Mint NextMove PCI, NextMove PCI MN1277 Installation Manual

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MN1277 04.2001

NextMove PCI

Installation Manual

MN1277

Issue 2.3

NextMove PCI Installation Manual

MN1277 04.2001

iii

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 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 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 PCI Installation Manual

MN1277 04.2001

Safety Information

MN1277 04.2001

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 PCI Installation Manual

MN1277 04.2001

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

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vii

Manual Revision History

Issue Date BOCL Reference Comments

1.0 Nov 1999 UM00506-000 First release of Hardware Guide based on NextMove PC Manual. Updated sections are:

NextMove PCI Overview

NextMove PCI Hardware Guide

1.1 July 1999 UM00506-001 Changes for i2 Breakout Unit

1.2 Sept 1999 UM00506-002 Substantial textual amendments

2.0 Nov 1999 UM00506-003 Added detail on using the controller

2.1 March 2000 UM00506-004 Updated for NextMove PCI issue 4

2.2 August 2000 UM00506-005 Updated for Mint v4.2 release

2.3 April 2001 UM00506-006 Updates from 04.2001 errata

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MN1277 04.2001

Contents

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Read Me First ............................................................................. 1

1.1 Key to Symbols Used in this Manual.........................................................2

Product Overview ...................................................................... 3

Hardware Guide ......................................................................... 7

3.1 Operating Environment.............................................................................8

3.2 Connection to the PCB .............................................................................9

3.3 Digital I/O..................................................................................................9

3.4 Analog I/O ..............................................................................................15

3.5 Encoder Interface ...................................................................................18

3.6 Relay ......................................................................................................19

3.7 Stepper Drive Outputs ............................................................................21

3.8 CAN Bus.................................................................................................22

3.9 Reset State.............................................................................................24

3.10 LEDs.......................................................................................................25

3.11 NextMove PCI Expansion Card ..............................................................26

3.12 Miscellaneous.........................................................................................28

3.13 NextMove PCI Breakout Unit ..................................................................28

Operation and Setup................................................................ 37

4.1 Installing NextMove PCI..........................................................................38

4.2 Baldor Motion Toolkit CD........................................................................40

4.3 Configuring your System ........................................................................42

4.4 Servo Setup............................................................................................46

4.5 Stepper Setup.........................................................................................59

4.6 Methods of Programming .......................................................................61

4.7 Documentation ....................................................................................... 61

4.8 Mint.........................................................................................................62

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4.9 Motion.....................................................................................................70

Options and Accessories ........................................................ 71

5.1 NextMove PCI.........................................................................................72

5.2 NextMove PCI Expansion Card ..............................................................72

5.3 Digital Output Modules ...........................................................................73

5.4 Breakout Unit..........................................................................................74

5.5 NextMove PC System Adapter ...............................................................75

5.6 Spares ....................................................................................................75

5.7 CAN Nodes.............................................................................................76

5.8 NextMove PCI CAN Bracket Board.........................................................77

5.9 Encoder Splitter/Buffer Board .................................................................79

Specifications and Product Data ............................................ 81

6.1 Machine Control I/O................................................................................82

6.2 Miscellaneous and Mechanical Specification ..........................................83

6.3 100-Pin Connector..................................................................................84

6.4 EMC & CE Marking..................................................................................86

Trouble Shooting Guide .......................................................... 89

Bibliography............................................................................. 93

Read Me First

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1. Read Me First

Details of the symbols used throughout this document.

NextMove PCI Installation Manual

MN1277 04.2001

This manual contains information for installing and commissioning the NextMove PCI intelligent motion controller.

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 PCI by way of screw terminations.



The disk icon together with filename is used to indicate that a Mint program ( the motion control language used to program NextMove PCI ) should be downloaded to the controller.

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.

Product Overview

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2. Product Overview

A brief overview of NextMove PCI and the software tools available on the Baldor Motion Toolkit.

NextMove PCI Installation Manual

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NextMove PCI is a high speed multi-axis intelligent motion controller for use in PCI bus based PC systems.

Figure 2-1: NextMove PCI, Expansion Card and Breakout Unit

1MBaud serial comms for

high speed card to card

data transfer

High speed

serial

commun-

ications

Analog inputs4x12bit

differential 0-5V, 0-10V

+/-5V or +/-10V

Drive enable / general purpose relay

4 x Servo-amplifier demands +/-10V, 14 bit

5 x Incremental Encoders, 3 channel, 7.5x10 edges/s max.

4Axesof

closed loop

Servo control

NextMove

Motion Controller

Inputs 0-4 second function Hardware position latch & fast interrupt input

2 CAN bus 1MBaud Industrial

Local Area Networks for

smart digital drives and I/O

PCI Bus

Interface

4k by 32 bit Dual Ported

RAM for high speed

communications with

PCI bus

4 Axes of

stepper

motors

4 x Step and direction signals to control stepper drives 3MHz maximum differential.

Digital

Outputs

12 x Digital outputs, opto-isolated PNP or NPN, 12-24V, 350mA max

Digital Inputs

20 x Digital inputs, opto-isolated PNP or NPN, 12-24V. User configurable as uncommitted inputs, limit inputs, stop input.

Expansion

card

connector

16 bit expansion bus for

'next slot' expansion cards

Analog

Inputs

32 bit Digital Signal

Processor system.

Up to 8 axes of motion

control-4high

performance

closed loop servo,

4 stepper.

expandable to 12

servo or 12 stepper.

MINT or C

programming

language.

2Mb RAM.

Figure 2-2: Technical Overview

Product Overview

MN1277 04.2001

NextMove PCI features the MintTM 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 PCI 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. Installing the Mint WorkBench will also install firmware (NMPCI.OUT) for NextMove PCI. 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 PCI Installation Manual

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Hardware Guide

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3. Hardware Guide

This chapter describes in detail the hardware interface to NextMove PCI.

NextMove PCI Installation Manual

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Figure 3-1: NextMove PCI Assembly

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

•

Power is supplied to the board via the PC power supply bus

•

The atmosphere shall not contain flammable gases or vapors

•

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

Hardware Guide

MN1277 04.2001

3.2 Connection to the PCB

All of the standard interfaces are brought out on the 100 pin D-type connector mounted on the metal bracket. The PCB connector is an AMP787082-9. For the convenience of the user a kit consisting of a cable assembly and a DIN rail mounting Breakout Unit is available. There are currently two types of Breakout Unit available. The standard type uses single part connectors (Baldor part no. PCI003-

501). A unit with two part connectors (Baldor part no. PCI003-502) is also available. These are described in Section 5.4.

Figure 3-2: NextMove PCI Breakout Unit

For ease of transition from NextMove PC to NextMove PCI, a converter is available to allow

NextMove PC Breakout Unit to be used (contact factory).

See section 6.3 for connector details.

3.3 Digital I/O

There are a total of 20 general purpose digital inputs and 12 general purpose digital outputs. The digital inputs are software configurable for any one of the following functions:

•

forward limit

(end of travel) input on any axis.

•

reverse limit

(end of travel) input on any axis.

•

home input

on any axis.

•

drive error

input on any axis.

•

stop input

(controlled) on any axis.

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 edge triggered (positive and negative) and their active level.

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.

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As well as the general purpose I/O, NextMove PCI also supports fast position latch inputs (IN0 to IN3) and optionally, digital outputs for stepper control. The stepper outputs can be programmed in software as general purpose outputs. The stepper outputs are discussed in section 3.5.

3.3.1 Standard Digital Inputs

There are sixteen optically isolated standard digital inputs arranged as two banks of 8. Each bank has its own common rail that must be referred to system ground and cannot be left disconnected. Each bank can have a separate supply or voltage level.

These inputs are available on connectors X1 and X2 on the NextMove PCI Breakout Unit.

X2: Digital Inputs 4 to 11

Pin Signal Function

Chassis

Shield connection

DIG_IN_4

Digital input 4 (referenced to Common0-7)

DIG_IN_5

Digital input 5 (referenced to Common0-7)

DIG_IN_6

Digital input 6 (referenced to Common0-7)

DIG_IN_7

Digital input 7 (referenced to Common0-7)

DIG_IN_8

Digital input 8 (referenced to Common8-19)

DIG_IN_9

Digital input 9 (referenced to Common8-19)

DIG_IN_10

Digital input 10 (referenced to Common8-19)

DIG_IN_11

Digital input 11 (referenced to Common8-19)

Chassis

Shield connection

Common0-7

Common for inputs 0-7

Common8-19

Common for inputs 8-19

X1: Digital Inputs 12 to 19

Pin Signal Function

Chassis

Shield connection

DIG_IN_12

Digital input 12 (referenced to Common8-19)

DIG_IN_13

Digital input 13 (referenced to Common8-19)

DIG_IN_14

Digital input 14 (referenced to Common8-19)

DIG_IN_15

Digital input 15 (referenced to Common8-19)

DIG_IN_16

Digital input 16 (referenced to Common8-19)

DIG_IN_17

Digital input 17 (referenced to Common8-19)

DIG_IN_18

Digital input 18 (referenced to Common8-19)

DIG_IN_19

Digital input 19 (referenced to Common8-19)

Chassis

Shield connection

n/c

Not connected

Common8-19

Common for inputs 8-19

Hardware Guide

MN1277 04.2001

The digital inputs use ac opto-isolators. The switching level is 12 to 24V (supplied by the user). If the driving signal switches high with reference to a low ground, the driving signal ground should be connected to the input common. If the driving signal switches low with reference to a driving signal supply rail, the driving supply rail should be connected to the input common.

When using the NextMove PC Breakout Unit and converter board (OPT025-506) the two

banks must use USR-V+ and USR-GND. Jumpers on the converter board select which voltage

is connected to the common rails.

Figure 3-3 shows a digital input connected to high-side (PNP) driving signals.

Figure 3-3:Digital Inputs, PNP configuration

Figure 3-4 shows a digital input connected to low-side (NPN) driving signals.

Figure 3-4: Digital Inputs, NPN Configuration

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

The inputs are conditioned using low pass RC filters and Schmitt trigger buffers. An input pulse must have a duration of at least 1ms (one software scan) to guarantee acceptance by the application program when configured as edge triggered.

As with all good wiring practice, the use of screened cable is recommended.

NextMove PCI Installation Manual

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Associated Mint keywords are:

#INx, INPUTACTIVELEVEL, IN, INx, INPUTMODE, INPUTNEGTRIGGER, INPUTPOSTRIGGER, INSTATE

3.3.2 Fast Position Interrupts: Digital Inputs 0 to 3

Digital inputs

DIG_IN_0

DIG_IN_3

can be used as high speed position latches.

The inputs are available on connector X3 on the NextMove PCI Breakout Unit.

Pin Signal Function

DIG_IN_0

Digital input 0

Common0-7

Return for inputs 0-7

Chassis

Shield connection

DIG_IN_1

Digital input 1

Common0-7

Return for inputs 0-7

Chassis

Shield connection

DIG_IN_2

Digital input 2

Common0-7

Return for inputs 0-7

Chassis

Shield connection

DIG_IN_3

Digital input 3

Common0-7

Return for inputs 0-7

Chassis

Shield connection

Digital inputs 0 to 3 are sensitive to noise. The use of screened twisted pair cabling is recommended.

The fast position inputs are routed through a programmable cross point switch which allows any input to cause the position of any combination of axes to be latched within 1µs - a feature essential in high speed print registration applications. When triggered, the position is captured and a user interrupt can be triggered to handle this event.

See section ‘Fast Position Latch’ in the ‘Mint v4 Programming Guide’ for more details.

3.3.3 Digital Outputs

There are twelve opto-isolated digital outputs driven via a module fitted to NextMove PCI. Two modules types are available:

Current sourcing, ‘PNP’ Darlington with overcurrent and short circuit protection (fitted as standard).

Current sinking, ‘NPN’, open drain N-channel MOSFET.

Hardware Guide

MN1277 04.2001

Figure 3-5: Digital Outputs with Current Sourcing Module

Figure 3-6: Digital Outputs with Current Sinking Module

The outputs are available on connectors X4 and X5 on the NextMove PCI Breakout Unit.

NextMove PCI Installation Manual

MN1277 04.2001

X5: Digital Outputs 0-5

Pin Signal Function

Chassis

Shield connection

DIG_OUT_0

Digital output 0

DIG_OUT_1

Digital output 1

DIG_OUT_2

Digital output 2

DIG_OUT_3

Digital output 3

DIG_OUT_4

Digital output 4

DIG_OUT_5

Digital output 5

n/c

Not connected

n/c

Not connected

Chassis

Shield connection

USR-V+

∗∗∗∗

Output power supply power

USR-GND

Output power supply ground

X4: Digital Outputs 6-11

Pin Signal Function

Chassis

Shield connection

DIG_OUT_6

Digital output 6

DIG_OUT_7

Digital output 7

DIG_OUT_8

Digital output 8

DIG_OUT_9

Digital output 9

DIG_OUT_10

Digital output 10

DIG_OUT_11

Digital output 11

n/c

Not connected

n/c

Not connected

Chassis

Shield connection

USR-V+

∗∗∗∗

Output power supply power

USR-GND

Output power supply ground

Note that USR-GND must be tied to system ground - it must not be left disconnected. When using current sourcing outputs, the user must supply 12-24V DC between USR-V+ and USR-GND.

The current sink / source capability of the NPN and PNP outputs respectively is 50mA.

As with all good wiring practice, the use of screened cable is recommended.

Associated Mint keywords are:

OUTPUTACTIVELEVEL, OUT, OUTx

∗

This power must be supplied externally

Hardware Guide

MN1277 04.2001

3.4 Analog I/O

3.4.1 Analog Inputs

Four 12-bit resolution analog inputs are provided. The inputs are available on connector X6 on the NextMove PCI Breakout Unit.

X6: Analog Inputs

Pin Signal Function

AGND

Analog ground

AIN_0+

Analog input 0 positive input

AIN_0-

Analog input 0 negative input

Chassis

Shield connection

AGND

Analog ground

AIN_1+

Analog input 1 positive input

AIN_1-

Analog input 1 negative input

Chassis

Shield connection

AGND

Analog ground

AIN_2+

Analog input 2 positive input

AIN_2-

Analog input 2 negative input

Chassis

Shield connection

AGND

Analog ground

AIN_3+

Analog input 3 positive input

AIN_3-

Analog input 3 negative input

Chassis

Shield connection

Shielded twisted pairs should be used and connected as shown. The shield connection should be made at one end only. If the source of the signal is already grounded there is no need to connect AGND (shown dotted).

The analog inputs pass through a differential buffer and second order Butterworth filter with a 1kHz cut-off frequency. Both the filtered and unfiltered signals are converted using a multiplexed 12-bit ADC, which has four software-selectable input voltage ranges: 0-5V, ±5V, 0-10V and ±10V.

The analog inputs are sampled by Mint at a rate of 2.5kHz.

NextMove PCI Installation Manual

MN1277 04.2001

Figure 3-7: Analog Buffer and Range Selection

Differential Mode:

The analog inputs are all true differential which means that the signal is measured relative to a reference rather than the controller ground. The differential mode makes the system more immune to common mode noise picked up in the cabling.

Figure 3-8: Analog Input, Differential Connection

Associated Mint keywords are:

ADCMODE, ADC

3.4.2 Analog Outputs (Drive Command)

There are four 14bit resolution analog outputs. The outputs are available on connector X7 on the NextMove PCI Breakout Unit. By default Mint™ and the Mint™ Motion Library use the analog outputs to control servo drives. Outputs 0 to 3 correspond to axes 0 to 3 respectively.

Hardware Guide

MN1277 04.2001

X7: Drive Signals (X7)

Pin Signal Function

DEMAND_0

Demand/command signal for axis 0

AGND

Analog ground

Chassis

Shield connection

DEMAND_1

Demand/command signal for axis 1

AGND

Analog ground

Chassis

Shield connection

DEMAND_2

Demand/command signal for axis 2

AGND

Analog ground

Chassis

Shield connection

DEMAND_3

Demand/command signal for axis 3

AGND

Analog ground

Chassis

Shield connection

Demand signals are outputs to the servo amplifiers. Shielded twisted pairs should be used and connected as shown. The shield connection should be made at one end only.

The outputs have a range of ±10V (1.22mV per bit).

Outputs 0 to 3 are inverted and buffered by op-amps, and may be used to drive loads of

≥

10kΩ. The outputs are referenced to PC system ground. DAC channels 4-7 are summed with the first three outputs with 1/16

of the gain i.e. 1/16th of the DAC channel 4 output is added to the DAC channel 0 output, and so on. DAC channels 4 – 7 can therefore be used to trim channels 0 - 3 (trim range ±0.625V).

The analog output buffer circuit is shown below.

Figure 3-9: Analog Output Buffer

Associated Mint keywords are:

DACLIMITMAX, DAC, DACMODE, DACOFFSET

NextMove PCI Installation Manual

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3.5 Encoder Interface

Up to five incremental encoders may be connected to NextMove PCI. The signals are brought out onto the NextMove PCI Breakout Unit via signals X12, X13, X14, X15 and X16. These are 9-pin D-type female sockets. The shell of the connector is connected to chassis. When possible, the use of individually screened twisted pair cable is recommended.

Figure 3-10: Encoder Connector

Pin Signal Function Cabling

Encoder V+

Power to the encoder

gnd

Power and signal ground

chA

Channel A true signal

!chA

Channel A complement signal

chB

Channel B true signal

!chB

Channel B complement signal

index

Index true signal (channel I or Z or C)

!index

Index complement signal (channel I or Z or C)

chassis

Chassis connection

Shell

chassis

Screen

The encoders must provide either complementary TTL or differential line drive (RS422/RS485) signals to operate with NextMove PCI. The input circuit uses MAX3095 differential line receivers with a pull ups and terminators. Each encoder channel has inputs A, B and Index.

The encoder power rail on X9 must be connected to VCC or supplied externally

Hardware Guide

MN1277 04.2001

Figure 3-11: Encoder Line Receiver Interface

The maximum input frequency of the encoder input is 7.5 million quadrature counts per second, one count per edge. This equates to a maximum frequency for the A and B signals of 1.87MHz.

Within Mint, ‘complement loss detection’ is highlighted as an ‘encoder transition warning’ within the AXISWARNING keyword. It must be enabled with the AXISWARNINGDISABLE keyword. Associated Mint keywords are:

ENCODER, ENCODERSCALE, ENCODERVEL, ENCODERWRAP, POS, SCALE, VEL

X9: Encoder Power

Pin Signal Function

Vcc

5V power connection (from the PC)

Vcc

5V power connection (from the PC)

Encoder V+

Power to the encoder connectors (normally +5V)

Encoder V+

Power to the encoder connectors (normally +5V)

GND

Digital ground (from the PC)

GND

Digital ground (from the PC)

USR-V+

Output power supply

USR-V+

Output power supply

USR-GND

Output power supply ground

USR-GND

Output power supply ground

Note: The encoder power can be linked to Vcc to supply the encoders with +5V, provided that the total current consumption of the encoders does not exceed 500mA. For externally powered encoders, the maximum is 30V provided total current consumption does not exceed 3A.

Warning – Encoder power must be connected before switching on. If the encoders are not powered then there will be no position feedback which could cause violent motion of the motor shaft if the system is enabled.

Encoder V+ must be connected to VCC or supplied externally

USR-V+ must be supplied externally

NextMove PCI Installation Manual

MN1277 04.2001

The encoder connectors are powered from pins 3 and 4 of the power connector X9. This voltage is with respect to digital ground. This connection scheme is to allow correct powering of the encoders where the required voltage is not 5V and/or the total current exceeds 500mA. For encoders requiring 5V power at a total current, for all encoders, of 500mA or less, the encoder V+ rail may be connected to V

by linking pins 2 (VCC) and 3 (Encoder V+) of X9. A link is fitted in this position

at the factory.

Baldor CAN

Note:- Replacing issue 1 units

If replacing issue 1 breakout units, connections to pins 3, 4, 5 and 6 of the issue 1 unit power connector(J10) must be connected to pins 5 and 6 only of the issue 2 unit power connector (X9).

3.6 Relay

A single pole change-over relay is included on the card to provide a volt-free contact for system enabling or general use. The relay signals are available on the NextMove PCI Breakout Unit via connector X8.

X8: Relay and CAN Power

Pin Signal Function

CAN-V+ 1

Power input for CAN 1 network (

CAN

open

). (12-24V)

CAN-GND 1

Ground for CAN 1 network (

CAN

open

)

CAN-V+ 2

Power input for CAN 2 network (Baldor CAN) (12-24V)

CAN-GND 2

Ground for CAN 2 network (Baldor CAN)

Relay-NC

Normally closed relay connection

Relay-NO

Normally open relay connection

Relay-COM

Common relay connection

USR-V+

Output power supply power

USR-GND

Output power supply ground

Chassis

Shield connection

Only isolated CAN channels require 24V to power to opto-isolation. Non isolated CAN

channels must not be powered.

The relay pins are isolated from any internal circuits on the NextMove PCI.

Hardware Guide

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The relay is controlled by a latch, which is cleared during reset of NextMove PCI. Reset occurs on power-down, watchdog error or under control of the host PC. The relay is energized under software control. The relay is the default global error output channel.

Due to the track rating on the PCB, the relay is limited to a rating of 150mA at 24V DC. The relay should be used for voltage free signal switching and should not be used for power.

Associated Mint keywords are:

RELAY, DRIVEENABLEOUTPUT, GLOBALERROROUTPUT

3.7 Stepper Drive Outputs

Eight stepper motor control outputs are available via connectors X10 and X11.

X10/X11: Stepper Drive Outputs

Figure 3-12: Stepper Output Connectors

The stepper drive outputs can operate at up to 3MHz. The signals from the controller are at TTL levels and is converted to differential drive on a module mounted on the Breakout Unit. The differential connections are brought out on 9 pin D-type connectors to allow 360° shielding when using high step rates. Two axes are brought out on to each connector. The outputs can be connected directly to drives with single ended logic inputs by connecting the compliment of the differential signal to the drive ground.

Signal Pin Nos. Function Cabling

Step n

1,5 Step signal True

!Step n

6,9 Step signal Complement

Dir n

2,4 Direction signal True

!Dir n

7,8 Direction signal Complement

GND

3 Signal ground

chassis

Shell Screen

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The outputs may be programmed in software for the following functions:

•

Step and direction for driving stepper motor drives.

•

Digital outputs for general purpose use. See the STEPPERIO keyword for details.

The outputs are all CMOS level signals and are referred to system ground.

3.8 CAN Bus

CAN (Controller Area Network) is a 1Mb/s local area network. Two transceivers for the CAN are fitted to NextMove PCI. Access to both channels it is made via a 10 pin 2mm pin header

J11

. The

connections are as follows:

Figure 3-13: NextMove PCI CAN Header Location

Pin No. Signal

1 CAN2 RX0 (from IC) 2 to Breakout Unit 3 CAN2 TX0 (from IC) 4 to Breakout Unit 5 CAN1 RX0 (from IC) 6 to Breakout Unit 7 CAN1 TX0 (from IC) 8 to Breakout Unit 9 GND

10 +5V

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Note: the signals on this connector are referenced to the PC host, there is no isolation. As standard, jumper links are present linking pin pairs 1 and 2, 3 and 4, 5 and 6, 7 and 8. These jumpers route the CAN signals to the Breakout Unit.

Pins 9 and 10 should NEVER be connected to together.

Removing the jumpers allows connection to a bulkhead mounted drive circuit and a connector or connector pair of the required type in the next PCI slot plate. These can be RJ45 for connection to other Baldor CAN nodes or 9 pin ‘D’ connectors for connection to other networks such as

CAN

open

. A CAN bracket card is available which is suitable if the customer is intending to only

use NextMove PCI as a CAN master, since this no longer requires the Breakout Unit.

CAN connections on the Breakout Unit are one RJ45 connector for CAN2 and a 9 pin D-type for CAN1; used for connection to

CAN

open

networks. If NextMove PCI is at the end of either network

a termination resistor must be connected by fitting the termination jumper on the Breakout Unit.

A range of CAN based I/O expansion modules is available for NextMove PCI. See section 5.7 for further details.

A very low error rate of CAN communication can only be achieved with a suitable wiring scheme. The following points should be observed:

1. CAN must be connected via twisted pair cabling. The connection arrangement is normally a simple multi-point drop. The CAN cables should have a characteristic impedance of 120Ω and a delay of 5ns/m. Other characteristics depend upon the length of the cabling:

Cable length Max bit rate

Non Isolated

Max bit rate

Isolated

Specific

resistance

Conductor area

0-40m (0-157ft) 1 Mbit/s 500 kbit/s

70m

Ω

0.25-0.34mm

40m-300m (157ft-1180ft)

200 kbit/s 100 kbit/s

60m

Ω

0.34-0.60 mm

300m-600m (1180-2362ft)

100 kbit/s 50 kbit/s

40m

Ω

0.50-0.60 mm

600m-1000m (2362ft-3937)

50 kbit/s 25 kbit/s

26m

Ω

0.75-0.80 mm

2. Terminators should be fitted at each end of the network only.

3. To reduce RF emissions, and more importantly to provide immunity to conducted interference, shielded twisted pair cabling should be used. If two CAN channels are bundled in a cable then each requires a twisted pair.

4. The 0V rails of all of the nodes on the network must be tied together through the CAN cabling. This ensures that the CAN signal levels transmitted by a NextMove PCI or CAN peripheral devices are within the common mode range of the receiver circuitry of other nodes on the network.

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CAN cables are available. See the section 5.7 for details on CAN accessories.

On the Breakout Unit, CAN is available on connectors X17 and X18.

Figure 3-14: CAN Connectors

Where an isolated transceiver module is used a supply of 12-24V, 60mA is required between CANV+ and CAN-GND. Non isolated module should not be powered.

Signal Function D-type Pin RJ-45 Pin Cabling

can+

CAN data signal 7 1

can-

CAN data signal 2 2

can V+

Power to the CAN nodes 9 5

gnd

Signal ground 3 4

chassis

Screen pin 1 -

NC No connection 4,5,6,8 3,6,7,8

chassis

Screen Shell Shell

3.9 Reset State

During PC power-up, NextMove PCI is held in reset (a safe non-operational state). It will also go into reset if the 5V supply drops below approximately 4.75V in order to prevent any uncontrolled operation of any of the integrated circuits during power down.

When NextMove PCI is in reset for any reason, most of the controlled interfaces fall into known states as detailed in the following sections.

It is also possible for NextMove PCI to be in a state known as software reset. This is a safe operational state where only the bootloader firmware present on NextMove PCI is running.

Hardware and software reset states should not be confused with the Mint keyword RESET which is used to clear axis errors.

Communications

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

Dual port RAM will contain no information at power up but will be accessible by the PC. A reset during operation will cause the DPR to stay in its current state.

Digital Outputs

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

Analog Outputs

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

Stepper/Encoder ASICs

The stepper/encoder ASICs will not generate stepper pulses or register any encoder input during reset. Position will be set to zero, i.e. if the unit goes into reset all position data will be lost.

3.10 LEDs

There are four bicolour LED’s on NextMove PCI. Two LEDs, S1 and S2, are status indicators and two, C1 and C2, are CAN traffic indicators. The LED’s can be

red

green

and may be

steady

flashing

. These states are shown in the following table for the status LED’s:

Figure 3-15: Status and CAN indicator LEDs

State LED Status

No power. All off In hardware reset. All red In software reset with no errors. Cycling green In software reset with POST1 errors. Cycling red Application running successfully. S1 flashing green (slow) Application running with initialization error. S1 flashing red (slow) Asynchronous error (for example: limit switch tripped). S2 flashing red (fast) Miscellaneous error (for example: output driver not powered). S2 flashing green (fast) Reception of CAN message on CAN2 C2 flashing

POST = power on self test

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Updating controller firmware All flashing green (slow) POST executing (after reset command) All red, go off sequentially

(C1,S1,S2,C2)

There are two bicolour LED’s on the NextMove PCI Expansion card. The LED’s can be

red

green

and may be

steady

flashing

. These states are shown in the following table:

Figure 3-16: Status and CAN indicator LEDs

Expansion LED Status State

All off No power or not used. Check main card LEDs. All red In hardware reset. Alternately flashing green In software reset with no errors. Alternately flashing red In software reset with POST2 errors. S1 flashing green (slow) Application running successfully. S1 flashing red (slow) Application running with initialization error. S2 flashing red (fast) Asynchronous error (for example: limit switch tripped). S2 flashing green (fast) Miscellaneous error (for example: output driver not powered).

3.11 NextMove PCI Expansion Card

A 64-pin socket on the top edge of NextMove PCI provides a 16-bit expansion bus. The Expansion Card has the same set of I/O as the main board (except for CAN) and uses the same Breakout Unit and cabling. NextMove PCI can directly support one or two Expansion Cards. Connection to the cards is made through a bridging PCB (the

Expansion Interconnect

) that plugs across the top of the

main and Expansion Cards.

POST = power on self test

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Figure 3-17: NextMove PCI Expansion Card

Notes:

The Expansion Interconnect is polarized to prevent mis-insertion. If two Expansion Cards are used then the Dual Interconnect board is needed. It highly advisable to exert a retaining force on the interconnect board, for example with a metal bracket and non-conductive padding. See section 5.2 for details on Expansion Card accessories.

The NextMove PCI Expansion card is available in 4 or 8 axis variants, providing an additional 4 or 8 servo / stepper axes. Each expansion card also adds 20 digital inputs, 12 digital outputs, 4 analog inputs, 4 analog outputs (drive command) and a relay.

The following sections of the Hardware Guide chapter are applicable to the expansion card as well as the main card:

3.2 Connection to the PCB

3.3 Digital I/O

3.4 Analog I/O

3.5 Encoder Interface

3.6 Relay

3.7 Stepper Drive Outputs

3.13 NextMove PCI Breakout Unit

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3.12 Miscellaneous

3.12.1 Emulator Connection

An 11-pin footprint on the rear of the card marked ‘ICE’ provides access to the processor for boundary scan emulation. To connect the Texas Instruments emulator pod, a two row 12 pin 0.1” pitch surface mount pin header with pin 8 missing must be fitted. The connections are those specified by Texas Instruments. See the ‘Mint v4 Embedded Programming Guide’ for details on emulator based system debugging.

3.12.2 System Watchdog

The system watchdog is a hardware protection method so that in the event of a firmware or ‘C’ program malfunction, the controller is put into software reset. It may be disabled during low level code development and debugging. After reset it is possible to determine that the reset was caused by the system watchdog and take different action from normal. See the ‘Mint v4 Embedded Programming Guide’ and the ‘Mint v4 PC Programming Guide’ for details.

3.13 NextMove PCI Breakout Unit

Two Breakout Units are available for use with the NextMove PCI Expansion Card, one with single part screw down terminals and the other with two part screw down terminals. The Breakout Unit is approximately 292mm (11.50 inches) long by 70mm (2.76 inches) wide by 62 mm (2.45 inches) high. The layout of the board is shown in Figure 3-18. It fits on to either a 35mm symmetric DIN rail (EN 50 022, DIN 46277-3) or a G-profile rail (EN 50 035, DIN46277-1). The Breakout Unit connects to NextMove PCI using the 100-Way cable.

Figure 3-18: NextMove PCI Breakout Unit Assembly

This section provides connection details for each connector. For further information, see the earlier detailed sections on each functional block.

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3.13.1 X1 - Inputs 12-19

Pin Signal Function

Chassis

Shield connection

DIG_IN_12

Digital input 12 (referenced to Common8-19)

DIG_IN_13

Digital input 13 (referenced to Common8-19)

DIG_IN_14

Digital input 14 (referenced to Common8-19)

DIG_IN_15

Digital input 15 (referenced to Common8-19)

DIG_IN_16

Digital input 16 (referenced to Common8-19)

DIG_IN_17

Digital input 17 (referenced to Common8-19)

DIG_IN_18

Digital input 18 (referenced to Common8-19)

DIG_IN_19

Digital input 19 (referenced to Common8-19)

Chassis

Shield connection

n/c

Not Connected

Common8-19

Common for Inputs 8-19

3.13.2 X2 - Inputs 4-11

Pin Signal Function

Chassis

Shield connection

DIG_IN_4

Digital input 4 (referenced to Common0-7)

DIG_IN_5

Digital input 5 (referenced to Common0-7)

DIG_IN_6

Digital input 6 (referenced to Common0-7)

DIG_IN_7

Digital input 7 (referenced to Common0-7)

DIG_IN_8

Digital input 8 (referenced to Common8-19)

DIG_IN_9

Digital input 9 (referenced to Common8-19)

DIG_IN_10

Digital input 10 (referenced to Common8-19)

DIG_IN_11

Digital input 11 (referenced to Common8-19)

Chassis

Shield connection

Common0-7

Common for Inputs 0-7

Common8-19

Common for Inputs 8-19

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3.13.3 X3 - High Speed Inputs

Pin Signal Function

DIG_IN_0

Digital input 0

Common0-7

Reference for inputs 0-7

Chassis

Shield connection

DIG_IN_1

Digital input 1

Common0-7

Reference for inputs 0-7

Chassis

Shield connection

DIG_IN_2

Digital input 2

Common0-7

Reference for inputs 0-7

Chassis

Shield connection

DIG_IN_3

Digital input 3

Common0-7

Reference for inputs 0-7

Chassis

Shield connection

3.13.4 X4 - Outputs 6-11

Pin Signal Function

Chassis

Shield connection

DIG_OUT_6

Digital output 6

DIG_OUT_7

Digital output 7

DIG_OUT_8

Digital output 8

DIG_OUT_9

Digital output 9

DIG_OUT_10

Digital output 10

DIG_OUT_11

Digital output 11

n/c

Not connected

n/c

Not connected

Chassis

Shield connection

USR-V+

∗∗∗∗

Output power supply power

USR-GND

Output power supply ground

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3.13.5 X5 - Outputs 0-5

Pin Signal Function

Chassis

Shield connection

DIG_OUT_0

Digital output 0

DIG_OUT_1

Digital output 1

DIG_OUT_2

Digital output 2

DIG_OUT_3

Digital output 3

DIG_OUT_4

Digital output 4

DIG_OUT_5

Digital output 5

n/c

Not connected

n/c

Not connected

Chassis

Shield connection

USR-V+

∗∗∗∗

Output power supply power

USR-GND

Output power supply ground

3.13.6 X6 - Analog Inputs

Pin Signal Function

AGND

Analog Ground

AIN_0+

Analog input 0 positive input

AIN_0-

Analog input 0 negative input

Chassis

Shield connection

AGND

Analog Ground

AIN_1+

Analog input 1 positive input

AIN_1-

Analog input 1 negative input

Chassis

Shield connection

AGND

Analog Ground

AIN_2+

Analog input 2 positive input

AIN_2-

Analog input 2 negative input

Chassis

Shield connection

AGND

Analog Ground

AIN_3+

Analog input 3 positive input

AIN_3-

Analog input 3 negative input

Chassis

Shield connection

∗

This power must be supplied externally

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3.13.7 X7 – Command Signals

Pin Signal Function

DEMAND_0

Command signal for axis 0

AGND

Analog ground

Chassis

Shield connection

DEMAND_1

Command signal for axis 1

AGND

Analog ground

Chassis

Shield connection

DEMAND_2

Command signal for axis 2

AGND

Analog ground

Chassis

Shield connection

DEMAND_3

Command signal for axis 3

AGND

Analog ground

Chassis

Shield connection

3.13.8 X8 - PSU connections

Pin Signal Function

CAN-V+ 1

Power input for CAN 1 network (

CAN

open

)

CAN-GND 1

Ground for CAN 1 network (

CAN

open

)

CAN-V+ 2

Power input for CAN 2 network (Baldor CAN)

CAN-GND 2

Ground for CAN 2 network (Baldor CAN)

Relay-NC

Normally closed relay connection

Relay-NO

Normally open relay connection

Relay-COM

Common relay connection

USR-V+

Output power supply power

USR-GND

Output power supply ground

Chassis

Shield connection

USR-V+ must be supplied externally

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3.13.9 X9 - Encoder Power

Pin Signal Function

Vcc

5V power connection (from the PC)

Vcc

5V power connection (from the PC)

Encoder V+

Power to the encoder connectors (normally +5V)

Encoder V+

Power to the encoder connectors (normally +5V)

GND

Digital ground (from the PC)

GND

Digital ground (from the PC)

USR-V+

Output power supply

USR-V+

Output power supply

USR-GND

Output power supply ground

USR-GND

Output power supply ground

3.13.10 X10, X11 - Steppers

Figure 3-19: Stepper D-types Connector

Signal Pin Nos. Function Cabling

Step n

1,5 Step signal true

!Step n

6,9 Step signal complement

Dir n

2,4 Direction signal true

!Dir n

7,8 Direction signal complement

GND

3 Signal ground

chassis

Shell screen

Encoder V+ must be connected to VCC or supplied externally

USR-V+ must be supplied externally

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3.13.11 X12, X13, X14, X15, X16 - Encoders

Figure 3-20: Encoder Connector

Pin Signal Function Cabling

Encoder V+

∗∗∗∗

Power to the Encoder (not always 5V)

gnd

Power and signal ground

chA

Channel A true signal

!chA

Channel A complement signal

chB

Channel B true signal

!chB

Channel B complement signal

index

Index true signal (channel I or Z or C)

!index

Index complement signal (channel I or Z or C)

chassis

Chassis connection

Shell

chassis

Screen

∗

This power rail must be connected to VCC or supplied externally

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3.13.12 X17, X18 - CAN

Figure 3-21: CAN Connectors

Signal Function D-type Pin RJ-45 Pin Cabling

can+

CAN data signal 7 1

can-

CAN data signal 2 2

can V+

Power to the CAN Nodes 9 5

gnd

Signal ground 3 4

chassis

Screen pin 1 -

NC No connection 4,5,6,8 3,6,7,8

chassis

Screen Shell Shell

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Operation and Setup

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4. Operation and Setup

This chapter is step by step guide to setting up a NextMove PCI servo and stepper control system. Basic familiarity with PC’s and the Windows environment is assumed.

Installing NextMove PCI into the PC.

Introduction to servo systems and tuning. Determining system gains and fine-tuning.

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4.1 Installing NextMove PCI

NextMove PCI can be installed into an AT style personal computer that has a free 7 inch PCI card slot. The Baldor Motion Toolkit CD supports the following operating systems only: Windows 95, Windows 98 and Windows NT version 4.

4.1.1 Placing the Card In the Computer

Before placing the card in the computer, carry out the following steps:

1. Exit any applications that are running and close all windows.

2. Turn off the power and unplug all power cords.

3. Remove the cover from your computers system unit.

4. Locate an unused PCI slot.

Note that before touching the card, be sure to discharge static electricity from hands by

touching a grounded metal surface, such as the screw on an electrical outlet’s plate cover.

Alternatively, wear an earth strap while handling the card.

5. Remove the cover from the slot, and save the screw for use later.

6. Discharge any static electricity from hands.

7. Remove the card from its protective wrapper. Do not to touch the gold contacts at the bottom of the card.

8. Align the bottom of the card (gold contacts) with the slot and press the card firmly into the socket. When correctly installed, the card locks into place.

9. Make sure that the top of the card is level (not slanted) and that the hole on top of the card’s metal bracket lines up with the screw hole at the back of the slot.

10. Anchor the card in place using the screw removed earlier.

11. Replace the computer cover and screws.

12. Reconnect any cables and power cords that were disconnected or unplugged and turn on the computer.

4.1.2 Installing Software

NextMove PCI is a plug and play device. Once the card has been inserted into the PC it will be detected the next time the PC is turned on. This detection process varies depending on the operating system running on the PC.

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Windows 95/98/ME:

As Windows 95/98/ME starts it will display a dialog box indicating that it has detected the presence of a new PCI card, the ‘Update Device Driver Wizard’. This utility will allow a device driver to be selected for NextMove PCI.

Figure 4-1: Windows 95 ‘Update Device Driver Wizard’

Place the Baldor Motion Toolkit CD into the CDROM of the computer. Select ‘Next’ and then manually specify the following directory which contains the device driver for NextMove PCI:

DRIVERS\NMPCI\WIN9x

Once the device driver has been selected Windows will continue to load.

Windows NT:

Under Windows NT there will be no indication that a new card has been installed. The device driver for NextMove PCI will need to be installed from the Baldor Motion Toolkit. Place the Baldor Motion Toolkit CD into the CDROM of the computer. The CD should auto-run and display the ‘Welcome to the Baldor Motion Toolkit’ page. If auto-run is disabled, browse the CD and double click the file SETUP.HTM.

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Select ‘NextMove PCI’ from the menu and select the ‘NextMove PCI NT Device Driver’ option on the NextMove PCI page of the Baldor Motion Toolkit. Once the device driver has been installed it will be necessary to restart your PC. This will load the device driver and enable communication with NextMove PCI.

If upgrading your device driver from a previous release, you must uninstall the old device

driver first. To do this, select ‘NextMove PCI Device Driver’ from the ‘Add/Remove

Programs’ group in Windows Control Panel.

The driver can also be found in the following directory.

DRIVERS\NMPCI\WINNT

Windows 2000:

The Windows NT device driver can be used under Windows 2000.

After installing the NextMove PCI card, turn the PC on. Enter the BIOS and disable the ‘Plug and Play’ option or select ‘Operating system is not plug and play compatible’. Exit the BIOS and let Windows 2000 boot.

Once Windows 2000 has loaded it will enter the Hardware Wizard.

•

Select 'Search for a suitable device driver', hit 'Next'.

•

Un-check all search locations, hit 'Next'.

•

Select the 'Disable the device' option, hit 'Finish'.

Restart the PC, the hardware wizard should not re-appear.

The Windows NT device driver then needs to be installed from the Baldor Motion Toolkit CD. Place the Baldor Motion Toolkit CD into the CDROM of the computer. The CD should auto-run and display the ‘Welcome to the Baldor Motion Toolkit’ page. If auto-run is disabled, browse the CD and double click the file SETUP.HTM. Using the Baldor Motion Toolkit install the NMPCI device driver, either by using the HTML front end or directly from CD Drive\Mint v4\Installation\NT NMPCI Device Driver.

The WinNT Device Driver works under Win2000, but the Device Manager may report a conflict and display the device along with a ! symbol. This is only because the Device Driver is not native to Win2000, and does not affect functionality.

4.2 Baldor Motion Toolkit CD

Place the Baldor Motion Toolkit CD in the CD drive of the PC. The CD will auto-run and display the home page. If auto-run is disabled, browse the CD and double click the file ‘SETUP.HTM’.

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Figure 4-2: Baldor Motion Toolkit - Home Page

Select the NextMove link and then select the ‘NextMove PCI’ option. This opens the page that allows the various NextMove PCI related applications to be installed.

Figure 4-3: Baldor Motion Toolkit – NextMove PCI page

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The

Mint WorkBench

is the IDE and user interface for communicating with a Mint controller.

Installing the Mint WorkBench will also install firmware (NMPCI.OUT) for NextMove PCI. The

Mint Configuration Tool

is a rapid getting started and configuration utility designed for use with a number of Mint v4 controllers. The rest of this chapter makes use of both of these applications and it is recommended that both of these are installed.

4.3 Configuring your System

This section shows you how to configure your system and check the system wiring. The Mint Configuration Tool allows easy setup of NextMove PCI and allows operational tests to be performed on the system.

A typical closed loop positioning system can be broken down into three elements:

Position controller

– performs real time positional control of the motor(s), stores the

application program and communicates with the user and other control equipment.

Servo amplifier

– takes command signals from the position controller to control the torque

or speed of the motor/actuator.

Motor/actuator

– translates electrical power from the servo amplifier into rotary or linear movement. The motor is fitted with a position sensor that feeds the output position back to the controller.

The controller works by sampling the position of the motor at regular intervals and comparing this position with its target position. It then instructs the amplifier to drive the motor to correct any positional error. This process is repeated typically 1000 times per second to ensure that the motor is always in the correct position.

4.3.1 Minimum System Wiring Example

The following section is a guide to setting up a minimum system. A minimum system is one where the controller and drives are configured to work with as little external wiring as possible. It is recommended that motors are tested and set up ‘on the bench’ and not within the machine.

This step-by-step example covers setting-up a system with one servo axis and one stepper axis. Connections to the controller are made via the 100-way cable assembly and din rail mounted Breakout Unit (supplied as an option). Figure 4-4 is a simplified wiring diagram for the two axis system mentioned above. It should be noted that this is not the only possible configuration. It is important to read the associated text before attempting the set-up. For detailed wiring information, see section 3.

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Figure 4-4: Minimum System Wiring

The following table shows the minimum pin connections:

Breakout

Unit

Connector

Name of

Signal

Function Connection on Drive

X7: 1

Command0

Command signal for axis 0

command+

input

X7: 2

agnd

Reference for analog signals

command-

input

X13

encoder

Position feedback

encoder out

output.

Or direct from motor

X1: 2

dig_in_12

Error input

error

output

X10: 1 & 6

step0

Step output for stepper motor axis 4

step

input

X10: 2 & 7

dir0

Direction output for stepper motor axis 4

direction

input

X8: 7

relay-com

Common connection of relay

enable

input

X8: 6

relay-no

Normally open connection of relay Amplifier/Digital Ground

4.3.2 Starting with the Mint Configuration Tool

Start the Mint Configuration Tool by clicking the icon of the same name which can be found in the ‘Mint v4’ program group.

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Figure 4-5: Mint Configuration Tool Start Up Page

Select ‘Next’ and proceed to the ‘Controller Type Select’ page. NextMove PCI should have been found automatically and will appear in the ‘Controller Select’ dropdown. If you have more than one NextMove PCI then select the card number from the list. The card numbers are allocated automatically by the PCI and cannot be changed. If NextMove PCI does not appear in the list then refer to trouble shooting in section 7.

Figure 4-6: MCT Select Controller Drop-down

Clicking ‘Next’ will download firmware to the controller and bring up the ‘Axes Selection’ page. From here, you can decide which axes you wish to configure in the Mint Configuration Tool. This example assumes a 4 axis NextMove PCI. We will configure 2 axes, 1 servo and 1 stepper.

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Figure 4-7: MCT Axis Configuration

From the list given, axis 0 has been selected as a servo and axis 1 as a stepper.

NextMove PCI is available in a number of axis variants: 1, 2, 3, 4 or 8 axes. For the 1, 2, 3 and 4 axis cards, each axis, labeled 0 to 3, can be configured as a servo axis or a stepper axis. For the 8 axis card, axes 0 to 3 are servo axes and axes 4 to 7 are stepper axes. The axes selection screen will show the current configuration of each axis and the possible configurations. The Mint keyword VIEW CONFIG can also be used to show similar information. See the Mint v4 Advanced Programming Manual for further details on axis variants and mappings.

Click ‘Next’ to move to the ‘Scale Parameters’ page. Here you should set the scale factor for each axis.

Figure 4-8: MCT Scale Settings

Mint defines all positional and speed related motion keywords in terms of encoder quadrature counts for servo motors or steps for stepper motors. The scale factor allows the system to be scaled to your own units to suit your application. The diagram below shows the effect of scaling on positional information:

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Figure 4-9: The Effect of Scaling on Positional Information

In an XY application, for example, you may want to define all positions in millimeters or inches.

For each servo axis, either manually enter a scale factor for ‘Counts per user unit’ or select ‘Counts per revolution’ and select the number of lines on the encoder. For each stepper axis, either manually enter a scale factor for ‘Steps per user unit’ or select ‘Steps per revolution’ and select the number of steps per revolution.

4.4 Servo Setup

Clicking ‘Next’ brings up the ‘Test Select’ screen. In order to perform some basic tests on the system wiring, select ‘Perform Axes Configuration Test’.

The first test checks that the drive enable is correctly wired. By default NextMove PCI does not associate any physical output with a drive enable. In this example the relay will be used as the drive enable channel. Select ‘Relay0’ from the drop down list.

Figure 4-10: MCT Drive Enable Channel Drop-down

The assigned drive enable channel allows NextMove PCI to shut down the drive in the event of an error. Clicking the ‘Drive Enable’ button should enable the drive and the ‘Drive Disable’ button should disable the drive. If this is not the case, then the wiring and drive set-up should be checked.

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Figure 4-11: MCT Drive Enable Test

The next test checks that the command and direction signals to the drive. A positive command signal should result in a positive encoder change and a negative command signal should result in a negative encoder change.

Figure 4-12: MCT Command Test

If the encoder runs in the opposite direction when a command voltage is applied then the system may be re-wired or the ‘Advanced Encoder Settings’ button can be used to modify the encoder settings.

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Figure 4-13: MCT Advanced Encoder Mode Settings

If the position does not change then check the following:

•

The encoder cable is connected to the correct encoder input.

•

The encoder has power and is correctly wired.

If the motor does not move, check the following:

•

The amplifier is enabled.

•

There is a voltage output from the

command+

output.

4.4.1 Tuning a Servo Drive

At the lowest level of control software, instantaneous axis position demands produced by the controller software must be translated into motor demands. This is achieved by closed loop control of the motor. The motor is controlled to minimize the error between demand and actual position measured with an incremental encoder.

Every 1ms (or optionally 500us or 200us using the

LOOPTIME

keyword) the controller compares desired and actual positions and calculates the correct demand for the motor. The corrective signal is calculated by a PIDVFA (Proportional, Integral, Derivative, Velocity Feedback, Velocity Feed forward and Acceleration Feed forward) algorithm.

Control could be achieved by applying a signal proportional to the error alone, but this is a rather simplistic approach. Imagine that there is a small error between demanded and actual position. A proportional controller will simply multiply the error by some constant and apply the result to the motor via an amplifier. If the gain is too low, then the motor will not hold positional. As the gain is increased, the motor will present more resistance to positional error, but oscillations will increase in magnitude until the system becomes unstable.

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time

velocity

acceleration/deceleration rate ACCEL

axis speed during move SPEED

units of measure set by SCALE

Ideal trapezoidal velocity profile

time

velocity

Typical actual velocity profile

Overshoot

Following error (positional lag)

Underdamped Good Ideal

Figure 4-14: Velocity Profiles

To reduce the onset of instability a damping term is incorporated in the servo loop algorithm, called velocity feedback gain. Velocity feedback acts to resist rapid movement of the motor and hence allows the proportional gain to be set higher before vibration sets in. (In some applications, the velocity feedback is handled by the amplifier, called a velocity servo). The effect of too high proportional gain, or too low velocity feedback gain is illustrated by the "Under damped" line in Figure 4-14.

In NextMove PCI, an alternative damping method is provided in the form of the derivative of the error signal. Derivative action has the same effect as velocity feedback if the velocity feedback and feedforward terms are equal. In torque controlled systems, derivative action is generally the preferred term.

Below is a description of the servo loop terms and their effect on the response of an axis.

Proportional Gain

: This acts directly on the difference between the actual position of the axis and the desired position (following error). The larger the proportional gain the faster the axis will respond, however large values of proportional gain will introduce oscillation and result in a large settling times or in a worse case instability of the axis. Conversely, a small value of proportional gain will result in the axes responding slowly and never reaching the desired position.

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Derivative Gain

: This acts on the rate of change of following error. This term will speed up the response of an axis to the initial change in demand and reduce overshoot. As this term acts on the rate of change of following error when the axis is stationary the control effort generated by the derivative term should be zero. However in reality as servo axes are never truly at rest a large value of derivative gain will cause the axis to oscillate. In a worse case, the derivative term can introduce oscillation during motion which can lead to instability in the axis.

Integral Gain

: This acts on the accumulated following error so that the steady state following error of an axis may be reduced to zero. This term is generally slow to respond as accumulated following error takes time to become large enough to be significant in the servo loop. Using a large value of integral gain will cause oscillation and instability in the axis. Most servo axes are very sensitive to integral gain and generally can only cope with a very small value. Because of this, the size of the demand caused by the integral term can be limited which allows a larger value to be used without fear of introducing instability during motion.

Velocity Feedback

: This acts on the actual velocity of the axis. This term provides damping and will slug the response of the axis. This helps in reducing overshoot. If the effect of the velocity feedback term is dominant in the control law this will lead to instability in the axis.

Velocity Feedforward

: This acts on the demand velocity as generated by the profiler. As such this term cannot introduce steady state instability. This term can be used to pull in any following error when the axis is moving at a constant velocity.

Acceleration Feedforward

: This acts on the demand acceleration as generated by the profiler. As with velocity feedforward this term cannot introduce steady state instability. This term can be used to pull in any following error when the axis is moving at a constant acceleration.

Two types of servo amplifiers may be used with the controller:

1. Current or torque amplifiers use the demand signal to control the current flowing in the motor

armature and hence the torque of the motor.

2. Velocity controlled amplifiers (velocity servo) use the demand signal as a servo speed reference.

For general purpose applications, the torque amplifier is cheaper and simpler to set up, but the velocity servo gives better control, especially in high performance applications. For torque amplifiers, velocity feedback must be used to stabilize the system, but this is not normally required for a velocity servo since it incorporates its own internal velocity feedback.

A block diagram of the complete control loop, showing controller, amplifier, motor and gearbox is presented below. The amplifier / servo may be a simple current amplifier, or incorporate internal velocity feedback via a tachometer.

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Figure 4-15: Servo Loop Block Diagram

The controller has six terms incorporating proportional, derivative, velocity feedback/feed forward, integral and acceleration feed forward gains. The equation of the loop closure algorithm is as follows:

Command = KP.e + KD.

∆∆∆∆e/∆∆∆∆ττττ

- KV.v + KF.V + KI.

ΣΣΣΣ

e + KA.A

Terms Description

Proportional servo loop gain

Derivative of error

Velocity feedback gain

Velocity feed forward gain

Integral gain

Acceleration feed forward gain

Following error (quad counts)

Actual axis velocity (quad counts/sample time)

ττττ

Servo update period (sample time)

Demand axis velocity (quad counts/sample time)

Demand axis acceleration (quad counts/sample time

)

Tuning the closed loop involves selecting values for some or all of the terms KP, KD, KI, KV,

and KA to provide the best performance for a particular motor/encoder combination and load inertia. In view of the diversity of applications, these values all default to zero.

Two other functions, the

KINTLIMIT

and

DACLIMITMAX

are used to control the

command

output.

KINTLIMIT

determines the maximum value of the effect of integral action, KI.

ΣΣΣΣ

e. This is specified as a percentage (%) of the full scale demand output in the range of ±10V. Therefore if the integration limit = 25, the maximum effect of integral action is ±2.5V.

KVELFF Velocity Feedforw ard

Profile Generator

KACCEL Acceleration Feedforw ard

KPROP Proport ional Gain

KINT Integral Gain

KDERIV Derivati ve Gain

DACLIMITMAX Clip DAC output

Power Amp

Servo Motor

KVEL Velocity Feedback

Measured Velocity

Demand Position

Demand Velocity

Demand Acceleration

Measured Position

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DACLIMITMAX

determines the maximum value of the demand output as a percentage of the full

scale demand. Therefore if

DACLIMITMAX = 50

, the maximum demand output will be ±5V.

Tuning terms can be controlled in Mint using the following keywords:

Keyword Abbreviation Description

DACLIMITMAX DCX

Limit maximum DAC output

KPROP KP

Proportional gain

KDERIV KD

Derivative gain

KINT KI

Integral servo loop gain

KINTMODE KIM

Integration mode during motion

KINTLIMIT KIL

Range limit for integrator % of max DAC output

KVEL KV

Velocity feedback gain

KVELFF KF

Velocity feedforward gain

KACCEL KA

Acceleration feedforward gain

4.4.2 Selecting Servo Loop Gains

All servo loop parameters default to zero, so the motor will have no power applied to it on power up. Most servo amplifiers can be set up in either current (torque) control mode or velocity control mode. The procedure for setting system gains differs slightly for each.

In order to check that the encoder and motor are wired up correctly, it is recommended that the motor is tested and commissioned ‘on the bench’ and not in the machine (the motor or gearbox shaft should be in free air).

The Mint Configuration Tool allows online tuning of the position loop. Continuing the example setup from section 4.4, proceed to the ‘Servo Tuning’ page. The ‘Position Loop Tuning’ tab allows tuning terms to be entered and a sample move performed. Once the move is complete, motion data is uploaded from the controller which allows the response of the axis to be seen.

The ‘Following Error Fatal’ value is the maximum permissible error between the axis desired position and the axis measured position. If an axis becomes unstable, when it exceeds the maximum following error, it will be disabled. Because of this, the maximum following error should be set at a safe value. If an error occurs, the ‘Clear Errors’ button needs to be pressed.

Figure 4-16: MCT Setting Fatal Following Error Limit

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Figure 4-17: MCT Tuning Terms are Entered in the ‘Gain Parameters’ Area

Figure 4-18: MCT Tuning Move

The 'rules of thumb' presented in the following sections for setting system gains, while adequate to get the system moving, will not provide the optimum response without further fine tuning of the system gains. Due to the number of parameters involved in tuning motors it is necessary to have a ‘feel’ for the effect that changing each gain term will have on the performance of an axis. In order to achieve an acceptable dynamic response, high gain values may be required, but these same values may cause the motor to hunt (a buzzing noise due to the motor vibrating on one encoder edge) when stationary. This can cause the machine to vibrate when at rest, especially if there is elasticity in the transmission such as a belt drive.

Further tuning may be carried out using the Mint WorkBench which provides a similar tuning interface to the Mint Configuration Tool.

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Figure 4-19: Mint WorkBench Tuning

After initial tuning has been completed, click ‘Next’ to proceed to the ‘Jog and Direction Test’ page. This allows a final check of system operation by jogging axis in either direction at selectable speeds, acceleration and deceleration rates.

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Figure 4-20: MCT Jog Test

4.4.3 System Gains for Current Control by Empirical

Method

After having confirmed that the encoder and motor are correctly wired, start applying some velocity feedback,

KVEL

. Start with a value of 1 and increase it until you feel some resistance in the motor.

For some motors it may be necessary to apply fractional gains; all gain terms are floating point numbers. Once the feedback gain has been set, apply some proportional gain,

KPROP

. Start off with a value which is a quarter of the feedback gain. Select a tuning move such as the step response and view the results of the motion.

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Figure 4-21: MCT Step Move Plot

If the motor starts to vibrate, increase the velocity feedback gain (damping),

KVEL

, or decrease the

proportional gain,

KPROP

. Increase proportional gain,

KPROP

, until the motor shaft becomes stiff.

Finally, set the velocity feed forward gain,

KVELFF

, to the same value as the velocity feedback gain,

KVEL

An alternative to using

KVEL

and

KVELFF

is to use the derivative term,

KDERIV

has

exactly the same effect on the system dynamics as

KVEL

when

KVEL=KVELFF

Figure 4-22: MCT Sinusoidal Move Plot

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4.4.4 System Gains for Velocity Control

Velocity controlled drives incorporate the velocity feedback term in the amplifier which provides system damping and therefore it is usually sufficient to have

KVEL = KDERIV = 0

on the controller. Usually, the value of the proportional gain,

KPROP

, will be less than with an equivalent current controlled system. Often a fractional value of proportional gain gives the best response. For example

KPROP=0.1

compared with 2 for current controlled drives.

Correct setting of the velocity feed forward gain,

KVELFF

, is important to get maximum response from the system. This is best performed using a storage oscilloscope (or the NextMove WorkBench) to record the tachometer output for fast point-to-point moves. This enables velocity/time profile for the motor to be seen in order to monitor actual acceleration and overshoot.

Referring to the servo loop block diagram, the velocity feed forward term is a block, which takes the instantaneous speed demand from the profile generator and adds this to the output block. Because

KVELFF

is a feed forward term, a very important difference between this and the other terms exists.

KVELFF

is outside the closed loop and therefore does not have an effect on system stability. This means that the term can be increased to maximum without causing the motor to oscillate, provided that the other terms are set-up correctly.

In practice however, a very high value of

KVELFF

is of no benefit to system performance. Instead,

it should be set such that a demand of

RPM from the profile generator results in a demand output to

the velocity drive, which gives x RPM on the motor shaft (a 1:1 relationship).

When set-up correctly,

KVELFF

will cause the motor to move at the demand speed from the profile generator. This is true without the PID terms in the closed loop doing anything except compensating for small errors in the position of the motor due to analog drift. This gives faster response to changes in demand speed, with lower following errors.

Example calculation of KVELFF:

In order to calculate the correct value for

KVELFF

, you need to consider the workings of the servo loop closure algorithms. In the servo loop, speeds are expressed in quadrature counts/servo loop closure time. For instance, a speed of 100 is 100 counts every 1ms with NextMove PCI (note that the default loop closure time is 1ms).

In this example the velocity of the servo is 3000RPM with a +10V input, and the encoder has 1000 counts per revolution.

At 3000RPM we require an analog voltage of +10V. 3000RPM relates to:

3000

50= revs per second

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Now the number of quadrature counts per loop closure time can be calculated by using the expression:

speed in rev per sec * encoder line count * 4

number of loop closures per second

The factor of 4 is included since the controller counts every edge of the pulse train coming from the encoder A and B channels, which gives four times better resolution than the number of lines.

50 1000 4 1000 200**/

quadrature counts per servo lop closure time

The DAC output has a resolution of 12 bits over the range -10V to +10V, therefore +10V = 2048 counts.

The feed forward term is therefore given by:

KVELFF

2048

200

10 24.

Increasing

KVELFF

above the calculated value will cause the controller to have a following error

ahead of the desired position. Decreasing

KVELFF

below this value will cause the controller to have a more normal following error behind the desired position. The calculated value above should give zero following error in normal running.

It is possible to investigate the effect of velocity feed forward gain by jogging the motor at constant speed and monitoring the axis following error for different values of

KVELFF

. When attempting this, make sure that there is zero integral gain since this will cause the following error to tend to zero under steady state conditions, thereby negating the effect of changes in

KVELFF

4.4.5 Eliminating Steady-State Errors

In systems where precise positioning accuracy is required, it is often necessary to position to within one encoder count. Proportional gain,

KPROP

, is not normally able to achieve this because a very small following error will only produce a small demand for the amplifier which may not be enough to overcome mechanical friction (this is particularly so for current controlled systems). This error can be overcome by applying some integral gain.

The integral gain,

KINT

, works by accumulating following error over time to produce a demand

sufficient to move the motor into the zero following error position.

KINT

can therefore also overcome errors caused by gravitational effects, such as vertically moving linear tables, where with current controlled drives, a non-zero

command

output is required to achieve zero following error.

Particular care is required when setting

KINT

since a high value can cause instability during moves.

The effect of

KINT

should be limited by setting the maximum range of the integration

(

KINTLIMIT

) to the minimum value that is sufficient to overcome friction or static loads.

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Typical values are:

KINTLIMIT = 5 KINT = 0.1

where

KINTLIMIT

limits the integral term to 5% of the full DAC output range.

KINT

is usually a

factor of 10 less than proportional gain,

KPROP

. With NextMove PCI, the integrator can be set to

operate in various modes:

1. The integrator is always applied.

2. The integrator is only applied during periods of constant velocity.

3. The integrator is only applied when the axis is at rest.

This functionality is set using the

KINTMODE

keyword.

4.5 Stepper Setup

The procedure for setting up a minimum stepper drive system is very much simpler than that for the servo system. The open loop control means there are no gains to set and there are no encoders.

Using the Mint Configuration Tool example, proceed to the ‘Drive Enable Test’ page.

In order to check that the motor is wired up correctly, it is recommended that the motor is tested and set up ‘on the bench’ and not when installed in the machine.

By default NextMove PCI does not associate any physical output with a drive enable. In this example the relay will be used as the drive enable channel. Select ‘Relay0’ from the drop down list.

Figure 4-23: MCT Drive Enable Channel Drop-down

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Figure 4-24: MCT Drive Enable Test

Click ‘Next’ to proceed to the ‘Jog and Direction Test’ page. This allows a final check of system operation by jogging axis in either direction at selectable speeds, acceleration and deceleration rates.

Figure 4-25: MCT Jog Test

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4.6 Methods of Programming

NextMove PCI can be programmed using several different languages. These are:

Language Location of Program Description

Mint On Controller Basic style language supplied with

controller.

Embedded C On Controller ANSI C compiled and linked using the

Texas Instruments C31 compiler to libraries supplied by Baldor.

Visual C/C++ On Host PC Microsoft Visual C/C++ compiled in

conjunction with source code or COM server supplied by Baldor.

Visual Basic On Host PC Microsoft Visual Basic using COM

server supplied by Baldor.

Delphi On Host PC Inprise Delphi using COM server

supplied by Baldor.

All methods of programming are based around the same command set. In general all commands may be called from any language, thus giving the user maximum programming flexibility.

For example, to load a move of 10 user units on axis zero:

Language Command

Mint

MOVEA.0 = 10

Embedded C

setMoveA (0,10);

Visual C/C++

myPCI.setMoveA (0, 10);

Visual Basic

myPCI.setMoveA 0, 10

For the host PC to communicate with NextMove PCI the controller must be running either Mint or an embedded application. The controller can only run one application at a time (either Mint or an embedded application). However there may be many applications on the host, all communicating with the same NextMove PCI.

For further details on programming the controller in any of the above languages see the ‘Mint v4 PC Programming Guide’.

4.7 Documentation

All NextMove PCI documentation is available on the Baldor Motion Toolkit CD. Documents are in Adobe Acrobat format (PDF). The Acrobat viewer may also be installed from the CD.

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Figure 4-26: Baldor Motion Toolkit - Documentation Page

4.8 Mint

Mint is a structured form of Basic which has been custom designed for motion control applications. The Mint language has been written to allow users to get started quickly with simple motion programs and also provides a wide range of more powerful commands for complex applications.

Mint is used in thousands of applications worldwide, servicing many high demand industries such as textiles and packaging. Applications range from simple single axis applications to complex multiaxis, multi-controller applications via a host-controlled link. It is Mint's flexible and powerful command set that is able to provide a solution to the vast number of industrial motion control applications.

In addition to usual Basic type commands such as

PRINT, FOR..NEXT

and

IF..THEN

, Mint

has a number of keywords dedicated to motion control and input/output.

Mint also provides full control over basic motor control parameters such as servo loop gains in addition to all the digital and analog I/O on the controller.

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Mint splits motion keywords into 2 categories; motion variables and motion commands. Motion variables are keywords that set axis parameters. These can be read or written (although not necessarily both). Motion commands initiate motion. For example:

SPEED[0,1] = 10,20 : REM Set slew speed on axes 0 and 1 ACCEL[0,1] = 100,200 : REM Set acceleration on axes 0 and 1 MOVER[0,1] = 50,100 : REM Load positional moves GO[0,1] : REM Start motion

The use of the square brackets controls 2 axes in the system, where axis 0 is the first axis followed by axis 1 and so on. The use of the square brackets is optional as Mint is very flexible in its multiaxis syntax. In this example, axis 0 is set up with a speed of 10 units/s, acceleration of 100 units/s

and a relative move of 50 units. Axis 1 is set up with a speed of 20 units/s, acceleration of 200 units/s

and a relative move of 100 units.

SPEED, ACCEL

and

MOVER

are all motion variables. The motion command GO is used to initiate motion. Most motion keywords can be abbreviated to 2 or 3 letters, for example,

SPEED

can be replaced with SP and

MOVER

replaced with MR. This saves both

on code space and typing. The example above could be abbreviated to:

SP[0,1]=10,20 : REM Set slew speed on axes 0 and 1 AC[0,1]=100,200 : REM Set acceleration on axes 0 and 1 MR[0,1]=50,100 : REM Load positional moves GO[0,1] : REM Start motion

The utility called Squash within Mint WorkBench enables programs to be compressed by replacing keywords with their abbreviated counterparts.

At any time during motion, the position of the motor can be printed using:

PRINT POS.0 : REM Print position of axis 0

Position can also be monitored using the WatchWindow in the Mint WorkBench.

See the Mint v4 Programming Guide for more details on Mint syntax.

Engineering units can be applied to an axis. In a linear table for example, there may be 1000 encoder counts per mm. The keyword

SCALE

(or SF for short) can be used to set the new scale

factor of the axis:

SCALE = 1000

This enables positions to be specified in mm and speeds in mm/s.

Mint programs consist of two files. The Configuration Buffer stores information relating to the machine set-up, for instance the servo loop gains. The Program Buffer stores the actual motion control program. The two files can contain the same instructions, except that the Configuration Buffer is only 8K maximum size, while the Program Buffer can be up to 1Mb.

4.8.1 The Configuration File

The Configuration buffer is used to store information about a system such as IO configuration, motor tuning values and scale factors. If a part of the system is modified, then only the Configuration Buffer should require modification.

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The Mint WorkBench has a built in editor which can be used to edit both Configuration and Program files. To create a new configuration file select ‘New…Config’ from the ‘File’ menu. This will open up an editor window into which you can type.

Figure 4-27: Mint WorkBench – Configuration File Editor

The configuration editor will syntax highlight all Mint keywords as they are typed. The correct syntax for the firmware being used can be uploaded from the controller by selecting the ‘Load Syntax’ option from the ‘Edit’ menu.

Figure 4-28: Download Button

In order to execute the configuration file in the editor window it must be downloaded to the controller by pressing the ‘download’ button.

Once the program has been downloaded to the controller it can be executed by either typing

RUN

the Mint command line or pressing the ‘play’ button.

Whenever a Mint program is

RUN

, the Configuration Buffer is executed first followed by the

Program Buffer. The Configuration or Program Buffer can be executed individually by typing:

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RUN CON

(for the

Configuration Buffer

)

RUN PROG

(for the

Program Buffer

)

The following list of parameters is normally set-up in the Configuration Buffer:

•

Servo loop gains

- to tune the system response.

•

Scale factor

- to set the units of measure of the application.

•

Maximum following error

- to set a safe maximum difference between actual and desired

positions.

•

Default speeds accelerations and decelerations for the system

- to determine the shape

of the trapezoidal velocity profile.

•

Error features such as hardware and software limits, stop inputs and error input.

The parameters in the Configuration Buffer are generally to be set-up only once for an application, but can at any time be altered in the Program Buffer.

The Mint Configuration Tool provides a graphical method for setting common parameters that would be placed in a configuration file. Having completed the Start Up Wizard, the Mint Configuration Tool can be started in wizard or manual modes. The wizard mode steps through each of the configuration screens for each axis selected during the Start Up Wizard.

Digital Inputs

Each of the digital input channels may be configured to be level (active high or low) or edge triggered (positive, negative or both edges). Digital inputs may also be assigned to axes for use as limit switch inputs etc.

Figure 4-29: MCT Digital Input Setup

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Digital Outputs

Each of the digital output channels may be configured to be active high or low. Digital outputs may also be assigned for use as drive enable channels or as a global error output signal.

Figure 4-30: MCT Digital Output Setup

Analog Inputs

Each analog input channel can be configured to read a number of voltage ranges and each channel can be read unfiltered or filtered through the Butterworth filters.

Figure 4-31: MCT Analog Input Setup

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Axis Params

This page allows basic axis parameters to be setup such as speed and acceleration. You may also specify if a datum cycle is to be included in the configuration file.

Figure 4-32: MCT Axis Parameters

Axis Errors

This page allows the error modes to be set for each error type. When an error occurs, the action specified will occur.

Figure 4-33: MCT Axis Errors

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Miscellaneous

This page allows the auxiliary encoder parameters to be set and the state of the Mint command line

ECHO

keyword.

Figure 4-34: MCT Miscellaneous Parameters

Create Config

This page allows you to select whether to generate a Mint Configuration file or C source code suitable for use in an embedded application.

Figure 4-35: MCT Create Configuration File

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4.8.2 The Program File

The Mint WorkBench has a built in editor which can be used to edit both Configuration and Program files. To create a new configuration file select ‘New…Program’ from the ‘File’ menu. This will open up an editor window into which you can type.

Figure 4-36: Mint WorkBench - Program Editor

As with the Configuration file, in order to execute the Program file, it must be downloaded to the controller.

Once the program has been downloaded to the controller it can be executed by either typing

RUN

the Mint command line or pressing the ‘play’ button on the Mint WorkBench Toolbar.

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4.9 Motion

NextMove PCI supports a wide range of motion:

Type of Motion Description Associated Mint

Keywords

Constant torque Constant torque output.

TORQUE

Constant velocity Constant velocity with imposed acceleration

and deceleration ramps.

JOG

Homing Datum to a known starting point.

HOME

Point to point Absolute and relative position moves with a

trapezoidal velocity profile.

MOVEA, MOVER, GO

Vector Multi-axis absolute and relative position

moves with a trapezoidal velocity profile.

VECTORA, VECTORA, GO

Circle Circular motion.

CIRCLEA, CIRCLER, GO

Incremental Positional move with a changing target

position.

INCA, INCR, GO

Analogue based Axis velocity based on error between

analogue measured and desired values.

HTA, GO

Synchronized motion

Master / Slave following with imposed ratios.

FOLLOW, FLY

Software variable gearbox.

User definable software CAM profile.

CAM, GO

Spline User definable cubic spline motion.

SPLINE, GO

For more details on motion keywords see the Mint v4 Programming Guide.

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5. Options and Accessories

NextMove PCI supports a number of options, including an axis Expansion Card and CAN I/O card. This chapter summarizes those options.

This chapter describes a lower-cost more compact alternative to using the Breakout Unit when NextMove PCI is being used only as a CAN network manager.

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5.1 NextMove PCI

NextMove PCI is supplied with a

software license

to control 1,2,3,4 or 8 axes. This license cannot

be upgraded in the field.

Similarly the NextMove PCI Expansion Card is supplied with a

software license

to control a further 4 or 8 axes. Again this license cannot be upgraded in the field. The total number of controllable axes is equal to the sum of those of the main and expansion card(s).

Item Order Code Description

Card Type Output

type

No. of

axes

Main PCI card PNP 1 PCI001-501 Main PCI card PNP 2 PCI001-502 Main PCI card PNP 3 PCI001-503 Main PCI card PNP 4 PCI001-504 Main PCI card PNP 8 PCI001-505

NMPCI main card with

PNP digital outputs,

various numbers of

axes supported.

Main PCI card NPN 1 PCI001-510 Main PCI card NPN 2 PCI001-511 Main PCI card NPN 3 PCI001-512 Main PCI card NPN 4 PCI001-508 Main PCI card NPN 8 PCI001-513

NMPCI main card with

NPN digital outputs,

various numbers of

axes supported.

Item Order Code Description NextMove PCI developer’s kit PCI010-502 A complete package, comprising the main

board, an output module of either polarity, a cable, the Breakout Unit, software and full

documentation. NextMove PCI Installation Manual

MN1277 Includes Baldor Motion Toolkit CD.

Mint v4 Programmer’s Manual MN1262 How to use Mint v4. Baldor Motion Toolkit CD SW1275 Mint WorkBench, Mint for NextMove PCI

and Libraries for developers.

5.2 NextMove PCI Expansion Card

The NextMove PCI Expansion Card provides an additional 4 or 8 axes of control and a full suite of analog and digital IO as per the main NextMove PCI card. The Expansion Card is connected to the main card via an Expansion Interconnect card.

Options and Accessories

MN1277 04.2001

Figure 5-1: NextMove PCI Expansion Card

All connections to the Expansion Card are brought out via a 100-way connector which can be used in conjunction with a NextMove PCI Breakout Unit (section 5.4).

Item Order Code Description

Card Type Output

type

No. of

axes

Axis Expansion Card PNP 4 PCI002-501 Axis Expansion Card PNP 8 PCI002-502 Axis Expansion Card NPN 4 PCI002-503 Axis Expansion Card NPN 8 PCI002-504

NMPCI Expansion Card with a choice of digital outputs and number of axes supported, supplied with interconnect

Item Order Code Description

Expansion Interconnect OPT025-504 Needed to connect NMPCI to an

Expansion Card

Dual Expansion Interconnect OPT025-505 Needed to connect NMPCI to two

Expansion Cards

5.3 Digital Output Modules

The digital output drive on NextMove PCI is in the form of a removable module which allows different types of outputs for different applications.

Currently there are two modules available:

1. Current sourcing, ‘PNP’ connection, over-current protected, Darlington module, with built in fly-back diodes.

NextMove PCI Installation Manual

MN1277 04.2001

2. Current sinking, ‘NPN’ connection, unprotected MOSFET module.

Item Order Code Description

Output driver module, sinking (‘NPN’)

OPT025-508 Provides N-channel MOSFET current

sinking outputs Output driver module, sourcing, (‘PNP’)

OPT025-507 Provides Darlington current sourcing

outputs

5.4 Breakout Unit

The NextMove PCI Breakout Unit is designed to give easy access to the various I/O and motor control signals.

Figure 5-2: NextMove PCI Breakout Unit

The Breakout Unit takes the NextMove PCI signals on the 100-way D-type connector and routes them to screw-down terminals for the digital I/O, 9-way D-types for the encoders and steppers. The CAN is brought out on a

CAN

open

compatible D-type for channel 1 and an RJ-45 for channel 2.

Pre-made cables of different lengths are available for connecting between the Breakout Unit and NextMove PCI.

Item Order Code Description

Breakout Unit PCI003-501

Breaks out the signals from the 100-way cable to

screw

down

terminals and signal conditioning.

Breakout Unit PCI003-502

Breaks out the signals from the 100-way cable to

two-

part connectors

and signal conditioning.

Cable 1.0 m CBL021-501 1.0 m 100-way cable to attach NextMove PCI to

Breakout Unit.

Cable 1.5 m CBL021-502 1.5 m 100-way cable to attach NextMove PCI to

Breakout Unit

Cable 3.0 m CBL021-503 3.0 m 100-way cable to attach NextMove PCI to

Breakout Unit

Options and Accessories

MN1277 04.2001

5.5 NextMove PC System Adapter

The NextMove PC adapter takes the output from the 100 way connector of NextMove PCI and converts it to be compatible with the NextMove PC cable, allowing for machine conversion from NextMove PC to NextMove PCI with minimal change to the physical wiring of the machine.

Figure 5-3: NextMove PCI to PC Adapter

Item Order Code Description

NextMove PC system adapter

OPT025-506 Allows NextMove PCI to connect to a

NextMove PC system.

5.6 Spares

Spare parts are available separately. Those shown shaded are located on the Breakout Unit and can also be supplied to aid those wishing to design a special backplane or Breakout Unit for their own product.

Item Order Code Description

Fuses FU056A01 Strip of 10 fuses for the digital outputs. Differential stepper driver module

OPT025-501 Drives the stepper outputs

CAN module (unisolated) OPT025-503 CAN transceiver SIL hybrid module.

Supports up to 1Mbit/s.

CAN module (isolated) OPT025-502 CAN transceiver SIL hybrid module.

Supports up to 500kbit/s.

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MN1277 04.2001

5.7 CAN Nodes

Figure 5-4: ioNODE Product Family

Digital I/O can be expanded easily on NextMove PCI using the Baldor CAN bus interface. This provides a high speed secure serial bus interface to a range of I/O devices as described:

• inputNode 8

: 8 opto isolated digital inputs.

• outputNode 8

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

• relayNode 8

: 8 relay outputs.

• ioNode 24/24

: 24 opto isolated input and 24 opto isolated outputs.

• keypadNode

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

Item Order Code Description

CAN Operator Panel – 3 Axes (keypadNode)

KPD002-502 27 key keypad and 4 line LCD display.

Runs on Baldor CAN bus. CAN Operator Panel – 4 Axes (keypadNode)

KPD002-505 41 key keypad and 4 line LCD display.

Runs on Baldor CAN bus. inputNode 8 ION001-503 8 digital inputs. Runs on Baldor CAN bus. outputNode 8 ION003-503 8 digital outputs. Runs on Baldor CAN bus. relayNode 8 ION002-503 8 relay outputs. Runs on Baldor CAN bus. ioNode 24/24 ION004-503 24 digital inputs and 24 digital outputs.

Runs on Baldor CAN bus.

Options and Accessories

MN1277 04.2001

5.8 NextMove PCI CAN Bracket Board

This is a lower-cost more compact alternative to using the Breakout Unit when the NextMove PCI controller is being used only as a CAN network manager. Both CAN channels are presented on 9 way D type connectors.

Figure 5-5: CAN Bracket Board

The CAN1 channel is presented on a 9 pin male D-type and is normally fitted with the isolated CAN transceiver module. CAN1 uses the

CAN

open

protocol.

The CAN2 channel is presented on a 9 pin male D-type and is normally fitted with the non-isolated CAN transceiver module. CAN2 uses the Baldor CAN protocol.

Where an isolated transceiver module is used a supply of 12-24V, 60mA is required between CANV+ and CAN-GND.

NextMove PCI Installation Manual

MN1277 04.2001

Figure 5-6: CAN Bracket: End View

Signal Function D-type Pin Cabling

can+

CAN data signal 7

can-

CAN data signal 2

can V+

Power to the CAN nodes 9

gnd

Signal ground 3

chassis

Screen pin 1

NC No connection 4,5,6,8

chassis

Screen Shell

J5 if fitted terminates the CAN1 network. J4 if fitted terminates the CAN2 network. There should be terminators at the both ends of each network and nowhere else.

Options and Accessories

MN1277 04.2001

Item Order Code Description

CAN bracket assembly OPT030-501 Provides alternative to Breakout Unit for

CAN connection

5.9 Encoder Splitter/Buffer Board

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

Item Order Code Description

2-way encoder splitter OPT008-501 Allows a single-ended or differential encoder

pulse train to be shared between two devices

4-way encoder splitter OPT029-501 Allows a single-ended or differential encoder

pulse train to be shared between four devices

NextMove PCI Installation Manual

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Specifications and Product Data

MN1277 04.2001

6. Specifications and Product Data

This chapter provides a product summary and describes the basis for

marking and describes how to avoid common EMC problems when using NextMove PCI.

NextMove PCI Installation Manual

MN1277 04.2001

6.1 Machine Control I/O

User Digital Inputs:

•

20 input lines.

•

PNP or NPN opto-isolated relative to common.

•

12 to 24V ±20% on, 2V max off.

•

Software programmable as

limit, home, stop

error

inputs for any

axis.

User Digital Outputs:

•

12 digital outputs through a sourcing Darlington (‘PNP’) or sinking FET (‘NPN’) module.

•

Software programmable as

drive enable

output for any axis.

•

50mA continuous source on all channels.

Fast Interrupt:

•

Inputs 0-3 double as fast inputs to the encoder ASICs.

•

Latches position of programmed axes within 1 microsecond on a falling edge.

Relay Output:

•

Volt free change over relay rated at 150mA @ 24V dc.

•

Contact sensitivity 10µA @ 10mV DC

•

1 output per controller, software programmable.

•

1 output per Expansion Card, software programmable.

•

Fail safe operation: relay de-energized on loss of power.

•

Software programmable to de-energize on an error.

Analog Inputs:

•

4 independent differential analog channels.

•

12 bit resolution.

•

Selectable second order low-pass Butterworth filter with a 1kHz cut off frequency.

•

Software selectable for voltage range (0-5V, 0-10V, ±5V and ±10V).

Analog Outputs:

•

1 output per axis for motor

command

signal (software configurable).

•

10V output (±0.1%) with ±0.625V trim.

•

14 bit resolution (1.21mV per bit).

Encoder Inputs:

•

Encoder input per axis for positional feedback via incremental encoder.

•

Operates with differential (TTL or RS422) output type.

•

Accepts three channel incremental encoders (A, B and Z). A and

channels are quadrature decoded.

•

Minimum requirement: Channel A and B .

•

Maximum encoder frequency: 7.5MHz quadrature count.

Stepper outputs:

•

Step and direction.

•

CMOS level outputs for external drive circuits.

•3Μ

Hz maximum output frequency.

Specifications and Product Data

MN1277 04.2001

6.2 Miscellaneous and Mechanical Specification

Power Input:

•15

W PCI card.

•

+5V at 1200mA

•

±12V at 250mA

•

User Power: +12V to 24V at 1200mA The exact figures depend on the loading, additional allowance must be made when powering the encoders from the PC’s 5V rail.

Weight:

•

Approximately 305g / 0.67lb

Operating

Temperature:

•

0 - 40

C / 32 - 104°F Ambient

NextMove PCI is a standard 7 inch PCI plug-in card. The nominal overall dimensions are 175mm (6.875") long by 106.7mm (4.2") deep.

The host must have a spare 7 inch PCI card slot. It must also be an AT type machine as this card cannot be fitted into MCA type machines. The card dimensions conform to the PCI standard except that it cannot be fitted with a Micro Channel bracket.

NextMove PCI Installation Manual

MN1277 04.2001

6.3 100-Pin Connector

The connections on the 100-pin D connector are as shown below, shaded groups of pins are referred to a common potential. Pin 2 column A of the 100 way connector is the square pin on the underside of the PCB.

If you intend to design your own Breakout Unit, see the ‘Designing NextMove PCI Breakout Units’ manual.

Notes:

1. ADC_1 means input to the analog to digital converter channel one.

2. DAC_1 means output from digital to analog converter channel one.

3. DIG_IN1 means digital input one (w.r.t. COMMON_n).

4. DIG_OUT1 means digital output one (w.r.t. USR-V+ and USR_GND).

5. Each stepper motor axis has 2 control lines STEP and DIR, which are TTL. The outputs are referred to the host's 0V (labeled GND).

6. CANn_TX and CANn_RX are the CAN connections. They are referred to the host's 0V (labeled GND).

7. The relay pins are isolated from internal circuits.

Specifications and Product Data

MN1277 04.2001

ANIN1+

ANIN1-

ANIN0+

ANIN0-

ANIN3+

ANIN3-

ANIN2+

ANIN2-

Demand 1

Demand 3

Demand 0

Demand 2

GND

AGND

GND

CAN2-TX

CAN2-RX

CAN1-TX

CAN1-RX

Encoder 0 !A

Encoder 0 A

Encoder 2 !A

Encoder 2 A

Encoder 0 !B

Encoder 0 B

Encoder 2 !B

Encoder 2 B

Encoder 0 !Z

Encoder 0 Z

Encoder 2 !Z

Encoder 2 Z

Encoder 1 !A

Encoder 1 A

Encoder 3 !A

Encoder 3 A

Encoder 1 !B

Encoder 1 B

Encoder 3 !B

Encoder 3 B

Encoder 1 !Z

Encoder 1 Z

Encoder 3 !Z

Encoder 3 Z

Master Enc !B

Master Enc B

Master Enc !A

Master Enc A

Master Enc Z

Master Enc !Z

Step 0

Dir 0

Dir 2

Step 2

Step 1

Dir 3

DOUT11

Dir 1

Step 3

USR-V+

DOUT8

DOUT10

DOUT9

USR-V+

DOUT5

DOUT7

DOUT6

USR-GND

DOUT2

DOUT4

DOUT3

USR-GND

COMMON 8-19

DOUT1

DOUT0

DIN17

DIN16

DIN19

DIN18

DIN13

DIN12

DIN15

DIN14

DIN9

DIN8

DIN11

DIN10

DIN5

DIN4

DIN7

DIN6

DIN1

DIN0

DIN3

DIN2

Relay Closed

Relay Open

COMMON 0-7

Relay Common

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MN1277 04.2001

6.4 EMC &

CECE

Marking

6.4.1 Machinery Directive 89/392/EEC

This deals with the safety of machinery. Just about any machine having a moving part has to comply with the essential requirements of this directive. This also applies to some mechanical sub-systems such as fans. Electronic sub-systems such as NextMove PCI do not fall within its scope. Note that to meet the safety requirements of this directive, the primary machine safety system can not be based on controller software (paying a notified body to audit the software and make-out a safety case is prohibitively expensive); use a hard-wired system with guard switches and so forth to protect personnel or equipment.

6.4.2 Low Voltage Directive 72/23/EEC

Applies to equipment powered from 75V DC to 1500V DC or 50V AC to 1000V AC. Hence does not apply to NextMove PCI.

6.4.3 EMC Directive 89/336/EEC

Applies to all ‘apparatus liable to cause disturbance or the performance of which is liable to be affected by such disturbance’. The expression ‘apparatus’ is defined for the purpose of the regulations as ‘...an electrical or electronic appliance or system consisting of a finished product or products having an intrinsic function which is intended for the end user, and is supplied or intended for supply or taken into service or intended to be taken into service as a single commercial unit’.

This wording brings automated machines within the scope of the directive but not necessarily their electronic sub-systems because of their lack of intrinsic function to the end user; however NextMove PCIs, built to issue 3 upwards will be CE marked in respect of the EMC directive subject to the conditions set out below.

6.4.4 EMC Performance of NextMove PCI

These data apply to product built to issue 3 or later when used with Baldor’s Breakout Unit and cable. Note that the equipment is suitable for light or heavy industrial use. In all tests NextMove PCI is mounted in a third party compliant PC. A 3m cable and Breakout Unit is used.

Letters in parentheses after ‘Pass’ indicate the performance criteria, as defined in EN50082-1 and EN50082-2. In brief, performance criterion A indicates that the apparatus continues to operate as intended. Criterion B indicates that after the test the apparatus continues to operate as intended, but during the test some performance degradation may occur, as long as there is no change in operating state or stored data. Criterion C indicates that temporary loss of function may occur as long as the function is recoverable automatically or with use of the controls.

Specifications and Product Data

MN1277 04.2001

Test Standard Comments

EN50081-1, 1992

Conducted

emissions

EN55022,

1994

Pass. Worst case margin >10.0 dB.

EN50081-1, 1992

Radiated

emissions

EN55022,

1994

Pass. Maximized emissions at 10m, worst case margin 5.1 dB at

33.09MHz.

EN50082-2, 1995

Radiated field

immunity

EN61000-4-3,

1995

Pass (A). 10.0V / m.

EN50082-2, 1995

Conducted

immunity

EN61000-4-4 Pass (A). 10.0V tests on each end of breakout cable and all

breakout ports.

EN50082-2, 1995

EFT / bursts

EN61000-4-4,

1995

Pass (B). Live, Neutral and Earth at ±1.0kV / ±2.0kV; breakout cable at ±1.0kV; all other breakout ports at ±2.0kV.

EN50082-2, 1995

Electrostatic

discharge (ESD)

EN61000-4-2,

1995

Pass (B). Test voltages: ±4.0kV (contact), ±8.0kV (air). Note: relative humidity 66%.

EN50082-1, 1997

Surge immunity

EN61000-4-5,

1995

Pass (B). Live – Earth, Neutral – Earth ±2.0kV. Live – Neutral

1.0kV.

EN50082-1, 1997

Dips and

interrupts

EN61000-4-11Pass (B) at –30% for 10 ms. Pass (C) at –60% for 100ms; Pass

6.4.5 Conditions of

CECE

marking

The apparatus shall be connected in accordance with the recommendations of this manual. There are certain restrictions regarding the length and type of cable:

Cable type Notes

unrestricted USR-V+, USR-GND, DIN8-19, COMMON2, DOUT0-11, drive enable

relay, main cable <3m must be screened DIN0-3, COMMON1, Analog inputs, DEMAND screened twisted pair encoders, CAN, steppers

The grounding point must be bonded to the system star grounding point / bus bar with a short, low impedance braid strap. USER-GND must be connected to earth.

NextMove PCI Installation Manual

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Trouble Shooting Guide

MN1277 04.2001

7. Trouble Shooting Guide

This chapter covers common problems found when using NextMove PCI.

NextMove PCI Installation Manual

MN1277 04.2001

Symptom Check

Cannot detect NextMove PCI

•

Check that the NextMove PCI driver has been installed. Cannot communicate with the controller.

•

Verify that the Mint WorkBench program is loaded and

that NextMove PCI is the currently selected controller.

The Mint operating system must be downloaded to the

controller. (e.g. NMPCI.OUT).

•

Check the card is firmly seated in its socket in the

computer and this socket is of the correct type.

•

Check that the green LED on the card is flashing

(approx. 0.5Hz).

Controller appears to be poweredup and working but will not cause motors to turn over.

•

Check that the connections between motor and

controller are correct. Use the Mint Configuration Tool

to perform the basic system wiring tests described in

section 4.4.

•

Ensure that the amplifier is enabled and working when

the controller is not in error. (When the controller is

first powered up the amplifiers should be disabled if

there is no program running (there is often an LED on

the front of the amplifier to indicate status).

•

Check that the Configuration file is loaded into

controller and has been

RUN

, or that the servo loop

gains are correctly set-up. (Check the

Gains

window or

type

PRINT KP

to verify that the controller proportional gain KP is not zero and refer to servosystem set-up).

Motor runs off uncontrollably when controller is switched on.

•

Check that the encoders are connected to controller, have power through encoder V+ and are functioning correctly. (Use a dual trace oscilloscope to display both channels of the encoder and/or the complements simultaneously).

•

Check that the amplifiers are connected correctly to the controller and that with zero demand there is 0V at the amplifier demand input.

•

Verify that the controller and amplifier are correctly grounded to a common earth point.

Mint NextMove PCI, NextMove PCI MN1277 Installation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual