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NextMove BX
Installation Manual
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Baldor NextMove BX Installation Manual

MN1258V4 08/2000
NextMove BX
Installation Manual for Mint v4
Issue 4.0
NextMove BX Installation Manual for Mint™ v4
ii
Copyright
MN1258V4 08/2000
iii
Copyright Baldor UK Ltd © 2000. All rights reserved.
This manual is copyrighted and all rights are reserved. This document or attached software may not, in whole or in part, be copied or reproduced in any form without the prior written consent of Baldor UK. Baldor Optimised Control 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 UK assumes no responsibility for any errors that may appear in this document.
MINT
™
is a registered trademark of Baldor UK Ltd.
Windows 95, Windows 98 and Windows NT are registered trademarks of the Microsoft Corporation.
Limited Warranty
For a period of one (1) year from the date of original purchase, BALDOR will repair or replace without charge controls 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 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.
Baldor UK Ltd Mint Motion Centre 6 Bristol Distribution Park Hawkley Drive Bristol BS32 0BF U.K. Telephone: +44 (0) 1454 850 000 Fax: +44 (0) 1454 859 001 Web site: www.baldor.co.uk Sales email: sales@baldor.co.uk Support email: technical.support@baldor.co.uk
Baldor Electric Company Telephone: +1 501 646 4711 Fax: +1 501 648 5792 email: sales@baldor.com web site: www.baldor.com
Baldor ASR GmbH Telephone: +49 (0) 89 90508-0 Fax: +49 (0) 89 90508-492
Baldor ASR AG Telephone: +41 (0) 52 647 4700 Fax: +41 (0) 52 659 2394
Australian Baldor Pty Ltd Telephone: +61 2 9674 5455 Fax: +61 2 9674 2495
Baldor Electric (F.E.) Pte Ltd Telephone: +65 744 2572 Fax: +65 747 1708
NextMove BX Installation Manual for Mint™ v4
iv
Copyright
MN1258V4 08/2000
v
Safety Notice
:
Only qualified personnel should attempt the start-up procedure or troubleshoot this equipment.
This equipment may be connected to other machines that have rotating parts or parts that are controlled by this equipment. Improper use can cause serious or fatal injury. Only qualified personnel should attempt to start-up, program or troubleshoot this equipment.
Precautions:
WARNING: Do not touch any circuit board, power device
or electrical connection before you first ensure that no high voltage present at this equipment or other equipment to which it is connected. Electrical shock can cause serious or fatal injury. Only qualified personnel should attempt to start-up, program or troubleshoot this equipment.
WARNING: Be sure that you are completely familiar with
the safe operation of this equipment. This equipment may be connected to other machines that have rotating parts or parts that are controlled by this equipment. Improper use can cause serious or fatal injury. Only qualified personnel should attempt to program, start-up or troubleshoot this equipment.
WARNING: Be sure that you are completely familiar with
the safe programming of this equipment. This equipment may be connected to other machines that have rotating parts or parts that are controlled by this equipment. Improper programming of this equipment can cause serious or fatal injury. Only qualified personnel should attempt to program, start­up or troubleshoot this equipment.
WARNING: Be sure all wiring complies with the National
Electrical Code and all regional and local codes. Improper wiring may result in unsafe conditions.
NextMove BX Installation Manual for Mint™ v4
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WARNING: The stop input to this equipment should not
be used as the single means of achieving a safety critical stop. Drive disable, motor disconnect, motor brake and other means should be used as appropriate. Only qualified personnel should attempt to program, start­up or troubleshoot this equipment.
WARNING: Improper operation or programming of the
control may cause violent motion of the motor shaft and driven equipment. Be certain that unexpected motor shaft movement will not cause injury to personnel or damage to equipment. Peak torque of several times the rated motor torque can occur during control failure.
WARNING: The motor shaft will rotate during the homing
procedure. Be certain that unexpected motor shaft movement will not cause injury to personnel or damage to equipment.
CAUTION: To prevent equipment damage, be certain that
the input power has correctly sized protective devices installed.
CAUTION: To prevent equipment damage, be certain that
input and output signals are powered and referenced correctly.
CAUTION: To ensure reliable performance of this
equipment be certain that all signals to/from the controller are shielded correctly.
CAUTION: Avoid locating this equipment above or
beside heat generating equipment or below water steam pipes.
CAUTION: Avoid locating this equipment in the vicinity
of corrosive substances or vapors, metal particles and dust.
Manual Revision History
vii
Manual Revision History
Issue Date BOCL
Reference
Comments
1.0 May 1998 MN00278-000 First release of Installation Manual comprising:
•
NextMove BX Overview
•
Getting Started Guide
• cTERM
for Windows User Guide
•
NextMove BX Hardware Guide
1.01 Sept 1998 MN00278-001 KeypadNode 4 information included.
1.02 Nov 1998 UM00507-000 New revision raised. Format improvements made.
4.0 August 2000 UM00580-000 New version of manual to support Mint v4 on NextMove BX. New BOCL reference UM00580. Modified MN reference MN1258V4.
NextMove BX Installation Manual for Mint™ v4
viii
Manual Revision History
ix
Read Me First ............................................................................. 1
1.1 Key to Symbols Used in this Manual.........................................................2
Product Overview ...................................................................... 3
Hardware Guide ......................................................................... 7
3.1 Operating Environment.............................................................................9
3.2 NextMove BX PCB Settings.....................................................................9
3.3 Power Connection ..................................................................................11
3.3.1 Front Panel Power Connection: J8.....................................................12
3.4 Digital I/O................................................................................................13
3.4.1 Digital Inputs: J1 and J2.....................................................................13
3.4.2 Fast Interrupts: J6..............................................................................15
3.4.3 Digital Outputs: J4..............................................................................16
3.5 Analog I/O ..............................................................................................19
3.5.1 Analog Inputs: J3 ...............................................................................19
3.5.2 Analog Outputs (Drive Command: J7)................................................20
3.6 Encoder Interface ...................................................................................21
3.7 Relay: J5.................................................................................................24
3.8 Serial Ports.............................................................................................24
3.8.1 RS232................................................................................................25
3.8.2 RS485................................................................................................26
3.8.3 RS485 Multi-Drop...............................................................................27
3.8.4 CAN Bus ............................................................................................28
3.9 Reset State.............................................................................................30
3.10 Battery Backup of Memory......................................................................31
3.10.1 Changing the Battery .........................................................................31
3.10.2 Charging the Battery ..........................................................................32
NextMove BX Installation Manual for Mint™ v4
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3.11 EEPROM................................................................................................32
3.12 System Watchdog ..................................................................................32
3.13 LED Status Display.................................................................................32
Operation and Setup................................................................ 35
4.1 Communicating with NextMove BX.........................................................36
4.2 Baldor Motion Toolkit CD........................................................................36
4.3 Configuring your System ........................................................................37
4.3.1 Minimum System Wiring Example......................................................38
4.3.2 Starting with the Mint Configuration Tool............................................40
4.4 Servo Setup............................................................................................42
4.4.1 Tuning a Servo Drive .........................................................................44
4.4.2 Selecting Servo Loop Gains...............................................................48
4.4.3 System Gains for Current Control by Empirical Method .....................51
4.4.4 System Gains for Velocity Control......................................................53
4.4.5 Eliminating Steady-State Errors .........................................................54
4.5 Methods of Programming .......................................................................55
4.6 Documentation .......................................................................................56
4.7 Mint.........................................................................................................57
4.7.1 The Configuration File........................................................................58
4.7.2 The Program File ...............................................................................63
4.8 Motion.....................................................................................................65
Options and Accessories ........................................................ 67
5.1 NextMove BX..........................................................................................68
5.2 CAN Nodes.............................................................................................68
5.3 Encoder Splitter/Buffer Board .................................................................69
Specifications and Product Data ............................................ 71
6.1 Machine Control I/O................................................................................72
Contents
xi
6.2 Miscellaneous and Mechanical Specification ..........................................73
6.3 EMC & CE Marking.................................................................................. 74
6.3.1 Machinery Directive 89/392/EEC........................................................74
6.3.2 Low Voltage Directive 72/23/EEC ......................................................74
6.3.3 EMC Directive 89/336/EEC ................................................................74
6.4 EMC Performance of NextMove BX........................................................75
6.5 EMC Advice............................................................................................75
Troubleshooting Guide............................................................ 77
7.1 Trouble Shooting Guide..........................................................................78
Bibliography............................................................................. 81
NextMove BX Installation Manual for Mint™ v4
xii
Read Me First
1
1. Read Me First
1
This chapter provides an overview of the manual and symbols used throughout this document.
NextMove BX Installation Manual for Mint™ v4
2
This manual is intended for use with NextMove BX running Mint v4. If Mint v3 is being used, then the NextMove BX installation manual MN1258 should be used in preference. The hardware details are common between these manuals but the software references are different.
1.1 Key to Symbols Used in this Manual
Throughout this section various icons and conventions are used to indicate specific functions:
The screwdriver icon indicates that it is necessary to make a physical connection to
NextMove BX by way of the screw terminations on the front panel of the controller.
The disk icon together with filename is used to indicate that a MINT program (the motion control language used to program NextMove BX) should be downloaded to the controller. The filename indicates the name of the buffer.
The prompt icon indicates that the following commands should be typed in directly to the terminal at the MINT P> or C> prompt.
[Ctrl]+[E]
Type
Ctrl
and E at the same time.
Hardware Features
3
2. Product Overview
2
A brief overview of NextMove BX and the software tools available on the Baldor Motion Toolkit.
NextMove BX Installation Manual for Mint™ v4
4
NextMove BX is an intelligent servo motion controller which supports up to four servo axes. It is supplied in an metal enclosure for the convenience of those customers who do not wish to install a rack system for a single card. For other situations the board is available in a 6U rack mounting format (NextMove RK).
Figure 2-1: NextMove BX Controller
RS 485 serial port
Serial
Commun-
ications
A
nalogue inputs 8 x 12 bit
single ended or 4 x 12 bit
differential +/-10V or 0-5V
Drive enable relay
4 x Servo-amplifier demands +/-10V, 12 bit
4 x incremental encoders, 3 channel, up to 8 million counts per second.
4 Axes of
Servo
Control
NextMove BX
Motion Controller
4 fast interrupt inputs with hardware position latches
CAN
Interface
2 x CAN bus 1MBaud in dustrial
Local Area Network for
connection to other intelligent
drives, I/O and key pad
Master
Encoder
Input
3 channel incremental encoder , up to 8 million counts per second
Digital
Outputs
8 x Digital outputs, opto-isolated PNP or NPN, 12-24V, 350mA max .
Digital Inputs
16 x Digital inputs, opto-isolated PNP or NPN, 12-24V. User configurable.
Power
Requirements
Logic supply 24 VoltsDC @ 0.7 A
A
nalogue
Inputs
32 bit floating point
Digital Signal
Processor system.
4 axes of
high performance
closed loop
servo control
MINT or C
programming
language.
512Kb RAM,
battery backed
512Kb FLASH ROM
RS 232 serial port
Figure 2-2: Technical Overview
Hardware Features
5
NextMove BX features the MintTM v4 motion control language. Mint is a structured form of Basic, custom designed for motion control applications, either stepper or servo. It allows users to quickly get up and running with simple motion control programs. In addition, Mint includes a wide range of powerful commands for complex applications.
Included with NextMove BX is the Baldor Motion Toolkit CD. This contains a number of utilities and useful resources to get the most from you Mint controller. These include:
Mint Configuration Tool
is a rapid getting started and configuration utility designed for use with a
number of Mint v4 controllers. See the ‘Mint Configuration Tool Users Guide’ for details.
Mint WorkBench
is the IDE and user interface for communicating with a Mint controller. See the
‘Mint WorkBench Users Guide’ for details.
PC Developer Libraries
allow PC applications to be written that communicate with Mint controllers. This includes C++ source and ActiveX interface. See the ‘Mint v4 PC Programming Guide’ for details.
Embedded Developer Libraries
allow embedded C31 applications to be developed using the Texas
Instruments TMS320C3x compiler. See the ‘Mint v4 Embedded Programming Guide’ for details.
Mint Code Analyzer Tool
is a utility designed to help in the process of upgrading to Mint v4. The utility will scan existing Mint and C application files and highlight the keywords and functions that have been changed from older firmware versions. See the ‘Mint v4 Code Analyzer Tool’ manual for details.
NextMove BX Installation Manual for Mint™ v4
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Hardware Features
7
3. Hardware Guide
3
This chapter describes in detail the hardware interface to the NextMove BX controller.
NextMove BX Installation Manual for Mint™ v4
8
Figure 3-1: NextMove BX Top Panel
Figure 3-2: NextMove BX Hardware
Hardware Features
9
3.1 Operating Environment
The safe operation of this equipment depends upon its use in the appropriate environment:
•
At an altitude of ≤ 2000m (6560ft) above sea level
•
In an ambient temperature of 0°C to 40°C (32°F to 104°F)
•
In relative humidity levels of 80% for temperatures up to 31°C (87°F) decreasingly linearly to 50% relative humidity at 40°C (104°F), non-condensing
•
The pollution degree according to IEC664 shall not exceed 2
•
The 24V dc supplied to the unit to power the control circuit shall be isolated from the mains using double or reinforced insulation so as to constitute a safety extra low voltage supply. The inputs and outputs of control circuit shall also be confined to SELV circuits
•
The atmosphere shall not contain flammable gases or vapors
•
There shall not be abnormal levels of nuclear radiation or X-rays
•
The product shall be secured by the slots in the flange, the protective earth/ground stud shall be bonded to a safety earth/ground by a 25A conductor.
3.2 NextMove BX PCB Settings
Anti-static pre-cautions must be taken before handling the printed circuit board (PCB).
Access to jumpers, EEPROM and other components can be achieved via a slide-down cover on the right hand side of the box. The cover is held in place by a set screw which should first be removed. A screwdriver may then be required to ease the cover free.
NextMove BX Installation Manual for Mint™ v4
10
Figure 3-3: Board Settings
Hardware Features
11
3.3 Power Connection
The unit requires 24V dc ±20% at approximately 700mA (max.) for the logic power supply unit. The unit also takes 12-24V dc ±20% at approximately 400mA (max.) for the isolated outputs and 12V to 24V dc or -12V to -24V dc ±20% at approximately 200mA for the isolated digital inputs and fast interrupts.
psu in +
Power Supply
Unit
+12V +5V
0V
-12V
psu in -
Figure 3-4: NextMove BX Power Supply Unit
The unit has an on board power supply to provide the following:
•
5V regulated output for incremental encoders.
•
+/-12V output, 5V output for general use. Note that these must not be used for machine I/O. Do not attempt to draw more than 200mA from the 12V rails and no more than 650mA from the 5V (including the encoders).
If the encoders require more than 650mA total, some of them (or all) must be powered from an
external 5V supply. This additional supply must NOT be connected to the NextMove BX 5V
supply.
NextMove BX Installation Manual for Mint™ v4
12
3.3.1 Front Panel Power Connection: J8
Pin No Signal Function
1
psu in +
Power Input 24V dc (18-30V)
2
psu in -
Power Input 0V
3
chassis
Chassis ground for cable screen
4
+5V
Voltage output for analog circuitry @ 100mA
5
gnd
Ground
6
+12V
Voltage output for analog circuitry @ 50mA
7
gnd
Ground
8
-12V
Voltage output for analog circuitry @ 50mA
9
chassis
Chassis ground for cable screen
10
chassis
Chassis ground for cable screen
Two dc-dc converters are used to generate the internal logic voltages from a dc input of 24V ±20%. The logic power rails are brought out on the front panel for analog sensors and associated circuitry. These rails should not be used for machine I/O,
usr-V+
and
usr-gnd
should be used instead.
The controller has opto-isolation between the microprocessor controller and the inputs and outputs to provide noise immunity required for industrial environments. The power supply unit inputs (24V dc) include isolated grounds.
Using a power supply of 24V dc at 2A is sufficient to drive all the outputs at 50mA and with all the inputs on.
- WARNING -
Applying mains voltages to NextMove BX (110V/220V) will damage the unit. Ensure that the
power input voltages comply.
Hardware Features
13
3.4 Digital I/O
There are a total of 16 general purpose digital inputs and 8 general purpose digital outputs. The digital inputs are software configurable for any one of the following functions:
•
Forward
limit
(end of travel) input on axis of the axes.
•
Reverse
limit
input on any of the axes.
•
home
input on any of the axes.
•
drive error
input on any of the axes.
•
stop
input (controlled) on any of the axes.
The inputs can be programmed such that any of the axes can share the same input if necessary.
The inputs are also programmable in software for being edge triggered (positive and negative) or level triggered (active high or low).
The digital outputs can be programmed as a
drive enable
output for any axis or
general error
output
. Again, axes can share the same output. The active level of the output is also software
programmable.
As well as the general purpose I/O, NextMove BX also supports four fast position latch inputs (described in section 3.4.2).
3.4.1 Digital Inputs: J1 and J2
Connector J2:
Pin No Signal Function
1
din 0
Digital input bit 0
2
din 1
Digital input bit 1
3
din 2
Digital input bit 2
4
din 3
Digital input bit 3
5
din 4
Digital input bit 4
6
din 5
Digital input bit 5
7
din 6
Digital input bit 6
8
din 7
Digital input bit 7
9
usr-com
Common reference for Inputs
10
usr-com
Common reference for Inputs
NextMove BX Installation Manual for Mint™ v4
14
Connector J1:
Pin No Signal Function
1
din 8
Digital input bit 8
2
din 9
Digital input bit 9
3
din 10
Digital input bit 10
4
din 11
Digital input bit 11
5
din 12
Digital input bit 12
6
din 13
Digital input bit 13
7
din 14
Digital input bit 14
8
din 15
Digital input bit 15
9
usr-com
Common reference for Inputs
10
usr-com
Common reference for Inputs
Inputs may be 12 to 24V positive or negative with respect to
usr-com. usr-com
is shared with the
interrupt inputs.
The sixteen digital inputs are optically isolated using ac input isolators. One input pin of each device is connected to the common reference. This common rail may be connected to a positive voltage, e.g.
usr-V+,
for use with NPN drive transistors or low-side switches. Alternatively the common rail
may be connected to a negative voltage, e.g.
usr-gnd
, for use with PNP drive transistors or high-side
switches.
In either case the user provides an external supply which drives the inputs with a voltage in the range 12V to 24V ±20%.
The voltage applied to the inputs should be in the range 12 to 24V ±20% (9.6 to 28.8V) above or below the
usr-com
rail to activate the inputs. If the voltage exceeds the maximum stated, the input
circuit may overheat and be damaged The voltage applied should be less than 3V above or below the
usr-com
rail to deactivate the inputs.
The inputs have low pass filters and Schmitt trigger buffers An input pulse must have a duration of at least 2ms (one software scan) to guarantee acceptance by the application program. Pulses below 2ms are not guaranteed to be ignored.
Figure 3-5: Digital Input Circuit
Hardware Features
15
Associated MINT keywords are:
#INx, INPUTACTIVELEVEL, IN, INx, INPUTMODE, INPUTNEGTRIGGER, INPUTPOSTRIGGER, INSTATE
3.4.2 Fast Interrupts: J6
Pin No Signal Function
1
fast-int 0
Fast interrupt 0
2
chassis
Chassis ground for cable screen
3
usr-com
Common reference
4
fast-int 1
Fast interrupt 1
5
chassis
Chassis ground for cable screen
6
usr-com
Common reference
7
fast-int 2
Fast interrupt 2
8
chassis
Chassis ground for cable screen
9
usr-com
Common reference
10
fast-int 3
Fast interrupt 3
Interrupt inputs may be 12 to 24V positive or negative with respect to
usr-com. usr-com
is shared
with the digital inputs.
There is a facility for 4 high speed external interrupts on NextMove BX. These are isolated using high speed opto-isolators and full bridge rectification. They are driven in the same way as the digital inputs, see the digital input section for details on the voltage levels. The interrupt inputs can cause an interrupt on both activating and deactivating edges of the signal. Fast interrupt 0 has a maximum latency of 30µs. Fast interrupts 1 to 3 have a maximum latency of 1ms.
Because of the fast response time of the input circuitry (approx. 200ns)these inputs are more susceptible to high frequency noise. Care must be taken with shielding/screening and routing of these signals, i.e. do not route high speed interrupt cabling near motor drive cabling.
Figure 3-6: Fast Interrupt Input Circuit
See section ‘Fast Position Latch’ in the ‘Mint v4 Programming Guide’ for more details.
NextMove BX Installation Manual for Mint™ v4
16
3.4.3 Digital Outputs: J4
Pin No Signal Function
1
out 0
Digital output bit 0
2
out 1
Digital output bit 1
3
out 2
Digital output bit 2
4
out 3
Digital output bit 3
5
out 4
Digital output bit 4
6
out 5
Digital output bit 5
7
out 6
Digital output bit 6
8
out 7
Digital output bit 7
9
usr-V+
Power for output driver
10
usr-gnd
0v reference for outputs
usr-V+
can be 12-24V +/20% relative to
usr-gnd
. Damage to the unit may occur if the voltage
exceeds 30V and the operation will be unpredictable below 8V
The eight digital outputs are opto-isolated. They are driven by a PNP open collector Darlington type UDN2987A with internal over-current and over temperature protection. The over-current circuit shuts down the faulty output and indicates the error to the processor and thus to the application which, after corrective action, can reset the device. Note that there is a single
error
output and so
the program is unable to determine which output is at fault. Also there is a single
reset
input which resets all of the outputs. Any outputs which are ON when the device is reset will go OFF during the reset. This lasts approximately 10ms.
Hardware Features
17
USR-V+
CURRENT
SENSE
OUTPUT n
OUT-5V
OUT-5V
10k
10k
CONTROL
LOGIC
RESET
AND
ERROR
LOGIC
COMMON
ONE OF EIGHT
1nF
CHASIS
USR-G ND
Main Board
Front Panel
VCC
1k
OUTPUT RESET
FROMCPU
1k
OUTPUT ERROR
1k
OUT-5V
USR-GND
USR-G ND
Figure 3-7: Digital Output Circuit
If the device is reset too often during a short circuit condition (greater than twice per second) the device will eventually overheat and will be damaged. Damage will also occur if the output is taken above
usr-V+
, however transient excursions above
usr-V+
are clamped and therefore tolerated.
Each output has a freewheeling diode in parallel with the load. This allows inductive loads (such as relays) to be used without damaging the output Darlington devices. The outputs can all switch 50mA continuously through a voltage of 12 to 24V. More current can be supplied, subject to a power dissipation limit (shown on the graph in Figure 3-8). Further information is given in the Allegro Semiconductors UDN2987 data sheet.
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