimum wiring required to allow the
NextMove BX

Host PC NextMove BX

II

and a single servo amplifier (motor drive) to work together.

Serial
communication

II

Servo amplifier (axis 0)

Error out

Demand +
Demand -

Enable*
Gnd*

Encoder output fr om
drive or motor

+24V

supply

Figure 14 - Example minimum system wiring - Axis 0

Each connection is described in Table 2.

Common

earth/ground

*Note:

This diagram shows the relay contacts
being used as a switch ac ross the servo
amplifier’s enable input.

If the servo amplifierrequires a 24V enable
signal then use the relay to switch 24V
from either the logic supply or user supply.

Input / Output 4-23MN1904

NextMove BX

connector

II

Name of
signal

Function Servo amplifier

connection

(Note: drive may be
labelled differently)

X1 DIN8 Error input Error output

X5

Relay COM Common connection of relay Enable input

Relay NC Normally closed connection

Ground

of relay

X7

Demand0 Command signal for axis 0 Demand+ input

AGND Reference for analog signals Demand- input

Shield Cable shield (Not connected)

X9 (Encoder 0) Position feedback for axis 0 Encoder out (or direct

from motor)

X8

+24V Logic supply +24V

0V Logic supply 0V

Table 2 - Minimum system wiring connections

4-24 Input / Output MN1904

5 Operation

5.1 Introduction

Before powering the NextMove BXIIyou will need to connect it to the PC using a serial cable
and install the supplied PC software WorkBench v5. This software includes a number of tools
to allow you to configure, tune and program the NextMove BX
of software installation or Windows applications you may need further assistance for this stage
of the installation

5.1.1 Connecting the NextMove BXIIto the PC

Connect the serial cable between a PC serial port (often labeled as “COM”) to the
NextMove BX
any port.

II

RS232 connector. WorkBench v5 can scan all the COM ports, so you can use

5.1.2 Installing the software

The CDROM c ontaining the software can be found separately within the packaging.

1. Insert the CDROM into the drive.

2. After a few seconds the setup wizard should start automatically. If the setup wizard does not

appear, select Run... from the Windows Start menu and type

d:\start

II

. If you do not have experience

5

where d represents the drive letter of the CDROM device (use the correct letter for your
installation).

Follow the on-screen instructions to install WorkBench v5. The setup wizard will copy the files
to appropriate folders on the hard drive. The default folder is C:\Program Files\Baldor\MintMT,
although this can be changed during setup.

5.1.3 Starting the NextMove BX

If you have followed the instructions in the previous sections, you should have now connected
all the power sources, your choice of inputs and outputs and the serial cable linking the PC
with the NextMove BX

II

.

II

5.1.4 Preliminary checks

Before you apply power for the first time, it is very important to verify the following:

H Disconnect the load from the motor until instructed to apply a load.

H Inspect all power connections for accuracy, workmanship and tightness.

H Verify that all wiring conforms to applicable codes.

H Verify that the NextMove BX

H Check all signal wiring for accuracy.

II

is properly earthed/grounded.

Operation 5-1MN1904

5.1.5 Power on checks

If at any time one of the Axis LEDs is illuminated red, this indicates that the NextMove BX
has detected a fault - see section 6.

1. Turn on the 24VDC supply.

2. After a brief test sequence the Status display should show the node number, for example
(the factory preset). If the display is not lit then re-check the power supply connections.

II

The NextMove BX

is now ready to be configured using WorkBench v5.

II

5-2 Operation MN1904

5.2 WorkBench v5

WorkBench v5 is a fully featured application for programming and controlling the
NextMove BX
other toolbars. Many functions can be accessed from the menu or by clicking a button - use
whichever you prefer. Most buttons include a ‘tool-tip’; hold the mouse pointer over the button
(don’t click) and its description will appear.

II

. The main WorkBench v5 window contains a menu system, the Toolbox and

5.2.1 Help file

WorkBench v5 includes a comprehensive help file that contains information about every Mint
keyword, how to use WorkBench v5 and background information on motion control topics. The
help file can be displayed at any time by pressing F1. On the left of the help window, the
Contents tab shows the tree structure of the help file. Each book

topics
search for them by name. The Search tab allows you to search for words or phrases
appearing anywhere in the help file. Many words and phrases are underlined and highlighted
with a color (normally blue) to show that they are links. Just click on the link to go to an
associated keyword. Most keyword topics begin with a list of relevant See Also links.

. The Index tab provides an alphabetic list of all topics in the file, and allows you to

contains a number of

Figure 15 - The WorkBench v5 help file

For help on using WorkBench v5, click the Contents tab, then click the small plus sign

beside the WorkB ench v5 book icon. Double click a topic name to display it.

Operation 5-3MN1904

5.2.2 Starting WorkBench v5

1. On the Windows Start menu, select Programs, WorkBench v5, WorkBench v5.

WorkBench v5 will start, and the Tip of the Day dialog will be displayed.

You can prevent the Tip of the Day dialog appearing next time by removing the check mark
next to Show tips at startup.

Click Close to continue.

2. In the opening dialog box, click Start New Project... .

5-4 Operation MN1904

3. In the Select Controller dialog, go to the drop down box near the top and select the PC serial
port to which the NextMove BX

(If you are unsure which PC serial port is connected to the NextMove BX

II

is connected.

II

, select Scan all

serial ports. During the detection process, a dialog box may be displayed to tell you that

WorkBench v5 has detected new firmware. Click OK to continue.)

Click Scan to search for the NextMove BX

When the search is complete, click on NextMove BX

II

.

II

in the list to highlight it, and click the

Select button.

Note: If the NextMove BXIIis not listed, check the serial lead between the

NextMove BX

II

and the PC. Check that the NextMove BXIIis powered correctly.

Click Scan to re-scan the ports.

When detection is complete, Fine-tuning mode will be displayed.

Operation 5-5MN1904

5.3 Configuring an axis

The NextMove BXIIis capable of controlling up to 4 servo axes, depending on model. Axis
numbering always begin at 0. For example, a four axis model has axes numbered 0, 1, 2 and

3. This section describes the basic setup for a single axis.

Note: The NextMove BX

axis allows most Mint commands to be executed as normal, with the virtual axis
simulating position and velocity information for any motion performed. No physical
axes are moved.

5.3.1 Selecting a scale

Mint defines all positional and speed related motion keywords in terms of encoder quadrature
counts (for servo motors). The number of quadrature counts is divided by the SCALE factor
allowing you to use units more suitable for your application. The unit defined by setting a value
for scale is called the user unit (uu).

Consider a motor with a 1000 line encoder. This provides 4000 quadrature counts for each
revolution. If SCALE is not set, a Mint command that involves distance, speed, or acceleration
may need to use a large number to specify a significant move. For example MOVER=16000
(Move Relative) would rotate the motor by 16000 quadrature counts - only four revolutions. By
setting a SCALE factor of 4000, the user unit becomes revolutions. The more understandable
command MOVER=4 could now be used to move the motor four revolutions.

In applications involving linear motion a suitable value for SCALE would allow commands to
express values in linear distance, for example inches, feet or millimetres.

1. In the Toolbox, click Setup, then click
the Parameters icon.

II

is also capable of controlling up to 4 ‘virtual’ axes. A virtual

2. Click the Scale tab.

3. Click in the Axis drop down box to select the
axis.

Each axis can have a different scale if required.

5-6 Operation MN1904

4. Click in the Scale box and type a value.

5. Click Apply.

This immediately sets the scaling factor for the
selected axis. It will remain in the
NextMove BX
or power is removed.

II

until another scale is defined,

5.3.2 Setting the drive enable output

The drive enable output allows NextMove BXIIto disable the drive in the event of an error.
Each axis can be configured with its own drive enable output, or can share an output with
other axes. If an output is shared, an error on any of the axes sharing the output will cause all
of them to be disabled.

The drive enable output can either be a digital output or the relay.

1. In the Toolbox, click the Digital I/O icon.

2. At the bottom of the Digital I/O screen, click the
Digital Outputs tab.

The left of the screen shows two yellow icons,
High and Low. These describe how the output
should behave when activated (to enable the
axis).

3. If you are going to use the relay, ignore this step
and go straight to step 4.

If you are going to use a digital output, drag the
appropriate yellow icon to the grey OUT icon
that will be used as the drive enable output. Its
color will change to bright blue.

Operation 5-7MN1904

4. If you are going to use the relay, drag the grey Relay0 icon to the grey X axis icon on the right
of the screen. To configure multiple axes to use the relay, repeat this step for the other axes.

If you are using a digital output, drag the bright blue OUT icon to the grey X axis icon on the
right of the screen. To configure multiple axes with the same drive enable output, repeat this
step for the other axes.

5. Click Apply at the bottom of the screen. This
sends the output configuration to the
NextMove BX

II

.

5.3.3 Testing the drive enable output

1. On the main WorkBench v5 toolbar, click the
Drive enable button. Click the button again.
Each time you click the button, the drive enable
output is toggled.

When the button is in the pressed (down)
position the drive should be enabled. When the
button is in the raised (up) position the drive
should be disabled.

If this is not working, or the action of the button is reversed, check the electrical
connections between the NextMove BX
check that you are using the correct normally open or normally closed connection.

If you are using a digital output, check that it is using the correct high or low output
expected by the drive.

II

and the drive. If you are using the relay output,

5-8 Operation MN1904

5.4 Testing and tuning

This section describes the method for testing and tuning an axis.

5.4.1 Testing the drive command output

This section tests the operation and direction of the axis command output. It is recommended
that the motor is disconnected for this test.

1. Check that the Drive enable button is pressed
(down).

2. In the Toolbox, click Application then click
the Edit & Debug icon.

3. Click in the Command window.

4. Type:

TORQUE.0=5

where 0 is the axis (demand output) to be
tested. In this example, this should cause a
demand of +5% of maximum output (0.5V) to
be produced at the Demand0 output
(connector X7, pin 1). See section 4.5.2 for
details of the demand outputs. In WorkBench v5, look at the Spy window located on the right
of the screen. The virtual LED Command display should show 5 (approximately). If there
seems to be no command output, check the electrical connections between the
NextMove BX

5. To repeat the tests for negative (reverse) demands, type:

TORQUE.0=-5

This should cause a demand of -5% of maximum output (-0.5V) to be produced at the
Demand0 output.

II

and the drive.

Operation 5-9MN1904

6. To remove the demand and stop the test, type:

STOP.0

This should cause the demand produced at the
Demand0 output to become 0V.

5-10 Operation MN1904

5.5 An introduction to closed loop control

This section describes the basic principles of closed loop control. If you are familiar with closed
loop control go straight to section 5.6.1.

When there is a requirement to move an axis, the NextMove BX
into a demand output voltage. This is used to control the drive (servo amplifier) which powers the
motor. An encoder or resolver on the motor is used to measure the motor’s position. Every 1ms
(adjustable using the LOOPTIME keyword) the NextMove BX
measured positions. It then calculates the demand needed to minimize the difference between
them, known as the following error.

This system of constant measurement and correction is known as closed loop control.
[ For the analogy,imagine you are in your car waiting at an intersection. You are going to go straight

on when the lights change, just like the car standing next to you which is called Demand. You’re
not going to race Demand though - your job as the controller (NextMove BX
level with Demand, looking out of the window to measure your position ].

The main term that the NextMove BX

II

uses to correct the error is called Proportional gain
(KPROP). A very simple proportional controller would simply multiply the amount of error by the
Proportional gain and apply the result to the motor [ the further Demand gets ahead or behind you,
the more you press or release the gas pedal ].

If the Proportional gain is set too high overshoot will occur, resulting in the motor vibrating back
and forth around the desired position before it settles [ you press the gas pedal so hard you go

right past Demand. To try and stay level you ease off the gas, but end up falling behind a little. You
keep repeating this and after a few tries you end up level with Demand, travelling at a steady
speed. This is what you wanted to do but it has taken you a long time ].
If the Proportional gain is increased still further, the system becomes unstable [ you keep pressing
and then letting off the gas pedal so hard you never travel at a steady speed ].

II

control software translates this

II

compares the demanded and

II

)istostayexactly

To reduce the onset of instability, a term called Velocity Feedback gain (KVEL) is used. This
resists rapid movement of the motor and allows the Proportional gain to be set higher before
vibration starts. Another term called Derivative gain (KDERIV) can also be used to give a similar
effect.

With Proportional gain and Velocity Feedback gain (or Derivative gain) it is possible for a motor
tocometoastopwithasmallfollowingerror[Demandstopped so you stopped too, but not quite
level ]. The NextMove BX

II

tries to correct the error, but because the error is so small the amount

of torque demanded might not be enough to overcome friction.

In this situation, a term called Integral gain (KINT) can be used. This sums the error over time,
so that the motor torque is gradually increased until the positional error is reduced to zero [ like

a person gradually pushing harder and harder on your car until they’ve pushed it level with

Demand]. However, if there is large load on the motor (it is supporting a heavy suspended weight
for example), it is possible for the output to increase to 100% demand. This effect can be limited
using the KINTLIMIT keyword which limits the effect of KINT to a given percentage of the
demand output. Another keyword called KINTMODE can even turn off integral action when it’s not
needed.

The remaining gain terms are Velocity Feed forward (KVELFF) and Acceleration Feed

forward (KACCEL).

Operation 5-11MN1904

In summary, the following rules can be used as a guide:

H KPROP: Increasing KPROP will speed up the response and reduce the effect of disturbances

and load variations. The side effect of increasing KPROP is that it also increases the
overshoot, and if set too high it will cause the system to become unstable. The aim is to set
the Proportional gain as high as possible without getting overshoot, instability or hunting on
an encoder edge when stationary (the motor will buzz).

H KVEL: This gain has a damping effect, andcan beincreased to reduce any overshoot. IfKVEL

becomes too large it will amplify any noise on the velocity measurement and introduce
oscillations.

H KINT: This gain has a de-stabilizing effect, but a small amount can be used to reduce any

steady state errors. By default, KINTMODE is set so that the KINT term is either ignored, or
is only applied during periods of constant velocity.

H KINTLIMIT: The integration limit determines the maximum value of the effect of integral action.

This is specified as a percentage of the full scale demand.

H KDERIV: This gain has a damping effect. The Derivative action has the same effect as the

velocity feedback if the velocity feedback and feedforward terms are equal.

H KVELFF: This is a feed forward term and as such has a different effect on the servo system

than the previous gains. KVELFF is outside the closed loop and therefore does not have an
effect on system stability. This gain allows a faster response to demand speed changes with
lower following errors, for example you would increase KVELFF to reduce the following error
during the slew section of a trapezoidal move. The trapezoidal test move can be used to
fine-tune this gain. This term is especially useful with velocity controlled servos

H KACCEL: This term is designed to reduce velocity overshoots on high acceleration moves.

Due to the quantization of the positional data and the speed of the servo loop, for the
acceleration feed forward term to affect the servo loop the acceleration of the axis must
exceed 1,000,000 encoder counts per second.

5-12 Operation MN1904

Figure 16 - The NextMove BXIIservo loop

Operation 5-13MN1904

5.6 Tuning an axis for current control

5.6.1 Selecting servo loop gains

All servo loop parameters default to zero, meaning that the demand output will be zero at
power up. Most servo amplifiers can be set to current (torque) control mode or velocity control
mode; check that the servo amplifier will operate in the correct mode. The procedure for
setting system gains differs slightly for each. To tune an axis for velocity control, go straight to
section 5.8. It is recommended that the system is initially tested and tuned with the motor shaft
disconnected from other machinery.

Note: The method explained in this section should allow you to gain good control of the

motor, but will not necessarily provide the optimum response without further
fine-tuning. Unavoidably, this requires a good understanding of the effect of the
gain terms.

1. In the Toolbox, click the Fine-tuning icon.

The Fine-tuning window is displayed at the
right of the screen. The main area of the
WorkBench v5 window displays the Capture
window. When tuning tests are performed, this
will display a graph representing the response.

2. In the Fine-tuning window, click in the KDERIV
box and enter a starting value of 1.

Click Apply and then turn the motor shaft by
hand. Repeat this process, slowly increasing
the value of KDERIV until you begin to feel
some resistance in the motor shaft. The exact
value of KDERIV is not critical at this stage.

3. Click in the KPROP box and enter a value that
is approximately one quarter of the value of
KDERIV. If the motor begins to vibrate,
decrease the value of KPROP or increase the
value of KDERIV until the vibration stops.
Small changes may be all that is necessary.

5-14 Operation MN1904

4. In the Move Type drop down box, check that
the move type is set to Step.

5. Click in the Distance box and enter a distance
for the step move. It is recommended to set a
value that will cause the motor to turn a short
distance, for example one revolution.

Note:

The distance depends on the scale set in
section 5.3.1. If you set a scale so that units could be expressed in revolutions (or other unit
of your choice), then those are the units that will be used here. If you did not set a scale, the
amount you enter will be in encoder quadrature counts.

6. Click in the Duration box and enter a duration
for the move, in seconds. This should be a
short duration, for example 0.15 seconds.

7. Click Go.

The NextMove BX
completed, WorkBench v5 will download captured data from the NextMove BX

II

will perform the move and the motor will turn. As the soon as the move is

II

. The data will

then be displayed in the Capture window as a graph.

Note: The graphs that you see will not look exactly the same as the graphs shown here!

Remember that each motor has a slightly different response.

8. Using the check boxes below the graph, select
the traces you require, for example Demand
position and Measured position.

Operation 5-15MN1904

5.6.2 Underdamped response

If the graph shows that the response is underdamped (it overshoots the demand, as shown in
Figure 17) then the value for KDERIV should be increased to add extra damping to the move.
If the overshoot is excessive or oscillation has occurred, it may be necessary to reduce the
value of KPROP.

Measured
position

Demand
position

Figure 17 - Underdamped response

9. Click in the KDERIV and/or KPROP boxes and
make the required changes. The ideal
response is shown in section 5.6.4.

5-16 Operation MN1904

5.6.3 Overdamped response

If the graph shows that the response is overdamped (it reaches the demand too slowly, as
shown in Figure 18) then the value for KDERIV should be decreased to reduce the damping of
the move. If the overdamping is excessive, it may be necessary to increase the value of
KPROP.

Demand
position

Measured
position

Figure 18 - Overdamped response

10. Click in the KDERIV and/or KPROP boxes and
make the required changes. The ideal
response is shown in section 5.6.4.

Operation 5-17MN1904

5.6.4 Critically damped response

If the graph shows that the response reaches the demand quickly and only overshoots the
demand by a small amount, this can be considered an ideal response for most systems.
See Figure 19.

Demand position

Measured position

Figure 19 - Critically damped (ideal) response

5-18 Operation MN1904

5.7 Eliminating steady-state errors

In systems where precise positioning accuracy is required, it is often necessary to position
within one encoder count. The proportional gain, KPROP, is not normally able to achieve this
because a very small following error will only produce a small demand for the drive which may
not be enough to overcome mechanical friction (this is particularly true in current controlled
systems). This error can be overcome by applying integral gain.

The integral gain, KINT, works by accumulating following error over time to produce a demand
sufficient to move the motor into the required position with zero following error. KINT can
therefore overcome errors caused by gravitational effects such as vertically moving linear
tables. With current controlled drives a non-zero demand output is required to hold the load in
the correct position, to achieve zero following error.

Care is required when setting KINT since a high value will cause instability during moves. A
typical value for KINT would be 0.1. The effect of KINT should also be limited by setting the
integration limit, KINTLIMIT, to the smallest possible value that is sufficient to overcome friction
or static loads, for example 5. This will limit the contribution of the integral term to 5% of the full
DAC output range.

1. Click in the KINT box and enter a small starting
value, for example 0.1.

2. Click in the KINTLIMIT box and enter a value
of 5.

With NextMove BX
modes:

H Never - the KINT term is never applied

H Always - the KINT term is always applied

H Smart - the KINT term is only applied when the demand is zero or constant.

This function can be selected using the KINTMODE drop down box.

II

, the action of KINT and KINTLIMIT can be set to operate in various

Operation 5-19MN1904

5.8 Tuning an axis for velocity control

Drives designed for velocity control incorporate their own velocity feedback term to provide
system damping. For this reason, KDERIV (and KVEL) can be set to zero.

Correct setting of the velocity feed forward gain KVELFF is important to get the optimum
response from the system. The velocity feed forward term takes the instantaneous velocity
demand from the profile generator and adds this to the output block (see Figure 16). KVELFF
is outside the closed loop and therefore does not have an effect on system stability. This
means that the term can be increased to maximum without causing the motor to oscillate,
provided that other terms are setup correctly.

When setup correctly, KVELFF will cause the motor to move at the speed demanded by the
profile generator. This is true without the other terms in the closed loop doing anything except
compensating for small errors in the position of the motor. This gives faster response to
changes in demand speed, with reduced following error.

5.8.1 Calculating KVELFF

To calculate the correct value for KVELFF, you will need to know:

H The speed, in revolutions per minute, produced by the motor when a maximum demand

(+10V) is applied to the drive.

H The setting for LOOPTIME. The factory preset setting is 1ms.

H The number of encoder lines for the attached motor. Baldor BSM motors use either 1000

or 2500 line encoders.

The servo loop formula uses speed values expressed in quadrature counts per servo loop.To
calculate this figure:

1. First, divide the speed of the motor, in revolutions per minute, by 60 to give the number of
revolutions per second. For example, if the motor speed is 3000rpm when a maximum
demand (+10V) is applied to the drive:

Revolutions per second = 3000 / 60

2. Next, calculate how many revolutions will occur during one servo loop. The factory preset
servo loop time is 1ms (0.001 seconds), so:

Revolutions per servo loop = 50 x 0.001 seconds

3. Now calculate how many quadrature encoder counts there are per revolution. The
NextMove BX
encoder, so for every encoder line there are 4 ‘quadrature counts’. With a 1000 line
encoder:

Quadrature counts per revolution = 1000 x 4

4. Finally, calculate how many quadrature counts there are per servo loop:

Quadrature counts per servo loop = 4000 x 0.05

II

counts both edges of both pulse trains (CHA and CHB) coming from the

=

=

=

=

50

0.05

4000

200

5-20 Operation MN1904

The analog demand output is controlled by a 12-bit DAC, which can create output voltages in
the range -10V to +10V. This means a maximum output of +10V corresponds to a DAC value
of 2048. The value of KVELFF is calculated by dividing 2048 by the number of quadrature
counts per servo loop, so:

KVELFF = 2048 / 200

=

10.24

5. Click in the KVELFF box and enter the value.

The calculated value should give zero
following error in normal operation. Using
values greater than the calculated value will
cause the controller to have a following error
ahead of the desired position. Using values
less than the calculated value will cause the
controller to have following error behind the
desired position.

6. In the Move Type drop down box, check that
the move type is set to Trapezoid.

7. Click in the Distance box and enter a distance for the step move. It is recommended to set
a value that will cause the motor to make a few revolutions, for example 10.

Note: The distance depends on the scale set in section 5.3.1. If you set a scale so that

units could be expressed in revolutions (or other unit of your choice), then those
are the units that will be used here. If you did not set a scale, the amount you
enter will be in encoder counts.

8. Click Go.

The NextMove BX
completed, WorkBench v5 will download captured data from the NextMove BX

II

will perform the move and the motor will turn. As the soon as the move is

II

. The data will

then be displayed in the Capture window as a graph.

Note: The graph that you see will not look exactly the same as the graph shown here!

Remember that each motor has a slightly different response.

9. Using the check boxes below the graph, select
the Measured velocity and Demand velocity
traces.

Operation 5-21MN1904

Demand velocity

Measured velocity

Figure 20 - Correct value of KVELFF

It may be necessary to make changes to the calculated value of KVELFF. If the trace for
Measured velocity appears above the trace for Demand velocity, reduce the value of KVELFF.
If the trace for Measured velocity appears below the trace for Demand velocity, increase the
value of KVELFF. Repeat the test after each change. When the two traces appear on top of
each other (approximately), the correct value for KVELFF has been found as shown in Figure

20.

5-22 Operation MN1904

5.8.2 Adjusting KPROP

The KPROP term can be used to reduce following error. Its value will usually be much smaller
than the value used for an equivalent current controlled system. A fractional value, for example

0.1, will probably give the best response.

1. Click in the KPROP box and enter a starting
value of 0.1.

2. Click Go.

The NextMove BXIIwill perform the move and the motor will turn. As the soon as the move is
completed, WorkBench v5 will download captured data from the NextMove BX
then be displayed in the Capture window as a graph.

Note: The graph that you see will not look exactly the same as the graph shown here!

Remember that each motor has a slightly different response.

3. Using the check boxes below the graph, select
the Measured position and Demand position
traces.

II

. The data will

Operation 5-23MN1904

Demand position

Measured position

Figure 21 - Correct value of KPROP

The two traces will probably appear with a small offset from each other. Adjust KPROP by
small amounts until the two traces appear on top of each other (approximately), as shown in
Figure 21.

5-24 Operation MN1904

5.9 Digital input/output configuration

The Digital I/O window can be used to setup other digital inputs and outputs.

5.9.1 Digital input configuration

The Digital Inputs tab allows you to define how each digital input will be triggered and,
optionally, if it is to be allocated to a special function, for example the Forward Limit. In the
following example, digital input 1 will be set to trigger on a falling edge, and allocated to the
forward limit input of axis 0:

1. In the Toolbox, click the Digital I/O icon.

2. At the bottom of the Digital I/O screen, click the
Digital Inputs tab. The left of the screen shows
a column of yellow icons - High, Low , Rising,
Falling and Rise/Fall. These describe how the
input will be triggered.

3. Drag the Falling icon

onto the IN1 icon . This will setup IN1 to respond to a falling edge.

Operation 5-25MN1904

4. Now drag the IN1 icon onto the Fwd Limit icon .

This will setup IN1 as the Forward Limit input of axis 0.

5. Click Apply to send the changes to the NextMove BXII.

Note: If required, multiple inputs can be configured before clicking Apply.

5.9.2 Digital output configuration

The Digital Outputs tab allows you to define how each digital output will operate and if it is to
be allocated to a drive enable output (see section 5.3.2). Remember to click Apply to send the
changes to the NextMove BX

II

.

5-26 Operation MN1904

5.10 Saving setup information

When power is removed from the NextMove BXII, configuration and tuning parameters are
lost. You should therefore save this information in a file, which can be loaded after the unit is
started. Alternatively, the information can be included in program files as part of the Startup
block. Program files are stored when power is removed, so the Startup block can be used to
restore configuration and tuning parameters automatically whenever a program is run.

1. In the Toolbox, click the Edit & Debug icon.

2. On the main menu, choose File, New File.

A new program editing window will appear.

3. On the main menu, choose Tools,
Upload Configuration Parameters.

WorkBench v5 will read all the
configuration information from the
NextMove BX
Startup block. For details of the Startup
block, see the Mint help file.

II

and place it in a

Operation 5-27MN1904

4. On the main menu, choose File, Save File . Locate a folder, enter a filename and click Save.

5.11 Loading saved information

1. In the Toolbox, click the Edit & Debug icon.

2. On the main menu, choose File, Open File...
Locate the file and click Open.

WorkBench v5 will open a new editing window to display the file.

A Startup block should be included in every Mint program, so that whenever a program is
loaded and run the NextMove BX
drive/motor combination has a slightly different response. If the same program is used on a
different NextMove BX

II

installation, the Startup block will need to be changed.

II

will be correctly configured. Remember that every

5-28 Operation MN1904

6 Troubleshooting

6.1 Introduction

This section explains common problems that may be encountered, together with possible
solutions.

6.1.1 Problem diagnosis

If you have followed all the instructions in this manual in sequence, you should have few
problems installing the NextMove BX
WorkBench v5, use the Error Log tool to view recent errors and then check the help file. If you
cannot solve the problem or the problem persists, the SupportMet feature can be used.

6.1.2 SupportMet feature

The SupportMet feature (on the Help menu) can be used to e-mail information to the Baldor
representative from whom you purchased the equipment. If required, you can choose to add
your program files as attachments. WorkBench v5 will automatically start up your e-mail
program and begin a new message, with comprehensive system information and selected
attachments already in place. You can add any additional message of your own and then send
the e-mail. The PC must have email facilities to use the SupportMet feature. If you prefer to
contact Baldor technical support by telephone or fax, contact details are provided at the front
of this manual. Please have the following information ready:

H The serial number of your NextMove BX

H Use the Help, SupportMe menu item in WorkBench v5 to view details about your system.

H The type of servo amplifier and motor that you are using.

H Give a clear description of what you are trying to do, for example trying to establish

communications with WorkBench v5 or trying to perform fine-tuning.

H Give a clear description of the symptoms that you can observe, for example the Status

display, error messages displayed in WorkBench v5, or the current value of any of the
Mint error keywords AXISERROR, AXISSTATUS, INITERROR, and MISCERROR.

H The type of motion generated in the motor shaft.

H Give a list of any parameters that you have setup, for example the gain settings you have

entered.

II

. If you do have a problem, read this section first. In

II

.

6

Troubleshooting 6-1MN1904

6.2 NextMove BXIIindicators

6.2.1 Status display

The Status LED normally displays the unit’s node number . To display
information about a specific axis, use the LEDkeyword (see the MintMT help
file). When a specific axis is selected, its LED (numbered 0-3) will be
illuminated, and the following symbols may be displayed by the Status LED.
Some characters will flash to indicate an error.

Spline. A spline move is being performed. See the Mint keyword SPLINE and related
commands.

Axis enabled.

Torque mode. The NextMove BX
and related commands.

Hold to Analog. The axis is in Hold To Analog mode. See the Mint keyword HTA and
related commands.

Follow and offset. When an axis is following a demand signal it may be necessary to
advance or retard the slave in relation to the master. To do this an offset move is
performed in parallel with the follow. See the Mint keywords FOLLOW and OFFSET.

Circle. A circle move is being performed. See the Mint keywords CIRCLEA or
CIRCLER.

Cam. A Cam profile is being profiled. See the Mint keyword CAM.
General error. See AXISERROR. The motion toolbar displays the status of

AXISERROR, which is a bit pattern of all latched errors. See also the Error Log topics in
the help file.

II

is in Torque mode. See the Mint keyword TORQUE

Error input. The ERRORINPUT has been activated and generated an error.
Flying shear. A flying shear is being profiled. See the Mint keyword FLY.

Position following error. A following error has occurred. See the Mint keyword
AXISERROR and associated keywords. Following errors could be caused by a badly
tuned drive/motor. At higher acceleration and deceleration rates, the following error will
typically be greater. Ensure that the drive/motor is adequately tuned to cope with these
acceleration rates.
The following error limit can be adjusted to suite your application (see Mint keywords
FOLERRORFATAL and VELFATAL). Following error could also be the cause of
encoder/resolver loss (see also Mint keyword FEEDBACKFAULTENABLE).

Follow mode. The axis is in Follow mode. See the Mint keyword FOLLOW.
Homing. The axis is currently homing. See the Mint keyword HOME.

Incremental move. An incremental move is being profiled. See the Mint keywords
INCA and INCR.

6-2 Troubleshooting MN1904

Jog. The axis is jogging. In the Mint help file, see the topics JOG, JOGCOMMAND and
Jog mode.

Offset move. The axis is performing an offset move.
Positional Move. The axis is performing a linear move. See the Mint keywords MOVEA

and MOVER.
Stop. A STOP command has been issued or the stop input is active.

Axis disabled. The axis/drive must be enabled before operation can continue. See
section 5.3.3. Click the Drive enable button in WorkBench v5.

Suspend. The SUSPEND command has been issued and is active. Motion will be
ramped to zero demand whilst active.

Reverse software or hardware limit. A reverse software limit has been activated.
See AXISERROR and/or AXISSTATUS to determine which applies.

Forward software or hardware limit. A forward software limit has been activated.
See AXISERROR and/or AXISSTATUS to determine which applies.

Firmware being updated (horizontal bars appear sequentially). New firmware is being
downloaded to the NextMove BX

II

.

Initialization error. An initialization error has occurred at power on. See the Error Log or
INITERROR topics in the help file. Initialization errors should not normally occur.

User defined symbols can be made to appear using the Mint keywords LED and LEDDISPLAY.

Troubleshooting 6-3MN1904

6.2.2 Motor control

Symptom Check

NextMove BXIIappears
to be working but will not
cause motor to turn.

Motor runs uncontrollably
when controller is
switched on.

Check that the connections between motor and drive are
correct. Use WorkBench v5 to perform the basic system tests
(see section 5.4).

Ensure that while the NextMove BX
enabled and working. When the NextMove BX

II

is not in error, the drive is

II

is first powered
up the drive should be disabled if there is no program running
(there is often an LED on the front of the drive to indicate
status).

Check that the servo loop gains are setup correctly - check the
Fine-tuning window. See sections 5.5 to 5.7.

Check that the encoders are connected, they have power
through Encoder V+ (if required, see sections 4.4.1 and 4.7.1)
and are functioning correctly. Use a dual trace oscilloscope to
display both channels of the encoder and/or the complement
signals simultaneously.

Motor runs uncontrollably
when controller is
switched on and servo
loop gains are applied, or
when a move is set in
progress. Motor then
stops after a short time.

Motor is under control, but
vibrates or overshoots
during a move.

Check that the drive is connected correctly, and that with zero
demand from the NextMove BX

II

there is 0V at the drive

demand input. See section 5.4.1.

Verify that the NextMove BX

II

and drive are correctly grounded

to a common earth point.

Check that the axis’ corresponding encoder and demand
signals are connected to the same axes of motion. Check the
demand to the drive is connected with the correct polarity.

Check that for a positive demand signal, a positive increase in
axis position is seen. The Mint DACMODE keyword can be used
to reverse DAC output polarity.

Check that the maximum following error is set to a reasonable
value. For setting up purposes, following error detection may
be disabled by setting FOLERRORMODE = 0.

Servo loop gains may be set incorrectly. See sections 5.5 to

5.8.

6-4 Troubleshooting MN1904

Symptom Check

Motor is under control, but
when moved to a position
and then back to the start
it does not return to the
same position.

Using an oscilloscope, check:

H all encoder channels are clear signals and free from

electrical noise;

H they are correctly wired to the controller;
H when the motor turns, the two square wave signals are 90

degrees out of phase. Also check the complement signals.

Ensure that the encoder lead uses shielded twisted pair cable
and that the shield is attached to the shield connection only at
the NextMove BX

Verify that the NextMove BX
to a common earth point.

II

end.

II

and drive are correctly grounded

6.2.3 Communication

If the problem is not listed below please contact Baldor Technical Support. An oscilloscope will
be useful for many of the electrical tests described below.

Symptom

Cannot detect NextMove BXIICheck that the NextMove BXIIis powered and the serial

Cannot communicate with the
controller.

Check

lead is properly connected.

Verify that WorkBench v5 is loaded and that
NextMove BX

II

is the currently selected controller.

6.2.4 Axis LED is red or Status LED shows a flashing symbol

If an axis LED is illuminated red and/or the Status display shows a flashing symbol, use the
Error Log tool in WorkBench v5 to view a list of recent errors. Alternatively, type
PRINT AXISERROR and PRINT MISCERROR as separate commands in the WorkBench v5
Command window. Each of these commands will return an error code, a description of which
can be found in the help file.

Press F1 and locate the AXISERROR and MISCERROR keywords. The Error Handling book
contains topics listing the Status display indicators and basic error codes. Remember that
many error codes are the sum of a bit pattern so may not be listed individually. For help on
understanding bit pattern values, see the Bit pattern values topic in the Keywords book.

Troubleshooting 6-5MN1904

6-6 Troubleshooting MN1904

7.1 Introduction

This section provides technical specifications of the NextMove BXII.

7.1.1 Input power

Description Unit Value

Logic supply input voltage VDC 24

Minimum input voltage VDC 18

Maximum input voltage 30

Logic supply input current (maximum) mA 700

User supply input voltage VDC 12-24

User supply input current (maximum) mA 850

7.1.2 Analog inputs (X3)

Description Unit Value

Type Single ended or differential

Common mode voltage range VDC ±10

Input impedance kÙ >20

Input ADC resolution bits 12

Equivalent resolution (±10V input) mV ±4.9

Sampling interval (variable) ms 0.22 - 2

7 Specifications

(software selectable)

(software selectable)

(includes sign bit)

7

Specifications 7-1MN1904

7.1.3 Analog outputs (Demands - X7)

Description Unit Value

Type Bipolar

Output voltage range VDC ±10

Output current (max) mA 1

Output DAC resolution bits 14

Equivalent resolution mV ±1.22

Update interval Immediate

7.1.4 Digital inputs (X1 & X2)

Description Unit Value

Type VDC Opto-isolated, AC inputs

Input voltage (Active high)

Nominal
Minimum

Input voltage (Active low)

Nominal
Maximum

Input current (approximate, per input) mA 11

Sampling interval ms 1

(includes sign bit)

VDC

24
12

VDC

0
2

7.1.5 Digital inputs (Interrupts) (X6)

Description Unit Value

Type VDC Non-isolated, AC inputs

Input voltage (Active high)

Nominal
Minimum

Input voltage (Active low)

Nominal
Maximum

Input current (approximate, per input) mA 9

7-2 Specifications MN1904

VDC

24
12

VDC

0
2

7.1.6 Digital outputs (X4)

Description Unit Value

Output current

(maximum continuous, each output)

Update interval Immediate

7.1.7 Relay output (X5)

Description Unit Value

Contacts Normally closed

Contact rating (resistive) 1A @ 24VDC

Maximum carrying current A 2

Maximum switching power 60VA, 24W

Maximum switching voltage 125VAC, 60VDC

Maximum switching current A 1

Contact resistance (maximum) mÙ 100

Update interval Immediate

7.1.8 Encoder interfaces (X9 - X13)

Description Unit Value

Encoder input A/B Differential, Z index

Maximum input frequency MHz 1.87

Output power supply to encoders (total) 5V, 650mA max.

Maximum recommended cable length 30.5m (100ft)

mA 50

or

0.5A @ 120VAC

7.1.9 CAN interfaces (X16 & X17)

Description Unit Value

Channels CANopen, Baldor CAN

Bit rate Kbit/s 10, 20, 50, 100, 125, 250, 500,

800, 1000

Specifications 7-3MN1904

7.1.10Environmental

Description Unit

Operating temperature range Min Max

°C

0

+40

Maximum humidity

Maximum installation altitude

(above m.s.l.)

See also section 3.2.

7.1.11 Weights and dimensions

Description Unit Value

Dimensions (HxWxD) 312mm x 58.5mm x 194mm

Weight 1.86kg

°F

%

m

ft

+32

80% for temperatures up to 87°F (31°C)

decreasingly linearly to 50% relative

humidity at 104°F (40°C), non-condensing

(according to DIN40 040 / IEC144)

2000

6560

(12.3in x 2.3in x 7.6in)

(4.1lb)

+104

7-4 Specifications MN1904

A Accessories

A.1 Introduction

The capabilities of the NextMove BXIIcan be expanded using additional peripheral devices.

A.1.1 Baldor CAN nodes

Digital I/O can be expanded easily on NextMove BXIIusing the Baldor CAN (CAN2)
connection. This provides a high speed serial bus interface to a range of I/O devices,
including:

H inputNode 8: 8 opto isolated digital inputs.

H relayNode 8: 8 relay outputs.

H outputNode 8: 8 opto isolated digital outputs with short circuit and over current protection.

H ioNode 24/24: 24 opto isolated input and 24 opto isolated outputs.

H keypadNode: General purpose operator panel (3 and 4 axis versions).

A

Catalog
number

ION001-503 8 digital inputs

ION002-503 8 relay outputs

ION003-503 8 digital outputs

ION004-503 24 digital inputs and 24 digital outputs

KPD002-502 27 key keypad and 4 line LCD display

KPD002-505 41 key keypad and 4 line LCD display

Description

Accessories A-1MN1904

A.1.2 Encoder Splitter/Buffer board

This is a stand-alone PCB that takes an encoder signal, either single ended or differential and
gives differential outputs. This is useful for ‘daisy chaining’ an encoder signal from a master
across a number of controllers.

Catalog number

OPT008-501

OPT029-501

Description

2-way encoder splitter - allows a single-ended or differential encoder
pulse train to be shared between two devices

4-way encoder splitter - allows a single-ended or differential encoder
pulse train to be shared between four devices

A-2 Accessories MN1904

Index

A

Abbreviations, 2-3
Accessories, A-1

Baldor CAN nodes, A-1
encoder splitter/buffer board, A-2

Analog I/O, 4-4

analog inputs - X3, 4-4
analog outputs - X7, 4-6

B

Baldor CAN nodes, A-1
Basic Installation, 3-1

C

CAN

accessories, A-1
Baldor CAN, 4-21
CANopen, 4-21
connectors, 4-20

specifications, 7-3
Catalog number, identifying, 2-2
Closed loop control, an introduction, 5-11
Configuration

axis, 5-6

digital inputs, 5-25

digital outputs, 5-26

selecting a scale, 5-6

setting the drive enable output, 5-7

testing the drive enable output, 5-8
Connector

locations, front panel, 4-2

locations, top panel, 4-1
Critically damped response, 5-18

D

Demands - X7, 4-6
Digital I/O, 4-7

configuration, 5-25–5-26
digital inputs - X1, 4-8
digital inputs - X2, 4-9
digital inputs - X6, 4-10

digital outputs - X4, 4-11
Dimensions, 3-4
Drive command output, 5-9
Drive enable output, 5-7

testing, 5-8

E

Encoder

input frequency, 4-13

interfaces - X9 to X13, 4-12
Environmental

location, 3-3

specification, 7-4

F

Features, 2-1

G

General information, 1-1

H

Hardware requirements, 3-1
Help file, 5-3

MN1904

Index

I

Indicators, 6-2

axis LEDs, 6-2, 6-5
status display, 6-2, 6-5

Input / Output

analog I/O, 4-4
analog inputs - X3, 4-4, 7-1
analog outputs (Demands) - X7, 4-6, 7-2
CAN - X16 & X17, 4-20
connection summary, 4-23
digital I/O, 4-7
digital inputs (Interrupts) - X6, 4-10, 7-2
digital inputs - X1, 4-8, 7-2
digital inputs - X2, 4-9, 7-2
digital outputs - X4, 4-11, 7-3
encoder interfaces - X9-X13, 4-12, 7-3
relay and user power - X5, 4-14, 7-3
RS232 - X15, 4-15

connecting Baldor HMI panels, 4-17

RS422/RS485 - X14, 4-18

Installation, 3-1

dimensions, 3-4
mechanical, 3-3

mounting, 3-4
Interrupts - X6, 4-10
Introduction to closed loop control, 5-11

L

LED indicators

axis LEDs, 6-2, 6-5

status display, 6-2, 6-5
Loading saved information, 5-28

M

Mounting, 3-4

O

Operation, 5-1

connecting to the PC, 5-1

installing the software, 5-1

power on checks, 5-2

preliminary checks, 5-1
starting, 5-1

Overdamped response, 5-17

P

PC Hardware requirements, 3-1
Power

connections - X8, 4-3
sources, 3-1

Precautions, 1-2

R

Receiving and Inspection, 2-2
Relay, 4-14

specifications, 7-3
Reset states, 4-22
RS232, 4-15
RS422/RS485, 4-18

S

Safety Notice, 1-2
Saving setup information, 5-27
Scale, selecting, 5-6
Serial connections

RS232, 4-15

RS422/RS485, 4-18
Specifications, 7-1

analog inputs - X3, 7-1

analog outputs (Demands) - X7, 7-2

CAN interfaces - X16 & X17, 7-3

digital inputs (Interrupts) - X6, 7-2

digital inputs - X1 & X2, 7-2

digital outputs - X4, 7-3

encoder interfaces - X9-X13, 7-3

environmental, 3-3, 7-4

input power, 7-1

relay output - X5, 7-3

weights and dimensions, 3-4, 7-4
Status display, 6-2, 6-5
System watchdog, 4-22

Index

MN1904

T

Testing and tuning, 5-9

testing the drive command output, 5-9
Tools, 3-2
Troubleshooting, 6-1

axis LED is red, 6-5

communication, 6-5

help file, 5-3

motor control, 6-4

problem diagnosis, 6-1

status display, 6-2

shows a flashing symbol, 6-5

SupportMe, 6-1
Tuning, 5-9

adjusting KPROP, 5-23

axis for current control, 5-14

axis for velocity control, 5-20

calculating KVELFF, 5-20

critically damped response, 5-18
eliminating steady-state errors, 5-19
overdamped response, 5-17
selecting servo loop gains, 5-14
underdamped response, 5-16

U

Underdamped response, 5-16
Units and abbreviations, 2-3

W

Watchdog, 4-22
WorkBench v5, 5-3

digital input/output configuration, 5-25
help file, 5-3
loading saved information, 5-28
saving setup information, 5-27
starting, 5-4

MN1904

Index

Index

MN1904

Comments

If you have any suggestions for improvements to this manual, please let us know. Write your
comments in the space provided below, remove this page from the manual and mail it to:

Manuals
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Mint Motion Centre
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Bristol
BS32 0BF
United Kingdom.

Alternatively, you can e-mail your comments to:

[e-mail]

Comment:

continued...

CommentsMN1904

Thank you for taking the time to help us.

Comments MN1904

Baldor Electric Company

P.O. Box 2400

Ft. Smith, AR 72902-2400

U.S.A.

Visit www.supportme.net for the latest documentation and software releases.

Australia

Australian Baldor PTY Ltd
Tel: [phone]
Fax: [phone]

Europe

Baldor ASR GmbH, Germany
Tel: [phone]
Fax: [phone]

Europe (Southern)

Baldor ASR AG, Switzerland
Tel: [phone]
Fax: [phone]

Japan

Baldor Japan Corporation
Tel: [phone]
Fax: [phone]

L T0158A01

Mexico

Baldor de Mexico
Tel: [phone]
Fax: [phone]

Singapore

Baldor Electric PTE Ltd
Tel: [phone]
Fax: [phone]

United Kingdom

Baldor UK Ltd
Tel: [phone]
Fax: [phone]

U.S.A. (Headquarters)

Baldor Electric Company
Tel: [phone]
Fax: [phone]

For additional office locations visit www.baldor.com

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