Baldor Nextmove ESB Installation Manual

NextMove ESB

Motion Controller

MOTION CONTROL

Installation Manual

1/04 MN1924

Contents i

MN1924

Contents

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

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

2.1 NextMove ESB 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 Mounting the NextMove ESB 3-2.....................................

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

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

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

4.1.1 Connector locations 4-2............................................

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

4.2.1 Analog inputs 4-3..................................................

4.2.2 Analog outputs 4-5.................................................

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

4.3.1 Digital inputs 4-7..................................................

4.3.2 Digital outputs 4-12.................................................

4.4 Other I/O 4-13..............................................

4.4.1 Stepper control outputs 4-13..........................................

4.4.2 Encoder inputs 0-2 4-14.............................................

4.4.3 USB port 4-15.....................................................

4.4.4 Serial port 4-16.....................................................

4.4.5 Using RS232 4-16..................................................

4.4.6 Multidrop using RS485 / RS422 4-17..................................

4.4.7 Connecting serial Baldor HMI Operator Panels 4-18......................

4.5 CAN 4-19..................................................

4.5.1 CAN connector 4-19................................................

4.5.2 CAN wiring 4-20....................................................

4.5.3 CANopen 4-21.....................................................

4.5.4 Baldor CAN 4-22...................................................

4.6 Connection summary - minimum system wiring 4-24.............

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MN1924

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

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

5.1.1 Connecting the NextMove ESB to the PC 5-1..........................

5.1.2 Installing WorkBench v5 5-1.........................................

5.1.3 Starting the NextMove ESB 5-1......................................

5.1.4 Preliminary checks 5-2.............................................

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

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

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

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

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

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

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

5.3.3 Testing the drive enable output 5-9...................................

5.4 Stepper axis - testing 5-10....................................

5.4.1 Testing the output 5-10..............................................

5.5 Servo axis - testing and tuning 5-11............................

5.5.1 Testing the demand output 5-11.......................................

5.5.2 An introduction to closed loop control 5-13..............................

5.6 Servo axis - tuning for current control 5-16......................

5.6.1 Selecting servo loop gains 5-16.......................................

5.6.2 Underdamped response 5-18.........................................

5.6.3 Overdamped response 5-19..........................................

5.6.4 Critically damped response 5-20......................................

5.7 Servo axis - eliminating steady-state errors 5-21.................

5.8 Servo axis - tuning for velocity control 5-22.....................

5.8.1 Calculating KVELFF 5-22............................................

5.8.2 Adjusting KPROP 5-25..............................................

5.9 Digital input/output configuration 5-27..........................

5.9.1 Digital input configuration 5-27........................................

5.9.2 Digital output configuration 5-28.......................................

5.10 Saving setup information 5-29.................................

5.10.1 Loading saved information 5-30.......................................

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

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

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

6.1.2 SupportMe feature 6-1.............................................

6.2 NextMove ESB indicators 6-2................................

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

6.2.2 Communication 6-3................................................

6.2.3 Motor control 6-4..................................................

Contents iii

MN1924

6.2.4 WorkBench v5 6-5.................................................

6.2.5 CANopen 6-6.....................................................

6.2.6 Baldor CAN 6-8...................................................

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

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

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

7.1.2 Analog inputs 7-1..................................................

7.1.3 Analog outputs 7-1.................................................

7.1.4 Digital inputs 7-2..................................................

7.1.5 Digital outputs - general purpose 7-2..................................

7.1.6 Relay output 7-2...................................................

7.1.7 Encoder inputs 7-2................................................

7.1.8 Stepper control outputs 7-3..........................................

7.1.9 Serial RS232/RS485 port 7-3........................................

7.1.10 CAN interface 7-3.................................................

7.1.11 Environmental 7-3.................................................

7.1.12 Weights and dimensions 7-4........................................

Appendices

A General A-1............................................

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

A.2 Feedback cables A-3.......................................

B CE Guidelines B-1......................................

B.1 Outline B-1................................................

B.1.1 EMC Conformity and CE marking B-1.................................

B.1.2 NextMove ESB compliance B-1......................................

B.1.3 Use of CE compliant components B-2.................................

B.1.4 EMC installation suggestions B-2.....................................

B.1.5 Wiring of shielded (screened) encoder cables B-2.......................

iv Contents

MN1924

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General Information 1-1MN1924

LT0189A02 Copyright Baldor (c) 2004. 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 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.

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

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1-2 General Information MN1924

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

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.

WARNING: 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.

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.

WARNING: 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.

CAUTION: 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 States this is the National Electrical code and local codes.

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

(electrostatic discharge) procedures when handling this drive.

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Introduction 2-1MN1924

2.1 NextMove ESB features

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

NextMove ESB 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.

Standard features include:

H Control of 4 stepper and 3 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 11 general purpose digital outputs.

H 2 differential analog inputs with 12-bit resolution.

H 4 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 MintMT controllers

and other third party devices.

H Programmable in MintMT.

2 Introduction

2

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2-2 Introduction MN1924

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

H Mint WorkBench v5

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

H PC Developer Libraries

Installing Mint WorkBench v5 will install ActiveX interfaces that allow PC applications to be
written that communi cate with the NextMove ESB.

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

The chapters should be read in sequence.

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

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Introduction 2-3MN1924

2.2 Receiving and inspection

When you receive your NextMove ESB, 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 ESB.

2. Remove the NextMove ESB from the shipping container and remove all packing material. The
container and packing materials may be retained for future shipment.

3. Verify that the catalog number of the NextMove ESB 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 ESB for external damage during shipment and report any damage
to the carrier that delivered it.

5. If the NextMove ESB 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

Different models of NextMove ESB are available. As a reminder of which product has been
installed, it is a good idea to write the catalog number in the space provided below.

NextMove ESB catalog number:

NSB002-501 or NSB002-502

Installed in: ________________________

Date: ______

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

Catalog
number

Description

NSB002-501 NextMove ESB controller with USB and RS232 serial connections

NSB002-502 NextMove ESB controller with USB and RS485 serial connections

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2-4 Introduction MN1924

2.3 Units and abbreviations

The following units and abbreviations may appear in this manual:

V Volt (also V AC 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)............

Nm 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..............

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Basic Installation 3-1MN1924

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 ESB.
This section describes the mechanical installation of the NextMove ESB.

3.1.1 Location requirements

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

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 NextMove ESB are shielded correctly.

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

generating equipment, or directly below water steam pipes.

CAUTION: Avoid locating the NextMove ESB 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 ESB is designed to be mounted indoors, permanently fixed and located.

H The NextMove ESB must be secured by the slots in the metal case.

H The NextMove ESB must be installed in an ambient temperature of 0°C to 45°C (32°F to

113°F).

H The NextMove ESB 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 45°C
(113°F), non-condensing.

H The NextMove ESB 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

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3-2 Basic Installation MN1924

3.1.2 Mounting the NextMove ESB

CAUTION: Before touching the unit 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 unit.

Ensure you have read and understood the location requirements in section 3.1.1. Mount the
NextMove ESB using the supplied M4 screws. For effective cooling, the NextMove ESB must
be mounted on a smooth non-flammable vertical surface. Orientation must be as shown in
Figure 1, with the two slots in the metal carrier / heat sink assembly at the bottom.

135 (5.3)

124 (4.9)

170 (6.7)

245 (9.65)

All dimensions shown as

mm (inches)

43 (1.7)

Mounting keyhole and slot detail

A

B

C

A 4.5mm
B 10mm
C 11m m

A

Drawings not to scale

Figure 1 - Package dimensions

There must be at least 20mm (0.8 in) clearance between the NextMove ESB and neighboring
equipment to allow sufficient cooling by natural convection. Remember to allow additional
space around the edges to accommodate the mating connectors and associated wiring. For
example, 70mm (2.8 in) clearance will be required for connection of the serial port cable.

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Basic Installation 3-3MN1924

3.1.3 Other requirements for installation

H The NextMove ESB requires +24V power supply capable of supplying 2A continuously.

If digital outputs are to be used, a supply will be required to drive them - see section 4.3.2.

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 USB port

or

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

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 5.

H A serial cable (connected as shown in section 4.4.4) or USB cable.

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

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3-4 Basic Installation MN1924

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Input / Output 4-1MN1924

4.1 Introduction

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

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

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

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

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

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

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

4 Input / Output

4

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4-2 Input / Output MN1924

4.1.1 Connector locations

Tightening torque for terminal block
connections is 0.3Nm (2.65 lbf-in)

X12 AIN 0-1
& relay

X7 Encoder2

X6 Encoder1

X4 DOUT 8-10

X2 STEP 0-1

AIN0+

AIN0­AGND
AIN1+

AIN1­Shield

REL COM

REL NC
REL NO

REL COM

CREF2
CREF1
CREF0
!RSTIN
USR GND
USR V+
USR V+
DOUT10
DOUT9
DOUT8

Shield
DIR1+
DIR1­STEP1+
STEP1­DGND
Shield
DIR0+
DIR0­STEP0+
STEP0­DGND

Serial

Required mating connectors:

Sauro CTF10008
Sauro CTF12008
Sauro CTF02008
9-pin D-type plug (male)
9-pin D-type sock et (female)
RJ45 plug
USB type B plug

1
2
3
4
5
6
7
8
9
10

12
11
10

9
8
7
6
5
4
3
2
1

10

9
8
7
6
5
4
3
2
1

X11 DOUT 0-7

DOUT0
DOUT1
DOUT2
DOUT3
DOUT4
DOUT5
DOUT6
DOUT7

USR V+

USR GND

1
2
3
4
5
6
7
8
9
10

X10 DIN 0-3
(fast interrupts)

DIN3

Shield

CREF0

DIN2

Shield

CREF0

DIN1

Shield

CREF0

DIN0

1
2
3
4
5
6
7
8
9
10

X9 DIN 4-11

DIN11
DIN10

DIN9
DIN8
DIN7
DIN6
DIN5
DIN4

CREF1

Shield

1
2
3
4
5
6
7
8
9
10

X8 DIN 12-19

DIN19
DIN18
DIN17
DIN16
DIN15
DIN14
DIN13
DIN12

CREF2

Shield

1
2
3
4
5
6
7
8
9
10

X13 AOUT 0-3
(demands)

DEMAND0

AGND
Shield

DEMAND1

AGND
Shield

DEMAND2

AGND
Shield

DEMAND3

AGND
Shield

1
2
3
4
5
6
7
8
9
10
11
12

X3 STEP 2-3

Shield
DIR3+
DIR3­STEP3+
STEP3­DGND
Shield
DIR2+
DIR2­STEP2+
STEP2­DGND

12
11
10

9
8
7
6
5
4
3
2
1

X5 Encoder0

X1 +24V in

+24V
0V

2
1

CANUSB

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Input / Output 4-3MN1924

4.2 Analo g I/O

The NextMove ESB provides:

H Two 12-bit resolution analog inputs.

H Four 12-bit resolution analog outputs.

4.2.1 Analog inputs

The analog inputs are available on connector X12, pins 1 & 2 (AIN0) and 4 & 5 (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, ADCMODE and other related ADC... keywords.

NextMove ESB

-

+

AIN0+

AIN0-

AGND

MintMT

ADC.0

-

+

120k

120k

15k

10k 10k

22nF

10nF

2

3

1

+12V

-12V

‘X12’

Figure 2 - Analog input, AIN0 shown

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

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4-4 Input / Output MN1924

AIN0

(ADC.0)

X12

AIN0

(ADC.0)

1

2

3

X12

AIN0-

Differential connection Single ended connection

AIN0+

1

2

3

AIN0+

GND

Figure 3 - AIN0 analog input wiring

AIN0

1kΩ,0.25W

potentiometer

(ADC.0)2

1

X12

1.5kΩ, 0.25W

0V

+24VDC

3

Figure 4 - Typical input circuit to provide 0-10V (approx.) input from a 24V source

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Input / Output 4-5MN1924

4.2.2 Analog outputs

The four analog outputs are available on connector X13, as shown in section 4.1.1.

H Four independent bipolar 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 (adjustable using the LOOPTIME keyword, factory

default 1kHz).

MintMT and the Mint Motion Library use analog outputs Demand0 to Demand2 to control servo
axes 0 to 2 respectively. The Demand3 output may be used as general purpose analog

output. 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 ESB

Demand0

Demand

±100%

120k

30k

-

+

AGND

100pF

TL084

47R

1

2

+12V

-12V

‘X13’

Figure 5 - Analog output - Demand0 shown

NextMove ESB

Demand0

AGND

1

2

13

12

MicroFlex / servo amplifier

AIN0+

AIN0-

Connect overall shield at

one end only

3Shield

Servo
amplifier
±10VDC
demand
input

-

+

‘X3’‘X13’

Figure 6 - Analog output - typical connection to a Baldor MicroFlex

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4-6 Input / Output MN1924

NextMove ESB

Demand0

AGND

2

FlexDriveII/ servo ampli fier

AIN0+

AIN0-

Connect overall shield at

one end only

3Shield

Servo
amplifier
±10VDC
demand
input

-

+

1

2

1

‘X1’

‘X13’

Figure 7 - Analog output - typical connection to a Baldor FlexDriveII, Flex+DriveIIor MintDrive

II

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Input / Output 4-7MN1924

4.3 Digital I/O

The NextMove ESB provides:

H 20 general purpose digital inputs.

H 11 general purpose digital outputs.

4.3.1 Digital inputs

Digital inputs are available on connectors X8, X9 and X10, as shown in section 4.1.1.
The digital inputs are arranged in three groups, each with their own common connection. This
allows each group to be configured independently for ‘active high’ or ‘active low’ operation.

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.

4.3.1.1 DIN0 - DIN3

Digital inputs DIN0 to DIN3 can be assigned as fast interrupts. These are used as high speed
position latches, allowing any combination of axes to be captured by the hardware. The
latency between input triggering and capture is 1µs. Special Mint keywords (beginning with the

letters FAST...) allow specific functions to be performed as a result of fast position inputs

becoming active. See the Mint help file for details.

DIN3

3k3

TLP115A

DGND

Mint

1k

Vcc

NextMove ESB

CREF0

4n7

100R

100pF

1

3

Shield 2

‘X10’

Figure 8 - Fast interrupt digital input - DIN3 shown

Digital inputs DIN0 to DIN3 use CREF0 as their common connection.

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

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

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4-8 Input / Output MN1924

4.3.1.2 DIN4 - DIN11

Digital inputs DIN4 to DIN11 have a common specification:

H Opto-isolated digital inputs.

H Sampling frequency: 1kHz.

Digital inputs DIN4 to DIN11 use CREF1 as their common connection.

DIN11

3k3

TLP280

DGND

Mint

INX.11

4k7

Vcc

NextMove ESB

CREF1

4n7

100R

1

9

Shield 10

‘X9’

Figure 9 - General purpose digital input - DIN11 shown

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.

4.3.1.3 DIN12 - DIN19

Digital inputs DIN12 to DIN19 have the same electrical specification as DIN4-11, except that
they use CREF2 as their common connection.

DIN19

3k3

TLP280

DGND

Mint

INX.19

4k7

Vcc

NextMove ESB

CREF2

4n7

100R

1

9

Shield 10

‘X8’

Figure 10 - General purpose digital input - DIN19 shown

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Input / Output 4-9MN1924

4.3.1.4 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.

4.3.1.5 Digital inputs - reset

The reset input !RSTIN is available on connector X4, and uses CREF1 as its common
connection. When the reset input is activated it will cause a hardware reset of the NextMove
ESB. This is equivalent to power-cycling the NextMove ESB. Due to the internal pull-up
resistor, the reset input may be left floating.

!RSTIN

3k3

TLP280

DGND

Reset

4k7

Vcc

NextMove ESB

CREF1

7

9

Shield

12

X3

‘X4’

Figure 11 - Reset input

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4-10 Input / Output MN1924

4.3.1.6 Typical digital input wiring

NextMove ESB

8

9

DIN4

CREF1

3k3

TLP280

User
supply
GND

User
supply
24V

‘X9’

Figure 12 - Digital input - typical ‘active high’ input connection using a switch

NextMove ESB

8

9

DIN4

CREF1

3k3

TLP280

User
supply
GND

User
supply
24V

‘X9’

Figure 13 - Digital input - typical ‘active low’ input connection using a switch

Note: The circuits shown in Figures 12 and 13 are not suitable for use with fast inputs

DIN0 to DIN3. Using a mechanical switch, relay contacts or other source liable to
signal ‘bounce’ could cause unwanted multiple triggering.

NextMove ESB

Status+

Status-

8

9

MicroFlex / equi pment output

DIN4

CREF1

NEC P S2562L-1

3k3

TLP280

User
supply
GND

User
supply
24V

3

2

‘X3’

‘X9’

Figure 14 - Digital input - typical connections from a Baldor MicroFlex

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Input / Output 4-11MN1924

NextMove ESB

USRV+

DOUT0

8

9

FlexDriveII/ equipment output

NEC P S2562L-1

3k3

TLP280

‘X1’

User
supply
GND

User
supply
24V

6

18

DIN4

CREF1

‘X9’

Figure 15 - Digital input - typical connections from a Baldor FlexDriveII,

Flex+Drive

II

or MintDrive

II

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4-12 Input / Output MN1924

4.3.2 Digital outputs

The digital outputs are available on connectors X4 and X11, as shown in section 4.1.1.
A digital 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.

4.3.2.1 DOUT0 - DOUT7

An external supply (typically 24VDC) is used to power the UDN2982 output devices, as shown
in Figure 16. When an output is activated, current is sourced from the user supply through a
UDN2982 output driver.

H A total of 500mA may be sourced by DOUT0 - DOUT7, providing an average 62.5mA per

output when all outputs are on (100% duty cycle, 24V supply).

H A maximum continuous current of 350mA may be sourced on any single output.

H The maximum allowable power dissipation for the UDN2982 driver is 1.5W.

If an output is used to drive an inductive load such as a relay, a suitably rated diode must be
fitted across the relay coil, observing the correct polarity. The use of shielded cable is
recommended.

TLP281

470R

NextMove ESB

MintMT

OUTX.0

10k

10k

DOUT0

USR GND

1

10

UDN2982

User
supply
24V

User
supply
GND

Output
Load

USR V+

9

+5V

Voltage

regulator

‘X11’

Figure 16 - Digital outputs (DOUT0-7) - DOUT0 shown

4.3.2.2 DOUT8 - DOUT10

DOUT8 - DOUT10 use the same type of output circuitry as DOUT0 - DOUT7, with their own
UDN2982 output driver. Because only three of the UDN2982’s eight outputs are being used,
the average current available on DOUT8 - DOUT10 is increased:

H A total of 500mA may be sourced by DOUT8 - DOUT10, providing an average 166mA per

output when all outputs are on (100% duty cycle, 24V supply).

H A maximum continuous current of 350mA may be sourced on any single output.

H The maximum allowable power dissipation for the UDN2982 driver is 1.5W.

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Input / Output 4-13MN1924

4.4 Other I/O

4.4.1 Stepper control outputs

The stepper control outputs are available on connectors X2 and X3, as shown in section 4.1.1.

There are four sets of stepper motor control outputs, operating in the range 0Hz to 500kHz.
Each of the step (pulse) and direction signals from the NextMove ESB is driven by DS26LS31
line drivers, providing RS422 differential outputs.

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

The FREQ keyword can be used to directly control the output frequency, between 60Hz and

500kHz - see the MintMT help file.

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

precautions when handling the NextMove ESB.

STEP0-

DGND

1

2

DS26LS31

STEP0+

3

NextMove ESB

Step

Output

GND

MicroFlex / servo amplifier

DGND

Step

Connect overall

shield at one end only

6Shield

Step / pulse
input

‘X3’

‘X2’

11

10

Figure 17 - Stepper output - typical connection to a Baldor MicroFlex

6

1

FlexDriveII/ servo amplifier

Pulse+

Pulse
GND

Step / pulse
input

‘X9’

STEP0-

DGND

1

2

DS26LS31

STEP0+

3

NextMove ESB

Step

Output

GND

Connect overall

shield at one end only

6Shield

‘X2’

Figure 18 - Stepper output - typical connection to a Baldor FlexDriveII,

Flex+Drive

II

or MintDrive

II

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4-14 Input / Output MN1924

4.4.2 Encoder inputs 0-2

Location X5, X6, X7

Mating connectors: 9-pin male D-type

Pin Name Description

1 CHA+ Channel A signal

2 CHB+ Channel B signal

3 CHZ+ Index channel signal

4 Shield Shield connection

5 GND Digital ground

6 CHA- Channel A signal complement

7 CHB- Channel B signal complement

8 CHZ- Index channel signal complement

9 +5V out Power supply to encoder

Three incremental encoders may be connected to NextMove ESB, 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 7.1.7 for details of the
encoder power supply.

CHA-

CHA+

to CPU

Vcc

NextMove ESB

MAX3095

120R

10k

1

6

Shield4

Connect overall shield to

connector backshells /

shield connections.

Twisted pair

MicroFlex
FlexDrive

II

Flex+Drive

II

MintDrive

II

encoder output

5 DGND

Connect internal s hield to DGND.
Do not connect other end.

CHA-

CHA+ 1

6

‘X7’ ‘X5’

Figure 19 - Encoder channel input - typical connection from a servo amplifier

(e.g. Baldor MicroFlex, FlexDrive

II

, Flex+DriveIIor MintDriveII)

1

5

6

9