Baldor NextMove ES Installation Manual

NextMove ES

Motion Controller

MOTION CONTROL

Installation Manual

01/10

Servo Systems Co. • 115 Main Road • P.O. Box

53 Green Pond Road, Suite #2 • Rockaway, NJ

07866ree: [phone]

Fax: [phone] • www.servosystems.com

Contents i

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 Dimensions and hole positions 3-2...................................

3.1.4 Other requirements for installation 3-3................................

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 - NES002-501 & NES002-502 4-2........

4.2.2 96-pin connector pin assignment - NES002-503 4-3.....................

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

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

4.3.2 Analog outputs 4-6.................................................

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

4.4.1 Digital inputs 4-8..................................................

4.4.2 Digital outputs 4-11.................................................

4.4.3 Error output - Error Out 4-13..........................................

4.5 Other I/O 4-14..............................................

4.5.1 Stepper control outputs 4-14..........................................

4.5.2 Encoder inputs 4-15................................................

4.5.3 USB port 4-16.....................................................

4.5.4 Serial port 4-17.....................................................

4.5.5 Using RS232 4-17..................................................

4.5.6 Multidrop using RS485 / RS422 4-19..................................

4.5.7 Connecting serial Baldor HMI Operator Panels 4-20......................

4.6 CAN 4-21..................................................

4.6.1 CAN connector 4-21................................................

4.6.2 CAN wiring 4-22....................................................

4.6.3 CANopen 4-23.....................................................

4.6.4 Baldor CAN 4-24...................................................

4.7 Connection summary - minimum system wiring 4-26.............

Servo Systems Co. • 53 Green Pond Road, Suite #2 • Rockaway, NJ 07866

07045-0097 • [phone] • Toll Free: [phone]

Fax: [phone] • www.servosystems.com

ii Contents

MN1928

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

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

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

5.2.1 Analog inputs 5-4..................................................

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

5.2.3 Digital inputs 0-7 5-6...............................................

5.2.4 Digital inputs 8-15 5-6..............................................

5.2.5 Digital inputs 16-19 5-7.............................................

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

5.2.7 Digital outputs 8-11 (NES002-501 / NES002-502 only) 5-8...............

5.2.8 Stepper axes outputs 0-1 5-9........................................

5.2.9 Stepper axes outputs 2-3 5-10........................................

5.2.10 Stepper axes outputs 4-5 (NES002-503 only) 5-12.......................

5.2.11 Power inputs 5-12..................................................

5.2.12 Encoder input 0 5-13................................................

5.2.13 Encoder input 1 5-13................................................

5.2.14 Serial port 5-14.....................................................

5.3 BPL010-502/503 backplane with opto-isolator card 5-15..........

5.3.1 Analog inputs 5-17..................................................

5.3.2 Analog outputs (demands) 5-19.......................................

5.3.3 Digital inputs 0-7 5-20...............................................

5.3.4 Digital inputs 8-15 5-21..............................................

5.3.5 Digital inputs 16-19 5-22.............................................

5.3.6 Digital outputs 0-7 5-26..............................................

5.3.7 Digital outputs 8-11 (NES002-501 / NES002-502 only) 5-28...............

5.3.8 Stepper axes outputs 0-1 5-29........................................

5.3.9 Stepper axes outputs 2-3 5-30........................................

5.3.10 Stepper axes outputs 4-5 (NES002-503 only) 5-32.......................

5.3.11 Power inputs 5-33..................................................

5.3.12 Encoder input 0 5-33................................................

5.3.13 Encoder input 1 5-34................................................

5.3.14 Serial port 5-34.....................................................

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 Mint Machine Center and Mint WorkBench 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 Mint Machine Center 6-3....................................

6.2.1 Starting MMC 6-4..................................................

6.3 Mint WorkBench 6-5........................................

6.3.1 Help file 6-6......................................................

6.3.2 Starting Mint WorkBench 6-7........................................

Servo Systems Co. • 115 Main Road • P.O. Box 97 • Montville, NJ,

07045-0097 • [phone] • Toll Free: [phone]

Fax: [phone] • www.servosystems.com

Contents iii

MN1928

6.4 Configuring an axis 6-9.....................................

6.4.1 Selecting the axis type 6-9..........................................

6.4.2 Selecting a scale 6-10...............................................

6.4.3 Setting the drive enable output 6-11...................................

6.4.4 Testing the drive enable output 6-12...................................

6.5 Servo axis - testing and tuning 6-13............................

6.5.1 Testing the demand output 6-13.......................................

6.5.2 An introduction to closed loop control 6-15..............................

6.6 Servo axis - tuning for current control 6-18......................

6.6.1 Selecting servo loop gains 6-18.......................................

6.6.2 Underdamped response 6-20.........................................

6.6.3 Overdamped response 6-21..........................................

6.6.4 Critically damped response 6-22......................................

6.7 Servo axis - eliminating steady-state errors 6-23.................

6.8 Servo axis - tuning for velocity control 6-24.....................

6.8.1 Calculating KVELFF 6-24............................................

6.8.2 Adjusting KPROP 6-27..............................................

6.9 Stepper axis - testing 6-29....................................

6.9.1 Testing the output 6-29..............................................

6.10 Digital input/output configuration 6-30..........................

6.10.1 Digital input configuration 6-30........................................

6.10.2 Digital output configuration 6-31.......................................

6.1 1 Saving setup information 6-32.................................

6.11.1 Loading saved information 6-33.......................................

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 Mint WorkBench 7-6...............................................

7.2.6 CANopen 7-6.....................................................

7.2.7 Baldor CAN 7-8...................................................

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

Servo Systems Co. • 115 Main Road • P.O. Box 97 • Montville, NJ,

07045-0097 • [phone] • Toll Free: [phone]

Fax: [phone] • www.servosystems.com

iv Contents

MN1928

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 Serial RS232/RS485 port 8-4........................................

8.1.13 CAN interface 8-5.................................................

8.1.14 Environmental 8-5.................................................

8.1.15 Weights and dimensions 8-5........................................

Appendices

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

A.1 Feedback cables A-1.......................................

Servo Systems Co. • 115 Main Road • P.O. Box 97 • Montville, NJ,

07045-0097 • [phone] • Toll Free: [phone]

Fax: [phone] • www.servosystems.com

www.baldormotion.com

General Information 1-1MN1928

LT0202A04 Copyright Baldor (c) 2010. All rights reserved.

This manual is copyrighted and all rights are reserved. This document or attached software may not,
in whole or in part, be copied or reproduced in any form without the prior written consent of BALDOR.
BALDOR makes no representations or warranties with respect to the contents hereof and specifically
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, Windows XP and Windows
Vista 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.

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

Baldor ASR AG
Telephone: [phone]
Fax: [phone]
Email: [e-mail]

Australian Baldor Pty Ltd

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

AustralianBaldorPtyLt

d

Telephone: [phone]
Fax: [phone]

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

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

1 General Information

1

Servo Systems Co. • 115 Main Road • P.O. Box 97 • Montville, NJ,

07045-0097 • [phone] • Toll Free: [phone]

Fax: [phone] • www.servosystems.com

www.baldormotion.com

1-2 General Information MN1928

Safety Notice

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

Precautions

Do not touch any circuit board, power device or electrical connection before you first
ensure that no high voltage is present at this equipment or other equipment to which it is
connected. Electrical shock can cause serious or fatal injury. Only qualified personnel
should attempt to start-up, program or troubleshoot this equipment.

Be sure that you are completely familiar with the safe operation and programming of this
equipment. This equipment may be connected to other machines that have rotating parts
or parts that are controlled by this equipment. Improper use can cause serious or fatal
injury.

MEDICAL DEVICE / PACEMAKER DANGER: Magnetic and electromagnetic fields in the
vicinity of current carrying conductors and industrial motors can result in a serious health
hazard to persons with cardiac pacemakers, internal cardiac defibrillators,
neurostimulators, metal implants, cochlear implants, hearing aids, and other medical
devices. To avoid risk, stay away from the area surrounding a motor and its current
carrying conductors.

The stop input to this equipment should not be used as the single means of achieving a
safety critical stop. Drive disable, motor disconnect, motor brake and other means should
be used as appropriate.

Improper operation or programming may cause violent motion of the motor shaft and
driven equipment. Be certain that unexpected motor shaft movement will not cause injury
to personnel or damage to equipment. Peak torque of several times the rated motor
torque can occur during control failure.

The safe integration of this equipment into a machine system is the responsibility of the
machine designer. Be sure to comply with the local safety requirements at the place 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 S tates this is the National
Electrical code and local codes.

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

WARNING

WARNING

WARNING

CAUTION

CAUTION

NOTICE

NOTICE

Servo Systems Co. • 115 Main Road • P.O. Box 97 • Montville, NJ,

07045-0097 • [phone] • Toll Free: [phone]

Fax: [phone] • www.servosystems.com

www.baldormotion.com

Introduction 2-1MN1928

2.1 NextMove ES features

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

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

Standard features include:

H Control of 2 servo axes and 4 or 6 stepper axes (model dependent).

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 USB serial port.

H RS232 or RS485 serial port (model dependent).

H CANopen or proprietary Baldor CAN protocol for communication with Mint controllers and

other third party devices.

H Programmable in Mint.

2 Introduction

2

Servo Systems Co. • 115 Main Road • P.O. Box 97 • Montville, NJ,

07045-0097 • [phone] • Toll Free: [phone]

Fax: [phone] • www.servosystems.com

www.baldormotion.com

2-2 Introduction MN1928

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 Mint controller . These include:

H Mint WorkBench

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

H PC Developer Libraries

Installing Mint WorkBench 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 Mint WorkBench releases by

visiting the website www.baldormotion.com/supportme.

Servo Systems Co. • 115 Main Road • P.O. Box 97 • Montville, NJ,

07045-0097 • [phone] • Toll Free: [phone]

Fax: [phone] • www.servosystems.com

www.baldormotion.com

Introduction 2-3MN1928

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:

NES002-50_____

Installed in: ________________________

Date: ______

Backplane catalog number: BPL010-50_______

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

Catalog
number

Description

NES002-501 NextMove ES controller card:

4 stepper axes, 2 servo axes. USB and RS232 serial connections.

NES002-502 NextMove ES controller card:

4 stepper axes, 2 servo axes. USB and RS485 serial connections.

NES002-503 NextMove ES controller card:

6 stepper axes, 2 servo axes. USB and RS232 serial connections.

BPL010-501 Backplane card: Non-isolated digital inputs and outputs

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

and ‘active high’ digital inputs.

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

and ‘active low’ digital inputs.

Servo Systems Co. • 115 Main Road • P.O. Box 97 • Montville, NJ,

07045-0097 • [phone] • Toll Free: [phone]

Fax: [phone] • www.servosystems.com

www.baldormotion.com

2-4 Introduction MN1928

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

mΩ milliohm.............

μF microfarad..............

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

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

Φ phase...............

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

μs microsecond..............

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

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

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

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

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

lbf-in pound force inch (torque)............

N·m Newton meter (torque).............

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

ASCII American Standard Code for Information Interchange...........

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

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

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

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

CiA CAN in Automation International Users and Manufacturers Group e.V..............

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

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

DS301 CiA CANopen Application Layer and Communication Profile..........

DS401 CiA Device Profile for Generic I/O Devices..........

DS403 CiA Device Profile for HMIs..........

EDS Electronic Data Sheet............

EMC Electromagnetic Compatibility............

HMI Human Machine Interface.............

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

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

LCD Liquid Crystal Display............

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

Mbps megabits/s...........

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

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

Servo Systems Co. • 115 Main Road • P.O. Box 97 • Montville, NJ,

07045-0097 • [phone] • Toll Free: [phone]

Fax: [phone] • www.servosystems.com

www.baldormotion.com

Basic Installation 3-1MN1928

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.

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

To ensure reliable performance of this equipment be certain that all signals to/from
the NextMove ES are shielded correctly.

Avoid locating the NextMove ES immediately above or beside heat generating
equipment, or directly below water steam pipes.

Avoid locating the NextMove ES in the vicinity of corrosive substances or vapors,
metal particles and dust.

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.

3 Basic Installation

3

CAUTION

CAUTION

CAUTION

CAUTION

Servo Systems Co. • 115 Main Road • P.O. Box 97 • Montville, NJ,

07045-0097 • [phone] • Toll Free: [phone]

Fax: [phone] • www.servosystems.com

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3-2 Basic Installation MN1928

3.1.2 Installing the NextMove ES card

Before touching the card, be sure to discharge static electricity from your body
and clothing by touching a grounded metal surface. Alternatively, wear an earth
strap while handling the card.

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.

3.1.3 Dimensions and hole positions

CAUTION

5mm(0.2 in)5mm(0.2in)

68 mm (2.68in) 35 mm (1.38 in)

3.75 mm (0.15in)

3.75 mm

(0.15 in)

135 mm (5.32in)

52.6 mm (2.1 in)

95 mm (3.74in)

30.9 mm (1.22in)

5mm(0.2 in) 5mm(0.2 in)

160 mm (6.3 in)

100 mm (3.94in)

Servo Systems Co. • 115 Main Road • P.O. Box 97 • Montville, NJ,

07045-0097 • [phone] • Toll Free: [phone]

Fax: [phone] • www.servosystems.com

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Basic Installation 3-3MN1928

3.1.4 Other requirements for installation

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

(excluding any option cards) is +5 V at 1 A, +12 V at 50 mA and -12 V at 50 mA. 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 PentiumIII

500 MHz

Intel PentiumIII / 4 or equivalent

1 GHz or faster

RAM 128 MB 1GB

Hard disk space 50 MB 50 MB

CD-ROM ACD-ROMdrive

Serial port USB port

or

RS232 or RS485 serial port (depending on NextMove ES model)

Screen 1024 x 768, 16-bit color 1 152 x 864, 16-bit color

Mouse A mouse or similar pointing device

Operating

system

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

2000, XP , Vista

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

H A USB cable, or a serial cable connected as shown in section 4.5.4.

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

Servo Systems Co. • 115 Main Road • P.O. Box 97 • Montville, NJ,

07045-0097 • [phone] • Toll Free: [phone]

Fax: [phone] • www.servosystems.com

www.baldormotion.com

3-4 Basic Installation MN1928

Servo Systems Co. • 115 Main Road • P.O. Box 97 • Montville, NJ,

07045-0097 • [phone] • Toll Free: [phone]

Fax: [phone] • www.servosystems.com

www.baldormotion.com

Input / Output 4-1MN1928

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

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

4 Input / Output

4

Component side

32

1

cba

Key

Servo Systems Co. • 115 Main Road • P.O. Box 97 • Montville, NJ,

07045-0097 • [phone] • Toll Free: [phone]

Fax: [phone] • www.servosystems.com

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4-2 Input / Output MN1928

4.2.1 96-pin connector pin assignment - NES002-501 & NES002-502

Row

Pin c b a

1 +5 VDC +5 VDC +5 VDC

2 +5 VDC +5 VDC +5 VDC

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 (NC) 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 (RX- on RS485)
21 DIN0 RTS (TX+ on RS485) TXD (TX- on RS485)
22 DOUT11 AOUT3 CTS (RX+ on RS485)

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 +12 VDC +12 VDC +12 VDC

30 AGND AGND AGND

31 -12 VDC -12 VDC -12 VDC

32 Shield Shield Shield

Table 1 - 96-pin connector pin assignment for 4 stepper + 2 servo models

Servo Systems Co. • 115 Main Road • P.O. Box 97 • Montville, NJ,

07045-0097 • [phone] • Toll Free: [phone]

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Input / Output 4-3MN1928

4.2.2 96-pin connector pin assignment - NES002-503

Row

Pin c b a

1 +5 VDC +5 VDC +5 VDC

2 +5 VDC +5 VDC +5 VDC

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 (NC) DGND DGND

13 DGND DOUT9 DIR4 DOUT8 STEP4

14 STEP2 STEP1 STEP0

15 DIR2 DIR1 DIR0

16 DOUT10 STEP5 DGND (NC)
17 DGND AOUT2 (NC)

18 DIN4 DIN15 DIN2

19 DIN3 DIN5 DIN7

20 DIN6 DIN1 RXD (RX- on RS485)
21 DIN0 RTS (TX+ on RS485) TXD (TX- on RS485)
22 DOUT11 DIR5 AOUT3 CTS (RX+ on RS485)

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 +12 VDC +12 VDC +12 VDC

30 AGND AGND AGND

31 -12 VDC -12 VDC -12 VDC

32 Shield Shield Shield

Table 2 - 96-pin connector pin assignment for 6 stepper + 2 servo models

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4-4 Input / Output MN1928

4.3 Analo g 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: ±10 V .

H Resolution: 12-bit with sign.

H Input impedance: 120 kΩ.

H Sampling frequency: 4 kHz maximum, 2 kHz 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 1 kHz.

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

NextMove ES

-

+

AIN0+

AIN0-

AGND

Mint

ADC(0)

-

+

120 k

120 k

a28

a30

b28

+12 V

-12 V

Figure 1 - Analog input, AIN0 shown

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

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Input / Output 4-5MN1928

AIN0

ADC(0)

AIN0

ADC(0)

b28

a28

a30

AIN0-

Differential connection Single ended connection

AIN0+

AIN0+

GND

b28

a28

a30

Figure 2 - AIN0 analog input wiring

AIN0

1kΩ,0.25W

potentiometer

ADC(0)

1.5 kΩ,0.25W

0V

+24 VDC

b28

a28

a30

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

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4-6 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 (model dependent).

H Output range: ±10 VDC (±0.1%).

H Resolution: 12-bit.

H Output current: 10 mA maximum.

H Update frequency: 10 kHz maximum (adjustable using the LOOPTIME keyword, factory

default 1 kHz).

Mint and the Mint Motion Library use analog outputs Demand0 and Demand1 to control drive
amplifiers. Demand outputs 0 and 1 are used by axes configured as servo (see section 6.4.1).
The Demand2 and Demand3 outputs may be used as general purpose analog outputs. See
the DAC keyword in the Mint help file.

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

NextMove ES

Demand0

Demand

±100%

-

+

AGND

TL084

47R

c27

a30

+12V

-12V

Figure 4 - Analog output - Demand0 shown

NextMove ES

Demand0

AGND

12

MicroFlex / drive amplifier

AIN0+

AIN0-

Connect overall shi eld at

one end only

a32Shield

Drive amplifier
±10 VDC
demand
input

-

+

c27

a30

13

‘X3’

Figure 5 - Analog output - typical connection to a Baldor MicroFlex

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Input / Output 4-7MN1928

NextMove ES

Demand0

AGND

2

FlexDriveII/ drive amplifier

AIN0+

AIN0-

Connect overall shi eld at

one end only

a32Shield

Drive amplifier
±10 VDC
demand
input

-

+

c27

a30

1

‘X1’

Figure 6 - Analog output - typical connection to a Baldor FlexDriveII, Flex+DriveIIor MintDrive

II

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4-8 Input / Output MN1928

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 5 V 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: 1 kHz.

DGND

DIN0

GND

Mint

INX(0)

+5V

NextMove ES

74AHCT14

c21

a3

Figure 7 - General purpose digital input - DIN0 shown

Do not connect 24 V 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 1 ms
(one software scan) to guarantee acceptance by Mint. 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 Mint 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 Mint help file.

CAUTION

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Input / Output 4-9MN1928

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 (20 MHz 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 5 V
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 Mint help file for details of each keyword.

4.4.1.3 Typical digital input wiring

DGND

DIN0

GND

Mint

INX(0)

+5V

NextMove ES

74AHCT14

c21

a3

Status+

Status-

MicroFlex / equipment output

NEC PS2562L-1

‘X3’

3

2

Figure 8 - Digital input - typical connections from a Baldor MicroFlex

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4-10 Input / Output MN1928

DGND

DIN0

GND

Mint

INX(0)

+5V

NextMove ES

74AHCT14

USRV+

DOUT0

FlexDriveII/ equipment output

NEC PS2562L-1

User
supply
GND

User
supply
24 V

‘X1’

6

18

c21

a3

Figure 9 - Digital input - typical connections from a Baldor FlexDriveII,

Flex+Drive

II

or MintDrive

II

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Input / Output 4-11MN1928

4.4.2 Digital outputs

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

H 12 or 8 general purpose digital outputs (model dependent).

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

H Update frequency: Immediate.

On models NES002-501 and NES002-502 there are 12 general purpose digital outputs.
On model NES002-503 there are 8 general purpose digital outputs, since DOUT8 - DOUT11
are reassigned to provide the STEP4/5 and DIR4/5 axis output signals.

A digital output can be configured in Mint 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 Mint
WorkBench (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 24 VDC), 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 2 W at 25 °C. The total output
requirements of DOUT0 - DOUT7 must not exceed this limit. The maximum current limit for an
individual output is 500 mA if only one output is in use, reducing to 150 mA 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 10. This will connect internal clamp diodes on
all outputs.

DOUT0

NextMove ES

ULN2803

Mint

OUTX(0)

74AHCT244

DGND

GND

Load
supply
24 V

Load
supply
GND

Output
Load

OUT COM

Connect to supply if

using inductive loads

c6

a3

a4

Figure 10 - Digital outputs (DOUT0-7) - DOUT0 shown

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4-12 Input / Output MN1928

4.4.2.2 DOUT8 - DOUT1 1

Outputs DOUT8 - DOUT11 are driven by a ULN2003 device. The outputs are designed to sink
current from an external supply (typically 24 VDC), 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 900 mW at 25 °C. The total output
requirements of DOUT8 - DOUT11 must not exceed this limit. The maximum current limit for
an individual output is 400 mA if only one output is in use, reducing to 50 mA 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 DIR3 and STEP3
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.

Note: On model NES002-503, DOUT8 - DOUT11 are not available as general purpose

digital outputs. The outputs are used to provide the additional STEP4/5 and
DIR4/5 stepper axes outputs (see section 4.5.1).

DOUT8

NextMove ES

ULN2003

Mint

OUTX(8)

74AHCT244

DGND

GND

Load
supply
24 V

Load
supply
GND

a13

a3

Output Load
(Relay with
diode shown)

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

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Input / Output 4-13MN1928

4.4.3 Error output - Error Out

The error output is available on pin b11. This
100 mA 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, which are situated at the top edge of the
card. Connect the load as shown in Figure 12.

Figure 12 - Error Out level configuration

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

4.4.3.1 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.

4.4.3.2 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(0)=1 will enable the error output; the command
RELAY(0)=0 will disable it. These commands are valid regardless of whether an
opto-isolating backplane is actually connected.

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

See the Mint help file for details of each keyword.

JP3

JP4

+12 V

+5 V

from

Mint

error out

Error

Out

GND

Jumpers Inactive Active

state state

JP3 JP4 JP5* (no error) (error)

Open coll ector 12 V
Open coll ector 0 V

12 V Open collector

0 V Open collector

NextMove ES

b11

JP3

JP4

Output
load

JP3

JP4

GND

Output
load

+5 V

GND

+12 V

b11

b11

100R

* JP5 inverts the active state

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4-14 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 or six sets of stepper motor control
outputs (model dependent), operating in the range
0 Hz to 500 kHz. Each of the step (pulse) and direction
signals from the NextMove ES is driven by one channel
of a ULN2003 open collector Darlington output device.

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

On models NES002-501 and NES002-502, STEP3
and DIR3 are sourced from the same ULN2003 device
used for the DOUT8 - DOUT11 digital outputs (see
section 4.4.2.2), so the current demands of these
digital outputs must also be considered.

On model NES002-503, STEP3 and DIR3 are sourced
from the same ULN2003 device used for the additional
STEP4 - STEP5 and DIR4 - DIR5 stepper axes outputs. In this case the ULN2003 device is
providing three sets of STEP and DIR outputs, so the specifications are identical to those for
STEP0 - STEP2 and DIR0 - DIR2, detailed above.

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

The ULN2003 drivers are static sensitive devices. Take appropriate ESD
precautions when handling the NextMove ES.

NextMove ES

STEP0

DGNDa3

a14

ULN2003

Step

Output

74AHCT244

GND

Figure 13 - Stepper output - STEP0 output shown

NES002-501 / NES002-502

ULN2003

device 1

STEP0
DIR0

STEP1
DIR1

STEP2
DIR2

STEP3
DIR3

DOUT8
DOUT9

DOUT10
DOUT11

ULN2003

device 2

NES002-503

ULN2003

device 1

STEP0
DIR0

STEP1

DIR2

STEP2
DIR2

STEP3
DIR3

STEP4

DIR4

STEP5
DIR5

ULN2003

device 2

CAUTION

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07045-0097 • [phone] • Toll Free: [phone]

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Input / Output 4-15MN1928

4.5.2 Encoder inputs

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.

CHA-

CHA+

to CPU

Vcc

NextMove ES

MAX3095

120R

10k

b7

b10

Shielda32

Connect overall shield to

connector backshells /

shield connections.

Twisted pair

MicroFlex
FlexDrive

II

Flex+Drive

II

MintDrive

II

encoder output

a11 DGND

Connect i nternal shield to DGND.
Do not connect other end.

CHA-

CHA+ 1

6

‘X7’

CHB-

CHB+

MAX3095

120R

a7

c10

Twisted pair

CHB-

CHB+ 2

7

CHZ-

CHZ+

MAX3095

120R

b8

b9

Twisted pair

CHZ-

CHZ+ 3

8

to CPU

to CPU

Vcc

10k

Vcc

10k

Figure 14 - Encoder input 0 - typical connection from a drive amplifier

(e.g. Baldor MicroFlex, FlexDrive

II

, Flex+DriveIIor MintDriveII)

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 5 MHz. However, the effect of
cable length is shown in Table 3:

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