Baldor MN1928 User Manual

MOTION CONTROL

NextMove ES

Motion Controller

Installation Manual

8/03 MN1928

Contents

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

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

2.1 NextMove ES features 2-1..................................

2.2 Receiving and inspection 2-3................................

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

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

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

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

3.1.1 Location requirements 3-1..........................................

3.1.2 Installing the NextMove ES card 3-2..................................

3.1.3 Other requirements for installation 3-2................................

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

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

4.2 96-pin edge connector 4-1...................................

4.2.1 96-pin connector pin assignment 4-2..................................

4.3 Analog I/O 4-3.............................................

4.3.1 Analog inputs 4-3..................................................

4.3.2 Analog outputs 4-5.................................................

4.4 Digital I/O 4-6..............................................

4.4.1 Digital inputs 4-6..................................................

4.4.2 Digital outputs 4-8.................................................

4.4.3 Error output - Error Out 4-10..........................................

4.5 Other I/O 4-11..............................................

4.5.1 Stepper control outputs 4-11..........................................

4.5.2 Encoder inputs 4-12................................................

4.5.3 RS232 serial connection 4-13........................................

4.5.4 USB connection 4-14...............................................

4.5.5 CAN connection 4-15...............................................

4.6 Connection summary - minimum system wiring 4-17.............

MN1928

Contents i

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

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

5.2 BPL010-501 non-isolated backplane 5-2.......................

5.2.1 Analog inputs 5-2..................................................

5.2.2 Analog outputs (demands) 5-3.......................................

5.2.3 Digital inputs 0-7 5-4...............................................

5.2.4 Digital inputs 8-15 5-4..............................................

5.2.5 Digital inputs 16-19 5-5.............................................

5.2.6 Digital outputs 0-7 5-5..............................................

5.2.7 Digital outputs 8-11 5-6.............................................

5.2.8 Stepper axes outputs 0-1 5-7........................................

5.2.9 Stepper axes outputs 2-3 5-8........................................

5.2.10 Power inputs 5-9..................................................

5.2.11 Encoder input 0 5-9................................................

5.2.12 Encoder input 1 5-10................................................

5.2.13 RS232 serial communication 5-10.....................................

5.3 BPL010-502/503 backplane with opto-isolator card 5-11..........

5.3.1 Analog inputs 5-12..................................................

5.3.2 Analog outputs (demands) 5-14.......................................

5.3.3 Digital inputs 0-7 5-15...............................................

5.3.4 Digital inputs 8-15 5-16..............................................

5.3.5 Digital inputs 16-19 5-17.............................................

5.3.6 Digital outputs 0-7 5-19..............................................

5.3.7 Digital outputs 8-11 5-21.............................................

5.3.8 Stepper axes outputs 0-1 5-22........................................

5.3.9 Stepper axes outputs 2-3 5-23........................................

5.3.10 Power inputs 5-24..................................................

5.3.11 Encoder input 0 5-24................................................

5.3.12 Encoder input 1 5-25................................................

5.3.13 RS232 serial communication 5-25.....................................

6 Operation 6-1..........................................

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

6.1.1 Connecting the NextMove ES to the PC 6-1............................

6.1.2 Installing WorkBench v5 6-1.........................................

6.1.3 Starting the NextMove ES 6-1.......................................

6.1.4 Preliminary checks 6-2.............................................

6.1.5 Power on checks 6-2...............................................

6.2 WorkBench v5 6-3..........................................

6.2.1 Help file 6-3......................................................

6.2.2 Starting WorkBench v5 6-4..........................................

6.3 Configuring an axis 6-6.....................................

6.3.1 Selecting a scale 6-6...............................................

6.3.2 Setting the drive enable output 6-7...................................

6.3.3 Testing the drive enable output 6-9...................................

6.4 Stepper axis - testing 6-10....................................

6.4.1 Testing the output 6-10..............................................

ii Contents

MN1928

6.5 Servo axis - testing and tuning 6-11............................

6.5.1 Testing the demand output 6-11.......................................

6.5.2 An introduction to closed loop control 6-13..............................

6.6 Servo axis - tuning for current control 6-16......................

6.6.1 Selecting servo loop gains 6-16.......................................

6.6.2 Underdamped response 6-18.........................................

6.6.3 Overdamped response 6-19..........................................

6.6.4 Critically damped response 6-20......................................

6.7 Servo axis - eliminating steady-state errors 6-21.................

6.8 Servo axis - tuning for velocity control 6-22.....................

6.8.1 Calculating KVELFF 6-22............................................

6.8.2 Adjusting KPROP 6-25..............................................

6.9 Digital input/output configuration 6-27..........................

6.9.1 Digital input configuration 6-27........................................

6.9.2 Digital output configuration 6-28.......................................

6.10 Saving setup information 6-29.................................

6.10.1 Loading saved information 6-30.......................................

7 Troubleshooting 7-1....................................

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

7.1.1 Problem diagnosis 7-1..............................................

7.1.2 SupportMe feature 7-1.............................................

7.2 NextMove ES indicators 7-2.................................

7.2.1 Status display 7-2.................................................

7.2.2 Surface mount LEDs D3, D4, D16 and D20 7-3.........................

7.2.3 Communication 7-4................................................

7.2.4 Motor control 7-4..................................................

7.2.5 WorkBench v5 7-5.................................................

8 Specifications 8-1......................................

8.1 Introduction 8-1............................................

8.1.1 Input power 8-1...................................................

8.1.2 Analog inputs 8-1..................................................

8.1.3 Analog outputs 8-1.................................................

8.1.4 Digital inputs (non-isolated) 8-2......................................

8.1.5 Digital inputs (opto-isolated) 8-2......................................

8.1.6 Digital outputs - general purpose (non-isolated) 8-3.....................

8.1.7 Digital outputs - general purpose (opto-isolated) 8-3.....................

8.1.8 Digital output - error output (non-isolated) 8-3..........................

8.1.9 Error relay (opto-isolated backplanes) 8-4.............................

8.1.10 Encoder inputs 8-4................................................

8.1.11 Stepper control outputs 8-4..........................................

8.1.12 CAN interface 8-4.................................................

8.1.13 Environmental 8-5.................................................

8.1.14 Weights and dimensions 8-5........................................

MN1928

Contents iii

Appendices

A Appendix A-1..........................................

A.1 Axis renumbering A-1.......................................

iv Contents

MN1928

AustralianBaldorPtyLt

d

1 General Information

Copyright Baldor (c) 2003. All rights reserved.LT0202A00

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
disclaims 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.

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]
Email: [e-mail]

Australian Baldor Pty Ltd
Telephone: [phone]
Fax: [phone]

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

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

General Information 1-1MN1928

Safety Notice

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

Precautions

WARNING: Do not touch any circuit board, power device or electrical connection before you

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

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

CAUTION: Electrical components can be damaged by static electricity. Use ESD

first ensure that no high voltage is present at this equipment or other equipment to
which it is connected. Electrical shock can cause serious or fatal injury.

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.

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

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.

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.

(electrostatic discharge) procedures when handling this drive.

1-2 General Information MN1928

2 Introduction

2.1 NextMove ES features

NextMove ES is a high performance multi-axis intelligent controller for servo and stepper
motors.

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

2

Standard features include:

H Control of 4 stepper and 2 servo axes.

H Point to point moves, software cams and gearing.

H 20 general purpose digital inputs, software configurable as level or edge triggered.

H 12 general purpose digital outputs and 1 error output.

H 2 differential analog inputs with 12-bit resolution.

H 2 single-ended analog outputs with 12-bit resolution.

H RS232 and USB serial connections.

H CANopen or proprietary Baldor CAN protocol for communication with MintMT controllers

and other third party devices.

H Programmable in MintMT.

Introduction 2-1MN1928

Included with NextMove ES is the Baldor Motion Toolkit CD. This contains a number of utilities
and useful resources to get the most from you MintMT controller. These include:

H Mint WorkBench v5

This is the user interface for communicating with the NextMove ES. Installing Mint
WorkBench v5 will also install firmware for NextMove ES.

H PC Developer Libraries

Installing Mint WorkBench v5 will install ActiveX interfaces that allow PC applications to be
written that communicate with the NextMove ES.

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

The chapters should be read in sequence.

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

Note: You can check that you have the latest firmware and WorkBench v5 releases by

visiting the website www.supportme.net.

2-2 Introduction MN1928

2.2 Receiving and inspection

When you receive your NextMove ES, 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 ES.

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

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

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

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

2.2.1 Identifying the catalog number

NextMove ES cards are available with a number of optional backplane connector cards. As a
reminder of which products have been installed, it is a good idea to write the catalog numbers
in the space provided below.

NextMove ES catalog number:

Backplane catalog number: BPL010-50_______

Installed in: ________________________

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

Catalog
number

NES002-501 NextMove ES controller card with USB connection

BPL010-501 Backplane card: Non-isolated

BPL010-502 Backplane card: Opto-isolated with ‘PNP’ (current sourcing) outputs and

BPL010-503 Backplane card: Opto-isolated with ‘NPN’ (current sinking) outputs and

Description

‘active high’ inputs.

‘active low’ inputs.

NES002-501

Date: ______

Introduction 2-3MN1928

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............

2-4 Introduction MN1928

3 Basic Installation

3.1 Introduction

You should read all the sections in Basic Installation.

It is important that the correct steps are followed when installing the NextMove ES.
This section describes the mechanical installation of the NextMove ES.

3.1.1 Location requirements

You must read and understand this section before beginning the installation.

3

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

CAUTION: To ensure reliable performance of this equipment be certain that all

CAUTION: Avoid locating the NextMove ES immediately above or beside heat

CAUTION: Avoid locating the NextMove ES in the vicinity of corrosive substances or

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

H The NextMove ES is designed to be mounted in a IEC297 / DIN41494 rack with card

frames and guides to support the card.

H The NextMove ES must be installed in an ambient temperature of 0°C to 40°C (32°F to

104°F).

H The NextMove ES must be installed 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.

H The NextMove ES must be installed where the pollution degree according to IEC664 shall

not exceed 2.

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

are powered and referenced correctly.

signals to/from the NextMove ES are shielded correctly.

generating equipment, or directly below water steam pipes.

vapors, metal particles and dust.

Basic Installation 3-1MN1928

3.1.2 Installing the NextMove ES card

CAUTION: Before touching the card, be sure to discharge static electricity from your

The NextMove ES is designed to be mounted in a IEC297 / DIN41494 rack with card frames
and guides to support the card. An additional backplane card is recommended (see section 5).

1. Mount the backplane connector card (optional) at the rear of the rack system.

2. Slide the NextMove ES card into the guide rails, ensuring that it plugs securely into the
backplane connector.

3. Confirm that any neighboring cards or equipment are not touching the NextMove ES card.

body and clothing by touching a grounded metal surface. Alternatively,
wear an earth strap while handling the card.

3.1.3 Other requirements for installation

H The NextMove ES requires +5V and ±12V power supplies. The total power requirement

(excluding any option cards) is +5V at 1A, +12V at 50mA and -12V at 50mA. If digital
outputs are to be used, a supply will be required to drive them - see section 4.4.2.

H A PC that fulfills the following specification:

Minimum specification Recommended specification

Processor Intel Pentium 133MHz Intel PentiumII 400MHz or faster

RAM 32MB 128MB

Hard disk space 40MB 60MB

CD-ROM ACD-ROMdrive

Serial port One free serial (COM) port, or USB port

Screen 800 x 600, 256 colors 1024 x 768, 16-bit color

Mouse A mouse or similar pointing device

Operating

system

Windows 95, Windows NT Windows 98*, Windows ME*,

Windows NT*, Windows 2000 or

Windows XP

* For USB support, Windows 2000 or Windows XP is required. Software installation will be
described later, in section 6.

H A serial cable (connected as shown in section 4.5.3) or a USB cable.

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

3-2 Basic Installation MN1928

4 Input / Output

4.1 Introduction

This section describes the input and output capabilities of the NextMove ES.

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...........

Most external connections to the NextMove ES card are made using an optional backplane
card, described in section 5.

4.2 96-pin edge connector

cba

4

Key

1

The pin assignment for the 96-pin DIN41612 connector is shown in
Table 1.

Component side

32

Input / Output 4-1MN1928

4.2.1 96-pin connector pin assignment

Pin c b a

1 +5VDC +5VDC +5VDC

2 +5VDC +5VDC +5VDC

3 DGND DGND DGND

4 DOUT6 DOUT7 OUT COM

5 DOUT3 DOUT4 DOUT5

6 DOUT0 DOUT1 DOUT2

7 Encoder 1 CHB+ Encoder 0 CHA+ Encoder 0 CHB+

8 Encoder 1 CHZ+ Encoder 0 CHZ+ Encoder 1 CHA+

9 Encoder 1 CHA- Encoder 0 CHZ- Encoder 1 CHZ-

10 Encoder 0 CHB- Encoder 0 CHA- Encoder 1 CHB-

11 DIN16 Error Out DGND

12 !RST IN DGND DGND

13 DGND DOUT9 DOUT8

14 STEP2 STEP1 STEP0

15 DIR2 DIR1 DIR0

16 DOUT10 DGND (NC)

17 DGND AOUT2 (NC)

18 DIN4 DIN15 DIN2

19 DIN3 DIN5 DIN7

20 DIN6 DIN1 RXD

21 DIN0 RTS TXD

22 DOUT11 AOUT3 CTS

23 DIN14 STEP3 DIR3

24 DIN17 DIN13 DIN10

25 DIN18 DIN9 DIN11

26 DIN12 DIN19 DIN8

27 Demand0 (AOUT0) Demand1 (AOUT1) AIN1-

28 AIN1+ AIN0+ AIN0-

29 +12VDC +12VDC +12VDC

30 AGND AGND AGND

31 -12VDC -12VDC -12VDC

32 Shield Shield Shield

Table 1 - 96-pin connector pin assignment

Row

4-2 Input / Output MN1928

4.3 Analog I/O

The NextMove ES provides:

H Two 12-bit resolution analog inputs.

H Four 12-bit resolution analog outputs.

4.3.1 Analog inputs

The analog inputs are available on pins a28 & b28 (AIN0) and a27 & c28 (AIN1).

H Differential inputs.

H Voltage range: ±10V.

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

H Input impedance: 120kΩ.

H Sampling frequency: 4kHz maximum, 2kHz if both inputs are enabled.

The analog inputs pass through a differential buffer and second order low-pass filter with a
cut-off frequency of approximately 1kHz.

Both inputs are normally sampled at 2kHz. However, an input can be disabled by setting
ADCMODE to4(_acOFF). With one input disabled, the remaining input will be sampled at 4kHz.
In MintMT, analog inputs can be read using the ADC keyword. See the MintMT help file for full
details of ADC and ADCMODE.

AIN0-

AIN0+

AGND

NextMove ES

a28

b28

a30

120k

120k

15k

22nF

-

+

10k 10k

-

+

10nF

MintMT

ADC.0

Figure 1 - Analog input, AIN0 shown

For differential inputs connect input lines to AIN+ and AIN-. Leave AGND unconnected.

Input / Output 4-3MN1928

AIN0+

AIN0-

b28

AIN0

a28

(ADC.0)

a30

Differential connection Single ended connection

AIN0+

GND

b28

a28

a30

AIN0

(ADC.0)

Figure 2 - AIN0 analog input wiring

+24VDC

1.5kΩ, 0.25W

0V

1kΩ,0.25W

potentiometer

b28

a28

a30

AIN0

(ADC.0)

Figure 3 - Typical input circuit to provide 0-10V (approx.) input from a 24V source

4-4 Input / Output MN1928

4.3.2 Analog outputs

The four analog outputs are available on a range of pins, as shown in section 4.2.1.

H Four independent analog outputs.

H Output range: ±10VDC (±0.1%).

H Resolution: 12-bit (accuracy ±4.9mV).

H Output current: 10mA maximum.

H Update frequency: 10kHz maximum (factory default 1kHz).

MintMT and the Mint Motion Library use analog outputs Demand0 and Demand1 to control
servo drives. Demand outputs 0 and 1 correspond to servo axes 4 and 5 respectively. The
Demand2 and Demand3 outputs may be used as general purpose analog outputs. See the
DAC keyword in the MintMT help file.

The analog outputs may be used to drive loads of 1kΩ or greater. Shielded twisted pair cable
should be used. The shield connection should be made at one end only.

NextMove ES

-

+

NextMove ES

Demand

±100%

30k

100pF

120k

-

TL084

+

Figure 4 - Analog output - Demand0 shown

Demand0

AGND

c27

a30

a32Shield

Connect overall shield at

one end only

47R

MicroFlex/ servo amplifier

13

12

AIN0+

AIN0-

c27

a30

Demand0

AGND

Servo
amplifier
±10VDC
demand
input

Figure 5 - Analog output - typical connection to a servo amplifier (Baldor MicroFlex shown)

Input / Output 4-5MN1928

4.4 Digital I/O

The NextMove ES provides:

H 20 general purpose digital inputs.

H 12 general purpose digital outputs.

4.4.1 Digital inputs

The digital inputs are available across a range of pins, as shown in section 4.2.1. All digital
inputs have a common specification:

H 5V digital inputs with internal pull-up resistors. Can also be assigned to special purpose

functions such as Home, Limit, Stop and Error inputs.

H Sampling frequency: 1kHz.

NextMoveES

+5V

10k

DIN0

DGND

c21

a3

74AHCT14

1nF

MintMT

INX.0

GND

Figure 6 - General purpose digital input - DIN0 shown

CAUTION: Do not connect 24V signals to the digital inputs.

These unprotected inputs are connected directly to TTL compatible 74AHCT14 devices. 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 MintMT. The use of shielded cable for inputs
is recommended.

4.4.1.1 General purpose inputs

The general purpose digital inputs DIN0 - DIN19 can be shared between axes, and are
programmable in Mint (using a range of keywords beginning with the letters INPUT... ) to
determine their active level and if they should be edge triggered. The state of individual inputs
can be read directly using the INX keyword. See the MintMT help file.

A general purpose digital input can be assigned to a special purpose function such as a home,
limit, stop or error input. See the keywords HOMEINPUT, LIMITFORWARDINPUT,
LIMITREVERSEINPUT, STOPINPUT, and ERRORINPUT in the MintMT help file.

4-6 Input / Output MN1928

4.4.1.2 Auxiliary encoder inputs - DIN17 (STEP), DIN18 (DIR), DIN19 (Z)

DIN17-DIN19 may also be used as an auxiliary encoder input. DIN17 accepts step (pulse)
signals and DIN18 accepts direction signals, allowing an external source to provide the
reference for the speed and direction of an axis. The step frequency (20MHz maximum)
determines the speed, and the direction input determines the direction of motion. Both the
rising and falling edges of the signal on DIN17 cause an internal counter to be changed. If 5V
is applied to DIN18 (or it is left unconnected) the counter will increment. If DIN18 is grounded
the counter will be decremented.

Typically, one channel of an encoder signal (either A or B) would be used to provide the step
signal on DIN17, allowing the input to be used as an auxiliary (master) encoder input. The
input can be used as a master position reference for cam, fly and follow move types. For this,
the MASTERSOURCE keyword must be used to configure the step input as a master (auxiliary)
encoder input. The master position reference can then be read using the AUXENCODER
keyword.

Since a secondary encoder channel is not used, DIN18 allows the direction of motion to be
determined. The Z signal on DIN19 can be supplied from the encoder’s index signal, and may
be read using the AUXENCODERZLATCH keyword.

See the MintMT help file for details of each keyword.

4.4.1.3 Reset input - !RSTIN

When grounded, the reset input will cause a hardware reset of the NextMove ES. This is
equivalent to power-cycling the NextMove ES. Due to the internal pull-up resistor, the reset
input may be left floating.

4.4.1.4 Typical digital input wiring

MicroFlex / equipment output

+5V

10k

NEC PS2562L-1

Status+

Status-

3

2

DIN0

DGND

c21

1nF

a3

Figure 7 - Digital input - typical connections from Baldor MicroFlex

74AHCT14

Input / Output 4-7MN1928

NextMoveES

MintMT

INX.0

GND

4.4.2 Digital outputs

The digital outputs are available across a range of pins, as shown in section 4.2.1.

H 12 general purpose digital outputs.

H One error output, configurable as a general purpose digital output.

H Update frequency: Immediate.

There are 12 general purpose digital outputs. An output can be configured in MintMT as a
general purpose output, a drive enable output or a global error output. Outputs can be shared
between axes and can be configured using WorkBench v5 (or the OUTPUTACTIVELEVEL
keyword) to determine their active level.

4.4.2.1 DOUT0 - DOUT7

Outputs DOUT0 - DOUT7 are driven by a ULN2803 device. The outputs are designed to sink
current from an external supply (typically 24VDC), but have no overcurrent or short circuit
protection. When an output is activated, it is grounded through the ULN2803.

The ULN2803 has a maximum power dissipation of 2W at 25°C. The total output requirements
of DOUT0 - DOUT7 must not exceed this limit. The maximum current limit for an individual
output is 500mA if only one output is in use, reducing to 150mA if all outputs are in use. These
limits are for a 100% duty cycle.

If the outputs are driving inductive loads such as relays, connect the OUT COM connection to
the output’s power supply, as shown in Figure 8. This will connect internal clamp diodes on all
outputs.

NextMove ES

MintMT

OUTX.0

ULN2803

c6

74AHCT244

DOUT0

Output
Load

Load
supply
24V

Connect to supply if

using inductive loads

a4

GND

a3

OUT COM

DGND

Load
supply
GND

Figure 8 - Digital outputs (DOUT0-7) - DOUT0 shown

4-8 Input / Output MN1928

4.4.2.2 DOUT8 - DOUT11

Outputs DOUT8 - DOUT11 are driven by a ULN2003 device. The outputs are designed to sink
current from an external supply (typically 24VDC), but have no overcurrent or short circuit
protection. When an output is activated, it is grounded through the ULN2003.

The ULN2003 has a maximum power dissipation of 900mW at 25°C. The total output
requirements of DOUT8 - DOUT11 must not exceed this limit. The maximum current limit for
an individual output is 400mA if only one output is in use, reducing to 50mA if all outputs are in
use. These limits are for a 100% duty cycle.

DOUT8 - DOUT11 are sourced from the same ULN2003 device as the DIR2 and STEP2
outputs (see section 4.5.1), so the current demands of these signals must also be considered.

If an output is driving an inductive load such as a relay, a suitably rated diode must be fitted
across the relay coil, observing the correct polarity. This is to protect the output from the
back-EMF generated by the relay coil when it is de-energized.

NextMove ES

MintMT

OUTX.8

ULN2003

74AHCT244

GND

a13

a3

DOUT8

DGND

Load
supply
24V

Output Load
(Relay w ith
diode shown)

Load
supply
GND

Figure 9 - Digital outputs (DOUT8-11) - DOUT8 shown

Input / Output 4-9MN1928

4.4.3 Error output - Error Out

The error output is available on pin b11. This 5V 100mA output can be used to stop external
equipment in the event of an error. The output level can be controlled using jumpers JP3, JP4
and JP5 as shown in Table 2. The jumpers are situated at the top edge of the card.

JP3
JP4

JP5

Jumpers

JP3 JP4 JP5

Inactive

state

(no error)

Floating 5V

0V Floating

0V 5V

5V Floating

Floating 0V

5V 0V

Table 2 - Error Out level configuration

There are a number of methods for controlling the error output.

4.4.3.1 RELAY keyword

If the NextMove ES is connected to an opto-isolated backplane (optional) the output directly
controls the relay (see section 5.3.1.1). For this reason, the error output can be controlled by
the RELAY keyword. The command RELAY=1 will enable the error output; the command
RELAY=0 will disable it. This is true regardless of whether an opto-isolating backplane is
connected.

4.4.3.2 DRIVEENABLEOUTPUT keyword

The DRIVEENABLEOUTPUT keyword can be used to configure the error output as the drive
enable output. For example, the command DRIVEENABLEOUTPUT.1=_RELAY0 will mean
that the error output will be the drive enable output for axis 1. When axis 1 is enabled, the
error output will be activated and the axis enabled. If multiple axes are configured to use the
error output as their drive enable output, enabling one axis will enable all of them. Similarly, if
one axis is disabled, all will be disabled.

Active

state

(error)

The RELAY keyword cannot control the error output if is configured as a drive enable output.

4.4.3.3 GLOBALERROROUTPUT keyword

By default, the error output is used as the global error output. In the event of an error on any
axis, the global error output will be deactivated. This action overrides the state of the error
output defined by other methods, such as the drive enable status or RELAY keyword.
Alternatively, the GLOBALERROROUTPUT keyword can be used to configure a general purpose
digital output to be the global error output.

See the MintMT help file for details of each keyword.

4-10 Input / Output MN1928

4.5 Other I/O

4.5.1 Stepper control outputs

The stepper control outputs are available across a range of pins, as shown in section 4.2.1.

There are four sets of stepper motor control outputs, operating in the range 10Hz to 1MHz.
Each of the step (pulse) and direction signals from the NextMove ES is driven by a ULN2003
open collector Darlington output device.

The ULN2003 has a maximum power dissipation of 900mW at 25°C. The total combined
output requirements of DIR0 - DIR2 and STEP0 - STEP2 must not exceed this limit. The
maximum current limit for an individual output is 400mA if only one output is in use, reducing to
50mA if all outputs are in use. These limits are for a 100% duty cycle.

DIR3 and STEP3 are sourced from the same ULN2003 device as the DOUT8 - DOUT11
outputs (see section 4.4.2.2), so the current demands of these signals must also be
considered.

It is recommended to use separate shielded cables for the step outputs. The shield should be
connected at one end only.

NextMove ES

Step

Output

ULN2003

74AHCT244

a14

STEP0

GND

Figure 10 - Stepper output - STEP0 output shown

DGNDa3

Input / Output 4-11MN1928

4.5.2 Encoder inputs

AandBsignal

The encoder inputs are available on pins a7-a10, b7-b10 and c7-c10. See section 4.2.1.

Two incremental encoders may be connected to NextMove ES, each with complementary A, B
and Z channel inputs. Each input channel uses a MAX3095 differential line receiver with pull
up resistors and terminators. Encoders must provide RS422 differential signals. The use of
individually shielded twisted pair cable is recommended. See section 8.1.10 for details of the
encoder power supply.

MicroFlex
X7 encoder
output

CHA+

1

6CHA-

Connect overall shield to

connector backshells /

shield connections.

CHA+

CHA-

Twisted pair

DGND

Shield

NextMove ES

10k

b7

b10

Connect internal shield to DGND.

a11

Do not connect other end.

a32

Vcc

120R

MAX3095

to CPU

Figure 11 - Encoder channel input - typical connection from a servo amplifier

(Baldor MicroFlex shown)

4.5.2.1 Encoder input frequency

The maximum encoder input frequency is affected by the length of the encoder cables.
The theoretical maximum frequency is 20 million quadrature counts per second. This is
equivalent to a maximum frequency for the A and B signals of 5MHz. However, the effect of
cable length is shown in Table 3:

A and B signal

frequency

meters feet

Maximum cable length

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 3 - Effect of cable length on maximum encoder frequency

4-12 Input / Output MN1928

4.5.3 RS232 serial connection

Location Serial

Mating connector: 9-pin female D-type

Pin Name Description 96-pin

connector

1 Shield Shield connection a32

2 RXD Receive Data a20

3 TXD Transmitted Data a21

6

1

4 (NC) (Not connected) a16*

5 DGND Digital ground a3

9

5

6 (NC) (Not connected) a17*

7 RTS Request To Send b21

8 CTS Clear To Send a22

9 DGND Digital ground a3

* Pins a16 and a17 are linked on the NextMove ES.

The serial connector duplicates the signals present on the 96-pin connector. It is used to
connect the NextMove ES to the PC running WorkBench v5, or other controller. If an optional
Baldor backplane is being used, its serial connector (section 5.2.13 or 5.3.13) will carry the
same signals. Do not attempt to use more than one set of serial connections at the same time.
The port provides a full-duplex RS232 serial port with the following preset configuration:

H 57,600 baud

H 1startbit

H 8 data bits

H 1stopbit

H No parity

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

The configuration can be changed using the SERIALBAUD keyword. It is stored in EEPROM
and restored at power up. The port is capable of operation at up to 115,200 baud.

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

Only the TXD, RXD and 0V GND connections are required for communication. Pins 4 and 6
are linked on the NextMove ES.

Input / Output 4-13MN1928

NextMove ES

(DCE)

RS232

RXD 2

TXD 3

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 12 - 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. A suitable
cable is available from Baldor, catalog number CBL001-501.

4.5.4 USB connection

Location USB

Mating connector: USB Type B (downstream) plug

Pin Name Description

142

1 VBUS USB +5V

2 D- Data-

3 D+ Data+

4 GND Ground

3

The USB connector can be used as an alternative method for connecting the NextMove ES to
a PC running WorkBench v5, or other controller. The NextMove ES is a self-powered, USB 1.1
compatible device. The maximum recommended cable length is 5m.

4-14 Input / Output MN1928

4.5.5 CAN connection

The CAN connection is made using the RJ45 connector on the NextMove ES card.

Location

NextMove ES card

Pin Name Description

1 CAN+ CAN channel positive

2 CAN - CAN channel negative

3 - (NC)

1

8

4 CAN 0V Ground/earth reference for CAN signals

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

6 - (NC)

7 - (NC)

8 - (NC)

Description

Opto-isolated CAN interface using a RJ45 connector.

CAN offers serial communications over a two wire twisted pair cable up to maximum length of
500m (1640ft). It offers very high communication reliability in an industrial environment; the
probability of an undetected error is 4.7x10

-11

. CAN is optimized for the transmission of small
data packets and therefore offers fast update of I/O devices (peripheral devices) connected to
the bus. The maximum (default) transmission rate on NextMove ES is 500Kbit/s.

Correct operation of CAN can only be achieved with screened/shielded twisted-pair cabling.
For improved noise immunity, CAN+ and CAN- must form a twisted pair 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

7

2

NextMove ES

RJ45 connector

Twisted pair Twisted pairs

T

R

0V

1

2

4

5

Figure 13 - Typical CAN network connections

NextMove ES

RJ45 connector

1

2

4

524V

End node

1

2

T

R

4

5

Input / Output 4-15MN1928

The CAN channel is opto-isolated. A voltage in the range 12-24V must be applied to pin 5 of
the CAN connector. An internal voltage regulator provides the 5V required for the isolated CAN
circuit. Practical operation of the CAN channel is limited to 500Kbit/s owing to the propagation
delay of the opto-isolators.

The CAN channel must be terminated by a 120Ω resistor connected
between CAN+ and CAN- at both ends of the network and nowhere
else. If the NextMove ES is at the end of the network then ensure
that jumper JP1, located just below the status display, is in position.
This will connect an internal terminating resistor.

JP1

A very low error rate over CAN can only be achieved with a suitable
wiring scheme, so the following points should be observed:

H The connection arrangement is normally a multi-point drop. The CAN cables should have

a characteristic impedance of 120Ω and a delay of 5ns/m. Other characteristics depend
upon the length of the cabling:

Cable length

Maximum

Resistance Conductor
theoretical
bit rate

0m ~ 300m (0ft ~ 984ft) 500Kbit/s <60mΩ/m 0.34 ~ 0.60mm

300m ~ 600m (984ft ~ 1968ft) 100Kbit/s <40mΩ/m 0.50 ~ 0.60mm

600m ~ 1000m (1968ft ~ 3280ft) 50Kbit/s <26mΩ/m 0.75 ~ 0.80mm

H The 0V connection of all of the nodes on the network must be tied together through the

CAN cabling. This ensures that the CAN signal levels transmitted by NextMove ES or
CAN peripheral devices are within the common mode range of the receiver circuitry of
other nodes on the network.

4.5.5.1 CANopen and Baldor CAN

The NextMove ES can communicate with other MintMT controllers over a CANopen network.
Baldor CAN is a proprietary CAN protocol, allowing the NextMove ES to communicate with a
range of Baldor ioNode CAN peripherals.

area

2

2

2

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, 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 NextMove ES has the
ability to act as the network manager node or as a slave on the CANopen network.

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. Optional MintMT
firmware can be downloaded to implement a proprietary Baldor protocol on CAN bus 2, based
on CAL (the CAN Application Layer). This supports both direct access to device parameters
and time-critical process data communication. Baldor CAN provides support for the full range
of Baldor ioNode CAN peripherals.

The baud rate and node number of the NextMove ES can be set using the BUSBAUD and
NODE keywords.

4-16 Input / Output MN1928

4.6 Connection su mmary - minimum system wiring

As a guide, Figure 14 shows an example of the typical minimum wiring required to allow the
NextMove ES and a single axis stepper amplifier to work together. The optional opto-isolating
backplane card BPL010-502 is shown. Details of the connector pins are shown in Table 4.

+24V user supply

X4

Serial

X2 X3

Encoder0 Encoder1

X1

Host PC

Backplane

X6

X5

X13

X12

X11

NextMove ES

Drive amplifier (axis 0)

Pulse+
Pulse­Direction+
Direction­Fault relay
Gnd
Enable
Gnd

X10

X9

X8

X7

+5V supply

±12V supply

Common

earth/ground

Notes:

In this example, the backpl ane’ s relay contacts are being
used to apply the 24V user supply to the drive amplifier’s
Enable input.

The backplane’s relay is driv en by the NextMove ES Error
Out signal. This signal may be c ontrolled by the keywords
DRIVEENABLEOUTPUT, GLOBALERROROUTPUT or RELAY.

The drive amplifier’s Fault relay connecti ons are shown
connected to digital input 0. If an error occurs, it can be
detected by using the MintMT Event IN0 ev ent.

The INPUTACTIVELEVEL keyword can be used to alter the
active state of the digital input.

Figure 14 - Example minimum system wiring

Input / Output 4-17MN1928

Backplane

S

t

l

f

0Step(pulse)

i

t

D

i

t

i

l

f

0Di

t

ioni

t

connector

Pin Name of

card

X6 9 USR GND User power supply GND Enable signal ground

X8 9 REL NO Switched relay contact Enable signal input

signal

10 REL COM Common relay connection

Function Connection on drive

(Note: drive may be
labelled differently)

(linkedtoUSRV+)

X9 2 STEP0-

3 STEP0+

4 DIR0-

5 DIR0+

X12 1 DIN0 Digital input 0 Fault relay output

11 USR GND User power supply GND Fault relay GND

Table 4 - Connector details for minimum system wiring shown in Figure 14

ep signa

rec

on signa

or axis

or axis

rec

npu

npu

4-18 Input / Output MN1928

5 Backplanes

5.1 Introduction

This section describes the optional backplane cards available for use with the NextMove ES.
These cards all provide standard wiring connections to the NextMove ES, but there are a
number of variants available:

H Baldor part number BPL010-501: Non-isolated backplane.

H Baldor part number BPL010-502: Isolated PNP backplane.

H Baldor part number BPL010-503: Isolated NPN backplane.

It is recommended to use one of these dedicated backplanes with your NextMove ES.

Each table shows the required mating connector and the associated pin on the NextMove ES
96-pin connector. Where multiple pins exist with the same function, for example AGND, one
example pin number is shown, but any identically named pin represents the same electrical
connection.

See section 4.2 for details of the 96-pin connector.

5

Input / Output 5-1MN1928

5.2 BPL010-501 non-isolated backplane

This backplane provides direct connection to the NextMove ES signals without isolation. The
electrical specifications of all signals are therefore the same as described in section 4.

In the following sections, the signals AGND, DGND and Shield are listed with nominal
corresponding pins on the 96-pin connector, although they are all electrically connected on the
backplane. The OUT COM pin on connector X11 is not connected to ground.

Some signals are duplicated on multiple identically named pins on the 96-pin connector.
In these cases, only the lowest numbered pin is listed.

CAUTION: Some components are static sensitive devices. T ake appropriate ESD

precautions when handling the backplane.

5.2.1 Analog inputs

Location X8

10

1

See section 4.3.1 for electrical specifications of the analog inputs.

Mating connector: Weidmüller Omnimate BL 3.5/10

Pin Name Description 96-pin

10 Shield Shield connection a32

9 DGND Digital ground a3

8 !RSTIN Reset input c12

7 ERROR Error output b11

6 AGND Analog ground a30

5 AIN1- Analog input AIN1- a27

4 AIN1+ Analog input AIN1+ c28

3 AGND Analog ground a30

2 AIN0- Analog input AIN0- a28

1 AIN0+ Analog input AIN0+ b28

connector

5-2 Input / Output MN1928

5.2.2 Analog outputs (demands)

Location X7

12

1

See section 4.3.2 for electrical specifications of the analog outputs.

Mating connector: Weidmüller Omnimate BL 3.5/12

Pin Name Description 96-pin

12 Shield Shield connection a32

11 AGND Analog ground a30

10 DEMAND3 Analog output AOUT3 b22

9 Shield Shield connection a32

8 AGND Analog ground a30

7 DEMAND2 Analog output AOUT2 b17

6 Shield Shield connection a32

5 AGND Analog ground a30

4 DEMAND1 Demand 1 output (AOUT1) b27

3 Shield Shield connection a32

2 AGND Analog ground a30

1 DEMAND0 Demand 0 output (AOUT0) c27

connector

Input / Output 5-3MN1928

5.2.3 Digital inputs 0-7

Location X12

10

1

See section 4.4.1 for electrical specifications of the digital inputs.

Mating connector: Weidmüller Omnimate BL 3.5/10

Pin Name Description 96-pin

10 Shield Shield connection a32

9 DGND Digital ground a3

8 DIN7 Digital input DIN7 a19

7 DIN6 Digital input DIN6 c20

6 DIN5 Digital input DIN5 b19

5 DIN4 Digital input DIN4 c18

4 DIN3 Digital input DIN3 c19

3 DIN2 Digital input DIN2 a18

2 DIN1 Digital input DIN1 b20

1 DIN0 Digital input DIN0 c21

5.2.4 Digital inputs 8-15

Location X13

10

1

Mating connector: Weidmüller Omnimate BL 3.5/10

Pin Name Description 96-pin

10 Shield Shield connection a32

9 DGND Digital ground a3

8 DIN15 Digital input DIN15 b18

7 DIN14 Digital input DIN14 c23

6 DIN13 Digital input DIN13 b24

5 DIN12 Digital input DIN12 c26

4 DIN11 Digital input DIN11 a25

3 DIN10 Digital input DIN10 a24

2 DIN9 Digital input DIN9 b25

1 DIN8 Digital input DIN8 a26

connector

connector

See section 4.4.1 for electrical specifications of the digital inputs.

5-4 Input / Output MN1928

5.2.5 Digital inputs 16-19

Location X6

5

1

See section 4.4.1 for electrical specifications of the digital inputs.

Mating connector: Weidmüller Omnimate BL 3.5/5

Pin Name Description 96-pin

5 DGND Digital ground a3

4 DIN19 Digital input DIN19 b26

3 DIN18 Digital input DIN18 c25

2 DIN17 Digital input DIN17 c24

1 DIN16 Digital input DIN16 c11

5.2.6 Digital outputs 0-7

Location X11

10

1

Mating connector: Weidmüller Omnimate BL 3.5/10

Pin Name Description 96-pin

10 DGND Digital ground a3

9 OUT COM Common a4

8 DOUT7 Digital output DOUT7 b4

7 DOUT6 Digital output DOUT6 c4

6 DOUT5 Digital output DOUT5 a5

5 DOUT4 Digital output DOUT4 b5

4 DOUT3 Digital output DOUT3 c5

3 DOUT2 Digital output DOUT2 a6

2 DOUT1 Digital output DOUT1 b6

1 DOUT0 Digital output DOUT0 c6

connector

connector

See section 4.4.2 for electrical specifications of the digital outputs.

Input / Output 5-5MN1928

5.2.7 Digital outputs 8-11

Location X5

5

1

See section 4.4.2 for electrical specifications of the digital outputs.

Mating connector: Weidmüller Omnimate BL 3.5/5

Pin Name Description 96-pin

5 DGND Digital ground a3

4 DOUT11 Digital output DOUT11 c22

3 DOUT10 Digital output DOUT10 c16

2 DOUT9 Digital output DOUT9 b13

1 DOUT8 Digital output DOUT8 a13

connector

5-6 Input / Output MN1928

5.2.8 Stepper axes outputs 0-1

Location X9

12

Mating connector: Weidmüller Omnimate BL 3.5/12

Pin Name Description 96-pin

connector

12 Shield Shield connection a32

11 DIR1+ Direction output 1+ b15

10 DIR1- Direction output 1-

9 STEP1+ Step (pulse) output 1+ b14

8 STEP1- Step (pulse) output 1-

1

7 DGND Digital ground a3

6 Shield Shield connection a32

5 DIR0+ Direction output 0+ a15

4 DIR0- Direction output 0-

3 STEP0+ Step (pulse) output 0+ a14

2 STEP0- Step (pulse) output 0-

1 DGND Digital ground a3

The stepper outputs on the backplane are driven by DS26LS31 line drivers, providing RS422
differential outputs.

CAUTION: The DS26LS31 drivers are static sensitive devices. T ake appropriate ESD

precautions when handling the backplane.

NextMove ES

Step

Output

GND

Backplane

DS26LS31

74AHCT244

ULN2003

96
pin

connector

Figure 15 - Stepper output - STEP0 output shown

‘X9’

STEP0-

2

STEP0+3

DGND

1

Input / Output 5-7MN1928

5.2.9 Stepper axes outputs 2-3

Location X10

12

Mating connector: Weidmüller Omnimate BL 3.5/12

Pin Name Description 96-pin

connector

12 Shield Shield connection a32

11 DIR3+ Direction output 3+ a23

10 DIR3- Direction output 3-

9 STEP3+ Step (pulse) output 3+ b23

8 STEP3- Step (pulse) output 3-

1

7 DGND Digital ground a3

6 Shield Shield connection a32

5 DIR2+ Direction output 2+ c15

4 DIR2- Direction output 2-

3 STEP2+ Step (pulse) output 2+ c14

2 STEP2- Step (pulse) output 2-

1 DGND Digital ground a3

The stepper outputs on the backplane are driven by DS26LS31 line drivers, providing RS422
differential outputs.

CAUTION: The DS26LS31 drivers are static sensitive devices. T ake appropriate ESD

precautions when handling the backplane.

NextMove ES

Step

Output

GND

74AHCT244

ULN2003

connector

pin

Backplane

96

DS26LS31

1

2

‘X10’

STEP2-

STEP2+3

DGND

Figure 16 - Stepper output - STEP2 output shown

5-8 Input / Output MN1928

5.2.10 Power inputs

Location X1

5

1

See section 3.1.3 for power requirements.

5.2.11 Encoder input 0

Location X3 Encoder0

9

6

5

1

Mating connector: Weidmüller Omnimate BL 3.5/5

Pin Name Description 96-pin

connector

5 DGND Digital ground a3

4 DGND Digital ground a3

3 +5 +5V input a1

2 -12 -12V input a31

1 +12 +12V input a29

Mating connector: 9-pin male D-type

Pin Name Description 96-pin

connector

1 CHA+ Channel A signal b7

2 CHB+ Channel B signal a7

3 CHZ+ Index channel signal b8

4 Shield Shield connection a32

5 DGND Digital ground a3

6 CHA- Channel A signal complement b10

7 CHB- Channel B signal complement c10

8 CHZ- Index channel signal complement b9

9 +5V out Power supply to encoder a1

Input / Output 5-9MN1928

5.2.12 Encoder input 1

Location X2 Encoder1

Mating connector: 9-pin male D-type

Pin Name Description 96-pin

1 CHA+ Channel A signal a8

2 CHB+ Channel B signal c7

3 CHZ+ Index channel signal c8

4 Shield Shield connection a32

9

6

5

5 DGND Digital ground a1

6 CHA- Channel A signal complement c9

1

7 CHB- Channel B signal complement a10

8 CHZ- Index channel signal complement a9

9 +5V out Power supply to encoder a1

See section 4.5.2 for specifications of the encoder inputs.

5.2.13 RS232 serial communication

Location X4 Serial

6

9

1

5

Mating connector: 9-pin female D-type

Pin Name Description 96-pin

1 Shield Shield connection a32

2 RXD Receive Data a20

3 TXD Transmitted Data a21

4 (NC) (Not connected) a16*

5 DGND Digital ground a3

6 (NC) (Not connected) a17*

7 RTS Request To Send b21

8 CTS Clear To Send a22

9 DGND Digital ground a3

connector

connector

This serial connector carries the same signals as the serial connector on the NextMove ES
control card. Do not use both serial connectors at the same time.

*Pins4and6arelinkedontheNextMoveES.

5-10 Input / Output MN1928

5.3 BPL010-502/503 backplane with opto-isolato r card

These backplanes are provided with an additional plug in card which provides opto-isolation
for many of the NextMove ES signals.

On BPL010-502, the general purpose digital outputs are PNP (current sourcing) outputs.
The general purpose digital inputs are activated when a positive voltage is applied.

On BPL010-503, the general purpose digital outputs are NPN (current sinking) outputs.
The general purpose digital inputs are activated when grounded.

There are two 96-pin connectors present on the opto-isolating backplane. The male connector
accepts the opto-isolator card. The female 96-pin connector nearest the edge of the backplane
accepts the NextMove ES card. The backplane will not operate without the opto-isolating card.

In the following sections, the signals AGND, DGND and Shield are listed with nominal
corresponding pins on the 96-pin connector, although they are all electrically connected on the
backplane. The OUT COM pin on connector X11 is not connected to ground.

All terminals labeled USR GND are electrically connected on the backplane, but are not
connected to the AGND, DGND or Shield terminals. USR GND forms an independent
common connection for the 0V side of the external power supply used for the digital inputs and
outputs. It will be necessary to link the OUT COM or USR COM terminal to USR GND to allow
the digital outputs to operate. However, the OUT COM and USR COM connectors have
different purposes depending on model - see sections 5.3.6.1 and 5.3.6.2.

Some signals are duplicated on multiple identically named pins on the 96-pin connector.
In these cases, only the lowest numbered pin is listed.

CAUTION: Some components are static sensitive devices. T ake appropriate ESD

precautions when handling the backplane.

Input / Output 5-11MN1928

5.3.1 Analog inputs

Location X8

10

Mating connector: Weidmüller Omnimate BL 3.5/10

Pin Name Description NextMove ES

96-pin
connector

10 REL COM Common relay contact

9 REL NO Normally open relay contact

8 REL NC Normally closed relay contact

7 REL COM Common relay contact

1

6 Shield Shield connection a32

5 AIN1- Analog input AIN1- a27

4 AIN1+ Analog input AIN1+ c28

3 AGND Analog ground a30

2 AIN0- Analog input AIN0- a28

1 AIN0+ Analog input AIN0+ b28

The analog inputs on the backplane are connected directly to the NextMove ES and do not
pass through any circuitry on the opto-isolator card. See section 4.3.1 for electrical
specifications of the analog inputs.

AIN0-

Backplane

2

1

3

96

pin

connector

NextMove ES

120k

120k

15k

22nF

-

+AIN0+

10k 10k

-

+

10nF

MintMT

ADC.0

‘X8’

AGND

Figure 17 - Analog input, AIN0 shown

5-12 Input / Output MN1928

5.3.1.1 Error relay connections

The double-pole relay on the opto-isolator card is controlled directly by the Error Out signal
(section 4.4.3), as shown in Figure 18.

NextMove ES

MintMT

GLOBALERROROUTPUT

or

DRIVEENABLEOUTPUT

Control

circuitry

Error Out

96

pin

connector

+5V

Relay

Backplane

7

9

8

‘X8’

REL COM

REL NO

REL NC

Figure 18 - Relay connections

The error output can be controlled by the RELAY keyword, and can be configured as the global
error output by setting GLOBALERROROUTPUT to 1000 (_RELAY0). See the Mint MT help file.

While there is no error, the relay is energized, and REL COM is connected to REL NO.
When an error occurs, the relay is de-energized, and REL COM is connected to REL NC.

CAUTION: It is important that the NextMove ES jumper settings are correct to allow it

to control the backplane relay. JP4 must be fitted. Jumpers JP3 and JP5
must be removed. See section 4.4.3 for jumper locations.

Input / Output 5-13MN1928

5.3.2 Analog outputs (demands)

Location X7

12

Mating connector: Weidmüller Omnimate BL 3.5/12

Pin Name Description NextMove ES

96-pin
connector

12 Shield Shield connection a32

11 AGND Analog ground a30

10 DEMAND3 Analog output AOUT3 b22

9 Shield Shield connection a32

1

8 AGND Analog ground a30

7 DEMAND2 Analog output AOUT2 b17

6 Shield Shield connection a32

5 AGND Analog ground a30

4 DEMAND1 Demand 1 output (AOUT1) b27

3 Shield Shield connection a32

2 AGND Analog ground a30

1 DEMAND0 Demand 0 output (AOUT0) c27

The outputs on the backplane are connected directly to the NextMove ES and do not pass
through any circuitry on the opto-isolator card. See section 4.3.2 for electrical specifications of
the analog outputs.

NextMove ES

100pF

Backplane

’X7’

Demand

±100%

30k

120k

-

TL084

+

47R

96

pin

connector

1

2

DEMAND0

AGND

Figure 19 - Analog output, DEMAND0 shown

5-14 Input / Output MN1928

5.3.3 Digital inputs 0-7

Location X12

10

1

The BPL010-502 and BPL010-503 opto-isolating cards use different input configurations.
Sections 5.3.5.1 and 5.3.5.2 describe the two input types.

Mating connector: Weidmüller Omnimate BL 3.5/10

Pin Name Description NextMove ES

96-pin
connector

10 Shield Shield connection a32

9 USR GND Customer power supply ground

8 DIN7 Digital input DIN7 a19

7 DIN6 Digital input DIN6 c20

6 DIN5 Digital input DIN5 b19

5 DIN4 Digital input DIN4 c18

4 DIN3 Digital input DIN3 c19

3 DIN2 Digital input DIN2 a18

2 DIN1 Digital input DIN1 b20

1 DIN0 Digital input DIN0 c21

Input / Output 5-15MN1928

5.3.4 Digital inputs 8-15

Location X13

10

1

The BPL010-502 and BPL010-503 opto-isolating cards use different input configurations.
Sections 5.3.5.1 and 5.3.5.2 describe the two input types.

Mating connector: Weidmüller Omnimate BL 3.5/10

Pin Name Description NextMove ES

96-pin
connector

10 Shield Shield connection a32

9 USR GND Customer power supply ground

8 DIN15 Digital input DIN15 b18

7 DIN14 Digital input DIN14 c23

6 DIN13 Digital input DIN13 b24

5 DIN12 Digital input DIN12 c26

4 DIN11 Digital input DIN11 a25

3 DIN10 Digital input DIN10 a24

2 DIN9 Digital input DIN9 b25

1 DIN8 Digital input DIN8 a26

5-16 Input / Output MN1928

5.3.5 Digital inputs 16-19

Location X6

10

1

The BPL010-502 and BPL010-503 opto-isolating cards use different input configurations.
Sections 5.3.5.1 and 5.3.5.2 describe the two input types.

Mating connector: Weidmüller Omnimate BL 3.5/10

Pin Name Description NextMove ES

10 Shield Shield connection a32

9 USR GND Customer power supply ground

8 USR GND Customer power supply ground

7 USR V+ Customer power supply

6 USR V+ Customer power supply

5 !RST IN Reset input c12

4 DIN19 Digital input DIN19 b26

3 DIN18 Digital input DIN18 c25

2 DIN17 Digital input DIN17 c24

1 DIN16 Digital input DIN16 c11

96-pin
connector

Input / Output 5-17MN1928

5.3.5.1 BPL010-502 - Active high inputs

The user power supply connection USR GND is common to all inputs. To activate an input, a
voltage must be applied that is sufficient to cause at least 5mA in the input circuit. To ensure
that an input becomes inactive, the current must be less than 1mA.

Backplane & opto-isolator card

‘X6’

NextMove ES

User
supply
24V

User
supply
GND

DIN16

‘X6’

USR GND

1

2k2

8

TLP521-4

96

pin

connector

+5V

10k

74AHCT14

Figure 20 - Digital input circuit (DIN16) with ‘active high’ inputs

5.3.5.2 BPL010-503 - Active low inputs

The user power supply connection USR V+ is common to all inputs. To activate an input it
must be grounded to the 0V side of the user power supply (USR GND). The internal pull-up
resistor on the NextMove ES allows the input to be left floating when inactive or not being
used.

Backplane & opto-isolator card

‘X6’

User
supply
24V

User
supply
GND

USR V+

‘X6’

DIN16

6

2k2

1

TLP521-4

96
pin

connector

+5V

10k

74AHCT14

MintMT

INX.16

GND

NextMove ES

MintMT

INX.16

GND

Figure 21 - Digital input circuit (DIN16) with ‘active low’ inputs

5-18 Input / Output MN1928

5.3.6 Digital outputs 0-7

Location X11

10

1

The digital outputs DOUT0 - DOUT7 are buffered by the opto-isolator card.

* The BPL010-502 and BPL010-503 opto-isolating cards use different output driver ICs, as
shown in Figures 22 and 23. Due to the pin configuration of these ICs, the functions of the X11
connector’s USR COM and OUT COM pins are different on the PNP and NPN cards.

Sections 5.3.6.1 and 5.3.6.2 describe the two output types.

Mating connector: Weidmüller Omnimate BL 3.5/10

Pin Name Description NextMove ES

96-pin
connector

10 USR COM Common supply connection* a3

9 OUT COM Common* a4

8 DOUT7 Digital output DOUT7 b4

7 DOUT6 Digital output DOUT6 c4

6 DOUT5 Digital output DOUT5 a5

5 DOUT4 Digital output DOUT4 b5

4 DOUT3 Digital output DOUT3 c5

3 DOUT2 Digital output DOUT2 a6

2 DOUT1 Digital output DOUT1 b6

1 DOUT0 Digital output DOUT0 c6

CAUTION: Digital outputs DOUT8 - DOUT11 on connector X5 are not buffered by the

opto-isolator card - see section 5.3.7.

Input / Output 5-19MN1928

5.3.6.1 BPL010-502 - PNP outputs

An external supply (typically 24VDC) is used to power the UDN2982 output devices, as shown
in Figure 22. When an output is activated, current is sourced from the user supply through the
UDN2982, which can source up to 75mA per output (all outputs on, 100% duty cycle).
Connect OUT COM to the user supply GND. This will connect internal transient suppression
diodes on all outputs. If an output is used to drive a relay, a suitably rated diode must be fitted
across the relay coil, observing the correct polarity (see Figure 24). The use of shielded cable
is recommended.

6

10

1

9

‘X6’

USR V+

‘X11’

USR COM

DOUT0

OUT COM

Output
Load

User
supply
24V

User
supply
GND

NextMove ES

OUTX.0

Control

circuitry

96
pin

connector

Backplane & opto-isolator card

+5V

2k2

UDN2982

TLP521-4

Figure 22 - Digital output circuit (DOUT0-7) with ‘PNP’ current sourcing module - DOUT0 shown

5.3.6.2 BPL010-503 - NPN outputs

An external supply (typically 24VDC) is used to power the UDN2803 output devices and drive
the load, as shown in Figure 23. When an output is activated it is connected to USR COM
through the ULN2803, which can sink up to 150mA per output (all outputs on, 100% duty
cycle). Connect OUT COM to the user supply 24V. This will connect internal transient
suppression diodes on all outputs. If an output is used to drive a relay, a suitably rated diode
must be fitted across the relay coil, observing the correct polarity (see Figure 24). The use of
shielded cable is recommended.

6

1

9

10

‘X6’

USR V+

‘X11’

DOUT0

OUT COM

USR COM

Output
Load

User
supply
24V

User
supply
GND

NextMove ES

OUTX.0

Control

circuitry

96
pin

connector

Backplane & opto-isolator card

+5V

2k2

ULN2803

TLP521-4

Figure 23 - Digital output circuit (DOUT0-7) with ‘NPN’ current sinking module - DOUT0 shown

5-20 Input / Output MN1928

5.3.7 Digital outputs 8-11

Location X5

Mating connector: Weidmüller Omnimate BL 3.5/5

5

Pin Name Description NextMove ES

96-pin
connector

1

5 DGND Digital ground a3

4 DOUT11 Digital output DOUT11 c22

3 DOUT10 Digital output DOUT10 c16

2 DOUT9 Digital output DOUT9 b13

1 DOUT8 Digital output DOUT8 a13

CAUTION: Digital outputs DOUT8 - DOUT11 on the backplane are not buffered by

the opto-isolator card; they are connected directly to the NextMove ES
outputs.

When an output is activated, it is grounded through the ULN2003, which can sink up to 50mA
per output (all outputs on, 100% duty cycle). If an output is used to drive a relay, a suitably
rated diode must be fitted across the relay coil, observing the correct polarity. This is to protect
the output from the back-EMF generated by the relay coil when it is de-energized.

User
supply

NextMove ES

MintMT

OUTX.8

74AHCT244

ULN2003

96
pin

connector

Backplane

1

’X5’

DOUT8

24V

Output Load
(Relay with
flyback diode
shown)

GND

5

Figure 24 - Digital output circuit (DOUT8-11) - DOUT8 shown

DGND

User
supply
GND

Input / Output 5-21MN1928

5.3.8 Stepper axes outputs 0-1

Location X9

12

Mating connector: Weidmüller Omnimate BL 3.5/12

Pin Name Description NextMove ES

96-pin
connector

12 Shield Shield connection a32

11 DIR1+ Direction output 1+ b15

10 DIR1- Direction output 1-

9 STEP1+ Step (pulse) output 1+ b14

1

8 STEP1- Step (pulse) output 1-

7 DGND Digital ground a3

6 Shield Shield connection a32

5 DIR0+ Direction output 0+ a15

4 DIR0- Direction output 0-

3 STEP0+ Step (pulse) output 0+ a14

2 STEP0- Step (pulse) output 0-

1 DGND Digital ground a3

The stepper outputs on the backplane are driven by DS26LS31 line drivers, providing RS422
differential outputs.

CAUTION: The DS26LS31 drivers are static sensitive devices. T ake appropriate ESD

precautions when handling the backplane.

NextMove ES

Step

Output

GND

74AHCT244

ULN2003

connector

pin

Backplane

96

DS26LS31

1

2

‘X9’

STEP0-

STEP0+3

DGND

Figure 25 - Stepper output - STEP0 output shown

5-22 Input / Output MN1928

5.3.9 Stepper axes outputs 2-3

Location X10

12

Mating connector: Weidmüller Omnimate BL 3.5/12

Pin Name Description 96-pin

connector

12 Shield Shield connection a32

11 DIR3+ Direction output 3+ a23

10 DIR3- Direction output 3-

9 STEP3+ Step (pulse) output 3+ b23

8 STEP3- Step (pulse) output 3-

1

7 DGND Digital ground a3

6 Shield Shield connection a32

5 DIR2+ Direction output 2+ c15

4 DIR2- Direction output 2-

3 STEP2+ Step (pulse) output 2+ c14

2 STEP2- Step (pulse) output 2-

1 DGND Digital ground a3

The stepper outputs on the backplane are driven by DS26LS31 line drivers, providing RS422
differential outputs.

CAUTION: The DS26LS31 drivers are static sensitive devices. T ake appropriate ESD

precautions when handling the backplane.

NextMove ES

Step

Output

GND

Backplane

DS26LS31

74AHCT244

ULN2003

96

pin

connector

Figure 26 - Stepper output - STEP2 output shown

‘X10’

STEP2-

2

STEP2+3

DGND

1

Input / Output 5-23MN1928

5.3.10 Power inputs

Location X1

5

1

See section 3.1.3 for power requirements.

5.3.11 Encoder input 0

Location X3 Encoder0

9

6

5

1

Mating connector: Weidmüller Omnimate BL 3.5/5

Pin Name Description NextMove ES

96-pin
connector

5 DGND Digital ground a3

4 DGND Digital ground a3

3 +5 +5V input a1

2 -12 -12V input a31

1 +12 +12V input a29

Mating connector: 9-pin male D-type

Pin Name Description 96-pin

connector

1 CHA+ Channel A signal b7

2 CHB+ Channel B signal a7

3 CHZ+ Index channel signal b8

4 Shield Shield connection a32

5 GND Digital ground a3

6 CHA- Channel A signal complement b10

7 CHB- Channel B signal complement c10

8 CHZ- Index channel signal complement b9

9 +5V out Power supply to encoder a1

5-24 Input / Output MN1928

5.3.12 Encoder input 1

Location X2 Encoder1

Mating connector: 9-pin male D-type

Pin Name Description 96-pin

1 CHA+ Channel A signal a8

2 CHB+ Channel B signal c7

3 CHZ+ Index channel signal c8

4 Shield Shield connection a32

9

6

5

5 GND Digital ground a1

6 CHA- Channel A signal complement c9

1

7 CHB- Channel B signal complement a10

8 CHZ- Index channel signal complement a9

9 +5V out Power supply to encoder a1

See section 4.5.2 for specifications of the encoder inputs.

5.3.13 RS232 serial communication

Location X4 Serial

6

9

1

5

Mating connector: 9-pin female D-type

Pin Name Description 96-pin

1 Shield Shield connection a32

2 RXD Receive Data a20

3 TXD Transmitted Data a21

4 (NC) (Not connected) a16*

5 DGND Digital ground a3

6 (NC) (Not connected) a17*

7 RTS Request To Send b21

8 CTS Clear To Send a22

9 DGND Digital ground a3

connector

connector

This serial connector carries the same signals as the serial connector on the NextMove ES
control card. Do not use both serial connectors at the same time.

*Pins4and6arelinkedontheNextMoveES.

Input / Output 5-25MN1928

5-26 Input / Output MN1928

6 Operation

6.1 Introduction

The software provided includes a number of applications and utilities to allow you to configure,
tune and program the NextMove ES. The Baldor Motion Toolkit CD containing the software
can be found separately within the packaging.

6.1.1 Connecting the NextMove ES to the PC

The NextMove ES can be connected to the PC using either RS232 or USB.

To use RS232, connect an RS232 serial cable between a PC serial port (often labeled as
“COM”) and the NextMove ES RS232 connector. W orkBench v5 can scan all the COM ports,
so you can use any port. If you are not using the Baldor serial cable CBL001-501, your cable
must be wired in accordance with Figure 12 in section 4.5.3.

To use USB, connect a USB cable between a PC USB port and the NextMove ES USB
connector. Your PC must be using Windows 2000 or Windows XP.

6.1.2 Installing WorkBench v5

You will need to install WorkBench v5 to configure and tune the NextMove ES.

1. Insert the CD 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

6

d:\start

where d represents the drive letter of the CD device.

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

6.1.3 Starting the NextMove ES

If you have followed the instructions in the previous sections, you should have now connected
power sources, your choice of inputs and outputs and a RS232 or USB cable linking the PC
with the NextMove ES.

Operation 6-1MN1928

6.1.4 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 ES is properly earthed/grounded.
H Check all signal wiring for accuracy.

6.1.5 Power on checks

1. Turn on the 5V and ±12V supplies.

2. After a brief test sequence (
number, for example
supply connections. A green surface mount LED (D16) near the center of the NextMove ES

should also be flashing once every two seconds. The NextMove ES is now ready to be
configured using WorkBench v5.

Note: If the red LED (D4) near the center of the NextMove ES remains illuminated, then

the supply voltage is too low. See section 7.2.2 for LED locations. If the status
display shows one of the digits 0 - 7 with a flashing decimal point, this indicates
that the NextMove ES has detected a fault and cannot be started. In this unlikely
event, please contact Baldor technical support.

6.1.5.1 Inst a lling the USB driver

If you have connected the NextMove ES to the PC using the USB connection, it will be
necessary to install the USB driver. When the NextMove ES is powered, Windows (2000 or
XP only) will automatically detect the controller and request the driver. The driver consists of
two files, baldorusb.inf and baldorusb.sys. Both files must be present for installation.

followed by ), the Status display should show the node

, the factory default. If the display is not lit then re-check the power

1. Follow the on-screen instructions to select and install the driver. The driver files are available
on the supplied Baldor Motion T oolkit CD. If you are using a copy of the driver located on the
hard disk, a floppy disk or another CD, the two driver files should be in the same folder.

2. During installation, Windows may report that the driver is ’unsigned’. This is normal for the
NextMove ES driver, so click the Continue Anyway button to continue with the installation.
When installation is complete, a new Baldor USB device will be listed in the Universal Serial
Bus controllers section of Windows Device Manager.

The NextMove ES is now ready to be configured using WorkBench v5.

Note: If the NextMove ES is later connected to a different USB port on the host

computer, Windows may report that it has found new hardware. Either install the
driver files again for the new USB port, or connect the NextMove ES to the original
USB port where it will be recognized in the usual way.

6-2 Operation MN1928

6.2 WorkBench v5

WorkBench v5 is a fully featured application for programming and controlling the
NextMove ES. The main WorkBench window contains a menu system, the Toolbox and 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.

6.2.1 Help file

WorkBench v5 includes a comprehensive help file that contains information about every
MintMT keyword, how to use WorkBench 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

number of topics
allows you to 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

contains a

Figure 27 - The WorkBench help file

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

beside the Wor kBench v5 book icon. Double click a topic name to display it.

Operation 6-3MN1928

6.2.2 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...

6-4 Operation MN1928

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 ES is connected. If you are unsure which PC serial port
is connected to the drive, select Scan all serial ports. If the NextMove ES is connected
using USB, it will be scanned automatically.

Click Scan to search for the NextMove ES.

When the search is complete, click ‘NextMove ES’ in the list to select it, and then click

Select.

Note: If the NextMove ES is not listed, check the serial or USB cable between the

NextMove ES and the PC. Check that the NextMove ES is powered correctly.
Click Scan to re-scan the ports.

4. A dialog box may be displayed to tell you that WorkBench v5 has detected new firmware.
Click OK to continue. WorkBench v5 reads back data from the NextMove ES. When this is
complete, Edit & Debug mode is displayed. This completes the software installation.

Operation 6-5MN1928

6.3 Configuring an axis

The NextMove ES is capable of controlling 4 stepper and 2 servo axes. This section describes
the basic setup for both types of axis. Commands typed in the Command window have
immediate effect - they do not need to be separately downloaded to the NextMove ES.

6.3.1 Selecting a scale

MintMT defines all positional and speed related motion keywords in terms of encoder
quadrature counts (for servo motors) or steps for stepper motors. The number of quadrature
counts (or steps) is divided by the SCALEFACTOR 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 servo motor with a 1000 line encoder. This provides 4000 quadrature counts for
each revolution. If SCALEFACTOR is not set, a MintMT 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 SCALEFACTOR of 4000, the user unit becomes revolutions.
The more understandable command MOVER=4 could now be used to move the motor four
revolutions.

The same concept applies to stepper motors, where the scale can be set according to the
number of steps per revolution. Typically, this would be 200 for a motor with a 1.8° step angle,
or 400 if driven in half step mode. By setting a SCALEFACTOR of 200 (or 400 if driven in half
step mode), the user unit becomes revolutions.

In applications involving linear motion a suitable value for SCALEFACTOR 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.

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.

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

6-6 Operation MN1928

5. Click Apply.

This immediately sets the scaling factor for
the selected axis, which will remain in the
NextMove ES until another scale is defined
or power is removed from the NextMove ES.
See section 6.10 for details about saving
configuration parameters.

6.3.2 Setting the drive enable output

A drive enable output allows NextMove ES to enable the external drive amplifier to allow
motion, or disable it 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 error output (see section 4.4.3). If
the NextMove ES is connected to a Baldor backplane with opto-isolating card, the error output
controls 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 yellow High and
Low icons. These describe how the output
should behave when activated (to enable the
axis).

3. If you are going to use the error output, 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. In this example, OUT1 is being used.
The icon’s color will change to bright blue.

Operation 6-7MN1928

4. If you are going to use
the error output, drag
theRelay0icontothe
grey Drive Enable OP
icon on the right of the
screen.

Note: The error output is represented by the Relay0 icon. This is because the error

output always controls a relay when the NextMove ES is used in conjunction with
an opto-isolating backplane. When the NextMove ES is not used with an
opto-isolating backplane, the Relay0 icon still represents the error output.

To configure multiple axes to use the error output, repeat this step for the other axes.

If you are using a digital
output, drag the bright
blue OUT icon to the
grey Drive Enable OP
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 ES.

See section 6.10 for details about saving
configuration parameters.

6-8 Operation MN1928

6.3.3 Testing the drive enable output

1. On the main WorkBench v5 toolbar, click the
Axis 0 button. In the Select Default Axes
dialog, select the axes to be controlled. Click
OK to close the dialog.

2. On the main WorkBench v5 toolbar, click the
Drive enable button. Click the button again.
Each time you click the button, the drive
enable outputs for the selected axes are
toggled.

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

If this is not working, or the action of the button is reversed, check the electrical
connections between the backplane and drive amplifier. If you are using the relay, check
that you are using the correct normally open (REL NO) or normally closed (REL NC)
connections.

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

Operation 6-9MN1928

6.4 Stepper axis - testing

This section describes the method for testing a stepper axis. The stepper control is an open
loop system so no tuning is necessary.

6.4.1 Testing the output

This section tests the operation and direction of the output. It is recommended that the system
is initially tested with the motor shaft disconnected from other machinery.

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

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

3. Click in the Command window.

4. Type:

JOG.0=2

where 0 is the axis (st epper output) to be
tested and 2 is t he speed.

The JOG command specifies the speed in
user units per s ec ond, s o the speed is
affected by SCALEFACTOR (section 6.3.1). If you have not s elec t ed a sc ale, the c ommand
JOG.0=2 will cause r otation at only 2 half s teps per s ec ond, so it may be neces s ar y to
increase this figure significantly, to 200 for ex ample. If you have selected a s c ale that
provides user units of revolutions (as des c r ibed in sec tion 6.3.1) JOG.0=2 will cause
rotation at 2 revolutions per second. If t here appears to be no step or direction output,
check the electrical connections on the back plane.

5. To repeat the tests for reverse moves, type:

JOG.0 = -2

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

STOP.0

6-10 Operation MN1928

6.5 Servo axis - testing and tuning

This section describes the method for testing and tuning a servo axis. The amplifier must
already have been tuned for basic current or velocity control of the motor.

6.5.1 Testing the demand output

This section tests the operation and direction of the demand output for axis 4. By default, axis
4 is a servo axis (although it can be reconfigured as a stepper - see section A.1). It is
recommended that the motor is disconnected from the load 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.4=5

where 4 is the axis 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 (backplane connector
X7, pin 1). In WorkBench v5, look at the Spy
window located on the right of the screen. In the Axis selection box at the top, select Axis 4.

The Spy window’s Command display should show 5 percent (approximately). If there seems
to be no command output, check the electrical connections on the backplane.

The Spy window’s Velocity display should show a positive value. If the value is negative check
that the DEMAND0 output, and the Encoder0 A and B channels, have been wired correctly.
If necessary, the ENCODERMODE keyword can be used to swap the encoder A and B channels,
thus reversing the encoder count - see the MintMT help file.

By default, axis 4 uses demand output 0 and encoder 0, and axis 5 uses demand output 1 and
encoder 1. See section 4.3.2 for details of the demand outputs.

Operation 6-11MN1928

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

TORQUE.4=-5

This should cause a demand of -5% of maximum output (-0.5V) to be produced at the
DEMAND0 output. Correspondingly, the Spy window’s Velocity display should show a
negative value.

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

STOP.4

This should cause the demand produced at
the DEMAND0 output to become 0V.

If it is necessary for the motor to turn in the opposite direction for a positive demand, then the
DACMODE and ENCODERMODE keywords should be used. The DACMODE keyword can be used
to invert the demand output voltage. The ENCODERMODE keywordmustalsobeusedto
reverse the incoming feedback signal, to correspond with the inverted demand output. Note
that if ENCODERMODE had already been used to compensate for a reversed encoder count (as
described in step 4. above), it will be necessary to change it back to its original setting to
correspond with the inverted demand output set using DACMODE. See the MintMT help file for
details of each keyword.

6-12 Operation MN1928

6.5.2 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 6.6.1.

When there is a requirement to move an axis, the NextMove ES control software translates
this 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 ES compares
the demanded and 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 ES)
is to stay exactly level with Demand, looking out of the window to measure your position ].

The main term that the NextMove ES 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 ].

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
motortocometoastopwithasmallfollowingerror[Demandstopped so you stopped too, but
not quite level ]. The NextMove ES tries to correct the error, but because the error is so small
the amount of torque demanded might not be enough to overcome friction.

This problem is overcome by using a term called Integral gain (KINT). 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 1ms sampling interval can be changed using the LOOPTIME keyword to either 2ms,
500µs, 200µs or 100µs.

Operation 6-13MN1928

The remaining gain terms are Velocity Feed forward (KVELFF) and Acceleration Feed
forward (KACCEL) described below.

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 on the whole response, and can be increased to

reduce any overshoot. If KVEL 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 always on (mode 1).

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 dependent on the rate of change of error, and so

is particularly useful for removing overshoot.

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.

6-14 Operation MN1928

Figure 28 - The NextMove ES servo loop

Operation 6-15MN1928

6.6 Servo axis - tuning for current control

6.6.1 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 6.8. It is recommended that the system is initially tested and tuned with the motor shaft
disconnected from other machinery. Confirm that the encoder feedback signals from the
motor or servo amplifier have been connected, and that a positive demand causes a positive
feedback signal.

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 Axis
selection box at the top and select Axis 4.
By default, axis 4 is a servo axis (although it
can be reconfigured as a stepper - see
section A.1).

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.

6-16 Operation MN1928

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.

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

5. Click in the Distance box andenter 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 6.3.1.

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.

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 ES will perform the move and the motor will turn. As the soon as the move
is completed, WorkBench v5 will upload captured data from the NextMove ES. 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 different response.

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

Operation 6-17MN1928

6.6.2 Underdamped response

If the graph shows that the response is underdamped (it overshoots the demand, as shown in
Figure 29) 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 29 - Underdamped response

9. Click in the KDERIV and/or KPROP boxes
and make the required changes. The ideal
response is shown in section 6.6.4.

6-18 Operation MN1928

6.6.3 Overdamped response

If the graph shows that the response is overdamped (it reaches the demand too slowly, as
shown in Figure 30) 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

10. Click in the KDERIV and/or KPROP boxes
and make the required changes. The ideal
response is shown in section 6.6.4.

Measured position

Figure 30 - Overdamped response

Operation 6-19MN1928

6.6.4 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 31.

Demand position

Measured position

Figure 31 - Critically damped (ideal) response

6-20 Operation MN1928

6.7 Servo axis - eliminating steady-state errors

In systems where precise positioning accuracy is required, it is often necessary to position
within one encoder count. 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 axes. 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
demand 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 ES, the action of KINT and KINTLIMIT can be set to operate in various 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 speed is zero or constant.

H Steady State - the KINT term is only applied when the demand speed is zero.

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

Operation 6-21MN1928

6.8 Servo axis - tuning 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 often 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 28).
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.

Before proceeding, confirm that the encoder feedback signals from the motor or servo
amplifier have been connected, and that a positive demand causes a positive feedback signal.

6.8.1 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 resolution of the encoder input.

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

=

50

=

0.05

=

4000

=

200

6-22 Operation MN1928

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

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

The calculated value should give zero
following error at constant velocity. 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 andenter 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.

=

10.24

Note: The distance depends on the scale set in section 6.3.1. 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 ES will perform the move and the motor will turn. As the soon as the move
is completed, WorkBench v5 will upload captured data from the NextMove ES. 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 different response.

Operation 6-23MN1928

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

Demand velocity

Measured velocity

Figure 32 - 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 32.

6-24 Operation MN1928

6.8.2 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 be a good starting figure which can then be increased slowly.

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

2. Click Go.

The NextMove ES will perform the move and the motor will turn. As the soon as the move
is completed, WorkBench v5 will upload captured data from the NextMove ES. 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 different response.

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

Operation 6-25MN1928

Demand position

Measured position

Figure 33 - Correct value of KPROP

The two traces will probably appear with a small offset from each other, which represents the
following error. Adjust KPROP by small amounts until the two traces appear on top of each
other (approximately), as shown in Figure 33.

Note: It may be useful to use the zoom function to magnify the end point of the move.

In the graph area, click and drag a rectangle around the end point of the traces.
To zoom out, right-click in the graph area and choose Undo Zoom.

6-26 Operation MN1928

6.9 Digital input/output configuration

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

6.9.1 Digital input configuration

The Digital Inputs tab allows you to define how each digital input will be triggered, and if it
should be assigned to a special purpose function such as a Home or Limit input. In the
following example, digital input 1 will be set to trigger on an active low input, 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 Low icon

onto the IN1 icon . This will setup IN1 to respond to a low input.

Operation 6-27MN1928

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 ES.

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

6.9.2 Digital output configuration

The Digital Outputs tab allows you to define how each digital output will operate and if it is to
be configured as a drive enable output (see section 6.3.2). Remember to click Apply to send
the changes to the NextMove ES.

6-28 Operation MN1928

6.10 Saving setup information

When power is removed from the NextMove ES all data, including configuration and tuning
parameters, is lost. Y ou should therefore save this information in a file, which can be loaded
when the card is next used.

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 ES and place it in a Startup
block. For details of the Startup block,
see the MintMT help file.

Operation 6-29MN1928

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

6.10.1 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.

A Startup block should be included in every Mint program, so that whenever a program is
loaded and run the NextMove ES will be correctly configured. Remember that every
drive/motor combination has a different response. If the same program is used on a
different NextMove ES installation, the Startup block will need to be changed.

6-30 Operation MN1928

7 Troubleshooting

7.1 Introduction

This section explains common problems and their solutions.
If you want to know the meaning of the LED indicators, see section 7.2.

7.1.1 Problem diagnosis

If you have followed all the instructions in this manual in sequence, you should have few
problems installing the NextMove ES. If you do have a problem, read this section first.
In 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 SupportMe feature can be used.

7.1.2 SupportMe feature

The SupportMe feature is available from the Help menu, or by clicking the buttononthe
motion toolbar. SupportMe can be used to gather information which can then be e-mailed,
saved as a text file, or copied to another application. The PC must have e-mail facilities to use
the e-mail 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 ES (if known).

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 A clear description of what you are trying to do, for example performing fine-tuning.

H A clear description of the symptoms that you can observe, for example 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.

7

Troubleshooting 7-1MN1928

7.2 NextMove ES indicators

7.2.1 Status display

The Status LED normally displays the unit’s node number. To display information
about a specific axis, use the LED keyword (see the MintMT help file). When a specific
axis is selected, 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 SPLINE keyword and related
commands.

Axis enabled.
Torque mode. The NextMove ES is in Torque mode. See the TORQUE keyword and

related commands.
Hold to Analog. The axis is in Hold T o Analog mode. See the HTA keyword 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 FOLLOW and OFFSET keywords.

Circle. A circle move is being performed. See the CIRCLEA or CIRCLER keywords.
Cam. A Cam profile is being profiled. See the CAM keyword.

General error. See the AXISERROR keyword. 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.

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

Position following error. A following error has occurred. See the AXISERROR keyword
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 suit your application (see the
FOLERRORFATAL and VELFATAL keywords). Following error could also be the cause
of encoder/resolver loss (see also the FEEDBACKFAULTENABLE keyword).

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

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

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

7-2 Troubleshooting MN1928

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

keywords.
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 6.3.3. 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 ES.

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.

When a node number between 1 and 15 is displayed, it is shown in hexadecimal format (1 - F).
For node numbers greater than 15, three horizontal bars are displayed. User defined symbols
can be made to appear using the keywords LED and LEDDISPLAY.

See the MintMT help file for details of each keyword.

7.2.2 Surface mount LEDs D3, D4, D16 and D20

The NextMove ES card contains a number of surface mount LEDs that indicate hardware
status:

D3

D3 (yellow):
Indicates that the FPGA is being initialized at startup. If this
LED remains illuminated after power up, download a system
file (which includes FPGA firmware) from WorkBench v5.

D4 (red):
Indicates that the card is in a hardware reset. If this LED
remains illuminated after power up, the supply voltage to the

D4

card is too low. Check power supply connections.

D16

D16 (flashing green):
Flashes at 0.5Hz to indicate normal operation. If this LED

D20

stops flashing, the firmware has stopped running. Power
cycle the card to cause a reset.

D20 (flashing orange during serial communication)
Indicates that the card is performing serial communication.
If this LED fails to illuminate, download a system file (which
includes communications firmware) from WorkBench v5.

Troubleshooting 7-3MN1928

7.2.3 Communication

If the problem is not listed below please contact Baldor technical support.

Symptom

Cannot detect NextMove ES Check that the NextMove ES is powered.

Cannot communicate with
the controller.

7.2.4 Motor control

Symptom Check

Controller appears to be
working but will not cause
motor to turn.

Check

For serial connections, check that the serial cable is wired
correctly and properly connected. Check that no other
application on the PC is attempting to use the same serial
port.

For USB connections, check that the cable is properly
connected. Check that the USB device driver has been
installed.

Verify that WorkBench v5 is loaded and that NextMove ES is
the currently selected controller.

Check that the NextMove ES card is correctly connected to
the backplane.

Check that the connections between motor and drive are
correct. Use WorkBench v5 to perform the basic system
tests (see section 6.5 or 6.4).

Confirm that the drive enable output has been configured
(see section 6.3.2).

Ensure that while the NextMove ES is not in error the drive
is enabled and working. When the NextMove ES 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).

(Servo outputs only) Check that the servo loop gains are
setup correctly - check the Fine-tuning window. See
sections 6.5.2 to 6.7.

Motor runs uncontrollably
when controller is switched
on.

Verify that the backplane (if used) and drive are correctly
grounded to a common earth point.

(Servo outputs only) Check that the correct encoder
feedback signal is connected to the encoder input, the
encoder has power (if required, see section 5.2.11) and is
functioning correctly.

Check that the drive is connected correctly to the
NextMove ES and that with zero demand there is 0V at the
drive’s demand input. See section 6.5.1.

7-4 Troubleshooting MN1928

Symptom Check

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.

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

(Servo outputs only) Check that the encoder feedback
signal(s) are connected to the correct encoder input(s).
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 ENCODERMODE keyword can
be used to change encoder input direction. The 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 outputs only) Servo loop gains may be set
incorrectly. See sections 6.5.2 to 6.7.

Verify that the backplane and drive are correctly grounded to
a common earth point.

(Servo outputs only) Using an oscilloscope at the backplane
connectors, check:

H all encoder channels are free from electrical noise;
H they are correctly wired to the controller;
H when the motor turns, the two square wave signals are

Ensure that the encoder cable uses shielded twisted pair
cable, with the outer shield connected at both ends and the
inner shields connected only at the NextMove ES end.

90 degrees out of phase. Also check the complement
signals.

7.2.5 WorkBench v5

Symptom Check

The Spy window does not
update

(Stepper outputs only) The motor is not maintaining
synchronization with the NextMove ES drive output signals
due to excessive acceleration, speed or load demands on
the motor.

Check that the acceleration, speed and load are within the
capabilities of the motor.

The system refresh has been disabled. Go to the T ools,
Options menu item, select the System tab and then
choose a System Refresh Rate (500ms is recommended).

Troubleshooting 7-5MN1928

7-6 Troubleshooting MN1928

8 Specifications

8.1 Introduction

This section provides technical specifications of the NextMove ES card. Separate
specifications for the optional opto-isolating backplanes are shown where necessary.

8.1.1 Input power

Description Value

Input power +5V, 1A

+12V, 50mA

-12V, 50mA

8.1.2 Analog inputs

Description Unit Value

Type Differential

Common mode voltage range VDC ±10

Input impedance kÙ 120

Input ADC resolution bits 12 (includes sign bit)

Equivalent resolution (±10V input) mV ±4.9

Sampling interval ìs 500 (both inputs enabled)

250 (one input disabled)

8

8.1.3 Analog outputs

Description Unit Value

Type Bipolar

Output voltage range VDC ±10

Output current (maximum) mA 10

Output DAC resolution bits 12

Equivalent resolution mV ±4.9

Update interval ìs 100 - 2000

(same as LOOPTIME; default = 1000)

Specifications 8-1MN1928

8.1.4 Digital inputs (non-isolated)

This specification is for the NextMove ES card when used separately or in conjunction with the
optional non-isolating backplane BPL010-501:

Description Unit Value

Type +5V inputs, non-isolated

Input voltage

Maximum
Minimum
High
Low

Input current (approximate, per input) mA 0.5

Sampling interval ms 1

VDC

5.5
0

>3.5V
<1.5V

8.1.5 Digital inputs (opto-isolated)

This specification is for the optional opto-isolating backplanes BPL010-502 or BPL010-503,
when used in conjunction with the NextMove ES card.

Description Unit Value

Type Opto-isolated

USR V+ supply voltage

Maximum
Minimum

Input voltage

BPL010-502 ‘active high’ inputs

VDC

30
12

VDC

Active: >12V
Inactive: <2V

BPL010-503 ‘active low’ inputs

Input current

(maximum per input, USR V+ = 24V)

mA 10

Active: 0V

Inactive: Unconnected

8-2 Specifications MN1928

8.1.6 Digital outputs - general purpose (non-isolated)

This specification is for the NextMove ES card when used separately or in conjunction with the
optional non-isolating backplane BPL010-501:

Description Unit Value

Load supply voltage

(maximum)

Output current

Max. sink per output, one output on

Max. sink per output, all outputs on

Update interval Immediate

V 50

mA DOUT0-7 DOUT8-11

500 400
150 50

8.1.7 Digital outputs - general purpose (opto-isolated)

This specification is for the optional opto-isolating backplanes BPL010-502 or BPL010-503,
when used in conjunction with the NextMove ES card.

Description Unit Value

USR V+ supply voltage

Maximum
Minimum

Output current (BPL010-502)

Max. source per output, one output on

Max. source per output, all outputs on

Output current (BPL010-503)

Max. sink per output, one output on

Max. sink per output, all outputs on

Update interval Immediate

VDC

30V
12V

mA DOUT0-7 DOUT8-11

350 400

75 50

mA DOUT0-7 DOUT8-11

500 400
150 50

8.1.8 Digital output - error output (non-isolated)

This specification is for the NextMove ES card when used separately or in conjunction with the
optional non-isolating backplane BPL010-501:

Description Unit Value

Output voltage V 5

Output current

(maximum)

Update interval Immediate

mA 100

Specifications 8-3MN1928

8.1.9 Error relay (opto-isolated backplanes)

This specification is for the optional opto-isolating backplanes BPL010-502 or BPL010-503,
when used in conjunction with the NextMove ES card. See sections 4.4.3 and 5.3.1.1.

All models Unit All models

Contact rating (resistive) 2A @ 28VDC

Operating time (max) ms 6

or

0.5A @ 125VAC

8.1.10 Encoder inputs

Description Unit Va lue

Encoder input RS422 A/B Differential, Z index

Maximum input frequency

(quadrature)

Output power supply to encoders 5V, 500mA max.

Maximum recommended cable
length

MHz 20

30.5m (100ft)

8.1.11 Stepper control outputs

Description Unit Va lue

Output type RS422 step (pulse) and direction

Maximum output frequency MHz 3

Output current

(maximum sink, per output)

mA

100

8.1.12 CAN interface

Description Unit Va lue

Signal 2-wire, isolated

Channels 2

Protocols CANopen

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

8-4 Specifications MN1928

Baldor CAN (with optional firmware)

8.1.13 Environmental

Description Unit

Operating temperature range Min Max

°C

0

+40

Maximum humidity

Maximum installation altitude

(above m.s.l.)

See also section 3.1.1.

8.1.14 Weights and dimensions

Description Value

Weight Approximately 140g (0.3lb)

Nominal overall dimensions 160mm x 100mm

°F

%

m

ft

+32

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

decreasingly linearly to 50% relative

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

(according to DIN40 040 / IEC144)

2000

6560

(6.3in x 3.937in)

+104

Specifications 8-5MN1928

8-6 Specifications MN1928