Baldor NextMove PCI Installation Manual
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Baldor NextMove PCI Installation Manual

Baldor NextMove PCI Installation Manual

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MOTION CONTROL
NextMove PCI
Motion Controller
Installation Manual
3/02
MN1903

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Summary of Contents for Baldor NextMove PCI

  • Page 1 MOTION CONTROL NextMove PCI Motion Controller Installation Manual 3/02 MN1903...

  • Page 3: Table Of Contents

    ....... . . 3.3.2 NextMove PCI Expansion card and CAN Bracket board ....
  • Page 4 4.6.2 CAN2 (Baldor CAN) - X18 ........
  • Page 5 ..........A.1.9 NextMove PCI CAN Bracket board ....... .
  • Page 6 MN1903 iv Contents...

  • Page 7: General Information

    This manual is copyrighted and all rights are reserved. This document or attached software may not, in whole or in part, be copied or reproduced in any form without the prior written consent of BALDOR. BALDOR makes no representations or warranties with respect to the contents hereof and specifically disclaims any implied warranties of fitness for any particular purpose.
  • Page 8 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.

  • Page 9: Introduction

    Introduction 2.1 NextMove PCI features NextMove PCI is a high speed multi-axis intelligent motion controller for use in PCI bus based PC systems. NextMove PCI features the MintMT motion control language. MintMT is a structured form of Basic, custom designed for stepper or servo motion control applications. It allows you to get started very quickly with simple motion control programs.
  • Page 10 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 MintMT controller. These include: Mint WorkBench v5 This is the user interface for communicating with the NextMove PCI. Installing Mint WorkBench will also install firmware for NextMove PCI.

  • Page 11: Receiving And Inspection

    4. Inspect the NextMove PCI for external damage during shipment and report any damage to the carrier that delivered it. 5. If the NextMove PCI is to be stored for several weeks before use, be sure that it is stored in a location that conforms to the storage humidity and temperature specifications shown in section 3.2.

  • Page 12: Units And Abbreviations

    2.3 Units and abbreviations The following units and abbreviations may appear in this manual: ....Volt (also VAC and VDC) ....Watt .

  • Page 13: Basic Installation

    3.1 Introduction You should read all the sections in Basic Installation. It is important that the correct steps are followed when installing the NextMove PCI. This section describes the mechanical and electrical installation of the NextMove PCI. 3.1.1 Hardware requirements...

  • Page 14: Location Requirements

    The safe operation of this equipment depends upon its use in the appropriate environment. The following points must be considered: The NextMove PCI must be installed in an enclosed cabinet located so that it can only be accessed by service personnel using tools.

  • Page 15: Installation

    3.3 Installation 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: Windows 95, Windows 98, Windows ME, Windows NT4 and Windows 2000.
  • Page 16 3-4 Basic Installation MN1903...

  • Page 17: Input / Output

    ... Analog Output Connections to the NextMove PCI card are made using the 100-pin cable assembly and DIN rail mounted NextMove PCI Breakout module (supplied as options, see Appendix A).

  • Page 18: 100-Pin Connector Pin Assignment

    4.2.1 100-pin connector pin assignment Signal Signal AIN0+ AIN1+ AIN0- AIN1- AIN2+ AIN3+ AIN2- AIN3- Demand0 Demand1 Demand2 Demand3 Analog GND +5V out CAN1 transmit CAN2 transmit CAN1 receive CAN2 receive Encoder 2 CHA- Encoder 0 CHA- Encoder 2 CHA+ Encoder 0 CHA+ Encoder 2 CHB- Encoder 0 CHB-...
  • Page 19 Signal Signal Direction Output 1 Direction Output 3 Step Output 3 DOUT11 DOUT10 USR V+ DOUT9 DOUT8 DOUT7 USR V+ DOUT6 DOUT5 DOUT4 CGND DOUT3 DOUT2 DOUT1 CGND DOUT0 Common2 DIN19 DIN17 DIN18 DIN16 DIN15 DIN13 DIN14 DIN12 DIN11 DIN9 DIN10 DIN8 DIN7...

  • Page 20: Analog I/O

    The NextMove PCI provides: Four 12-bit resolution analog inputs. The inputs are available on connector X6 on the NextMove PCI Breakout module. Four 14-bit resolution analog outputs. The outputs are available on connector X7 on the NextMove PCI Breakout module.

  • Page 21: Analog Inputs - X6

    4.3.1 Analog inputs - X6 Location Breakout module, connector X6 Name MintMT keyword / description AGND Analog ground AIN0+ AIN0 AIN0 AIN0- AIN1+ AIN1 AIN1 AIN1- Shield Shield connection AGND Analog ground AIN2+ AIN2 AIN2 AIN2- AIN3+ AIN3 AIN3 AIN3- Shield Shield connection Description...
  • Page 22 Breakout NextMove PCI module cable AIN0- AIN0+ MintMT ADC.0 AGND Figure 1 - Analog input wiring, AIN0 shown For differential inputs connect input lines to AIN+ and AIN-. Leave AGND unconnected. For single ended inputs, connect signal to AIN+. Connect signal ground to AIN- and AGND.

  • Page 23: Analog Outputs (Drive Demand/Command) - X7

    Demand / Command outputs 0 to 3 correspond to axes 0 to 3. The analog outputs may be used to drive loads of 10kΩ or greater. The outputs are referenced to PC system ground. Shielded twisted pair cable should be used. The shield connection should be made at one end only. NextMove PCI Breakout module Demand ±100%...

  • Page 24: Digital I/O

    4.4 Digital I/O There are a total of 20 general purpose digital inputs. Inputs can be configured in MintMT for any 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.
  • Page 25 MintMT keyword OUTPUTACTIVELEVEL, to determine their active level. The outputs are driven by a module fitted to the NextMove PCI card. Two module types are available: Current sourcing, PNP Darlington with overcurrent and short circuit protection (OPT025-507, fitted as standard).

  • Page 26: Digital Inputs - X1

    INX.19 10 Shield Shield connection (NC) 12 Common2 Common connection Description Eight general purpose optically isolated AC digital inputs. Sampling frequency: 1kHz Breakout NextMove PCI module cable MintMT DIN12 INX.12 DGND Common2 Active high: Active low: DINx = 12-24VDC (±20%)

  • Page 27: Digital Inputs - X2

    The inputs are conditioned using low pass RC filters and Schmitt trigger buffers. If an input is configured as edge triggered, the triggering pulse must have a duration of at least 1ms (one software scan) to guarantee acceptance by MintMT. Voltages below 2V are considered as 0V. The use of shielded cable for inputs is recommended.

  • Page 28: Digital Inputs - X3

    Shield connection Description Four fast position digital inputs. Sampling frequency: 1kHz (MintMT) Note: Digital inputs DIN0 to DIN3 are particularly sensitive to noise, so inputs must use shielded twisted pair cable. NextMove PCI DINx MintMT TLP115 Common1 Active high: Active low: DINx = 12-24VDC (±20%)

  • Page 29: Digital Outputs - X4

    12-24V supply (USR V+) as shown in Figure 5. The use of shielded cable is recommended. The CGND must be connected to the host PC’s GND. See section 4.5.3 for details about connecting the USR V+ supply. USR V+ NextMove PCI Breakout module OUTX.6...

  • Page 30: Digital Outputs - X5

    USR V+ NextMove PCI Breakout module OUTX.6 Output Output module load cable DOUT6 CGND Figure 6 - Digital output circuit with optional ‘NPN’ current sinking module - DOUT6 shown 4.4.5 Digital outputs - X5 Location Breakout module, connector X5 Pin Name...

  • Page 31: Other I/O

    Five identical encoder inputs, each with complementary A, B and Z channel inputs on a 9-pin female D-type connector Up to five incremental encoders may be connected to NextMove PCI. Each input channel uses a MAX3095 differential line receiver with pull up resistors and terminators. Encoders must provide either 5V differential signals or RS422/RS485 differential signals.

  • Page 32: Encoder Input Frequency

    4.5.2 Encoder input frequency The maximum encoder input frequency is affected by the length of the encoder cables. The theoretical maximum frequency is 7.5 million quadrature counts per second. This is equivalent to a maximum frequency for the A and B signals of 1.87MHz. However, the effect of cable length is shown in Table 3: Maximum cable length Frequency...

  • Page 33: Power - X9

    4.5.3 Power - X9 Location Breakout module, connector X9 Pin Name Description 1 Vcc +5V supply source from the host PC +5V supply source from the host PC 2 Vcc 3 Encoder V+ Power to the encoder connectors Power to the encoder connectors 4 Encoder V+ 5 GND Digital ground from the host PC...

  • Page 34: Relay And Can Power - X8

    The relay pins are isolated from any internal circuits on the NextMove PCI. The relay is controlled by a latch, which is cleared when the NextMove PCI resets. Reset can occur due to power-down, a watchdog error or when deliberately caused by the host PC. In normal operation the Relay NC contact is connected to Relay COM.

  • Page 35: Stepper Drive Outputs

    Four sets of stepper motor control outputs available on two 9-pin female D-type connectors The stepper drive outputs can operate at up to 3MHz. The signals from the NextMove PCI are at TTL levels but are converted to 5V differential drive signals by a circuit board mounted on the breakout module.

  • Page 36: Can Connections

    I/O devices (peripheral devices) connected to the bus. Up to 63 mixed type Baldor CAN peripherals may be connected to the NextMove PCI Baldor CAN network using the CAL protocol, with the limitation that only 4 enabled keypads are allowed at one time.

  • Page 37: Can1 (Canopen) - X17

    CANopen interface using a 9-pin male D-type connector with CiA standard DS102 pin configuration If NextMove PCI is at the end of the CANopen network the termination resistor must be connected by fitting the termination jumper J8, labelled “CO Term”, on the breakout module.

  • Page 38: Can2 (Baldor Can) - X18

    Description Baldor proprietary CAN interface using a RJ45 connector. If NextMove PCI is at the end of the Baldor CAN network a termination resistor must be connected by fitting the termination jumper J7, labelled “BC Term”, on the breakout module.

  • Page 39: Other I/O

    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.

  • Page 40: Connection Summary - Minimum System Wiring

    As a guide, Figure 9 shows an example of the typical minimum wiring required to allow the NextMove PCI and a single axis servo amplifier (motor drive) to work together. Details of the connector pins are shown in Table 4.
  • Page 41 Amplifier/Digital of relay Ground Table 4 - Connector details for minimum system wiring shown in Figure 9 This completes the input/output wiring. You should read the following sections in sequence before using the NextMove PCI. MN1903 Input / Output 4-25...
  • Page 42 4-26 Input / Output MN1903...

  • Page 43: Operation

    The software provided includes a number of applications and utilities to allow you to configure, tune and program the NextMove PCI. If you do not have experience of software installation or Windows applications you will need to seek further assistance for this stage of the installation.

  • Page 44: Installing The Driver Software - Windows Nt

    If auto-run is disabled, browse the CD and double click the file SETUP.HTM. 2. Go to the NextMove PCI area and select the NextMove PCI NT Device Driver option. Once the device driver has been installed, shut down all applications and restart the PC.

  • Page 45: Installing Workbench V5

    5.1.4 Installing WorkBench v5 You will need to install WorkBench v5 to configure and tune the NextMove PCI. 1. Insert the CDROM into the drive. 2. After a few seconds the setup wizard should start automatically. If the setup wizard does not appear, select Run...

  • Page 46: Starting Workbench V5

    5.1.5 Starting WorkBench v5 1. On the Windows Start menu, select Programs, WorkBench v5, WorkBench v5. WorkBench v5 will start, and the Tip of the Day dialog will be displayed. You can prevent the Tip of the Day dialog appearing next time by removing the check mark next to Show tips at startup.
  • Page 47 Click Scan to search for the NextMove PCI. When the search is complete, click ‘NextMove PCI card 0’ and then click Select. 4. A dialog box will appear to tell you that the NextMove PCI currently has no firmware. Click Yes to search for firmware.
  • Page 48 Select the file with extension ‘.chx’ and click Open to download the firmware. The firmware will be downloaded to the NextMove PCI. (A dialog box may be displayed to tell you that WorkBench v5 has detected the new firmware. Click OK to continue).

  • Page 49: Workbench V5

    WorkBench v5 is a fully featured application for programming and controlling the NextMove PCI. The main WorkBench window contains a menu system, the Toolbox and other toolbars. Many functions can be accessed from the menu or by clicking a button - use whichever you prefer.

  • Page 50: Configuring An Axis

    Commands typed in the Command window have immediate effect - they do not need to be separately downloaded to the NextMove PCI. 5.3.1 Choosing an axis - 1, 2, 3 and 4 axis cards For the 1, 2, 3 and 4 axis cards, each axis can be configured as either a servo axis or a stepper axis.

  • Page 51: Selecting A Scale

    4. Click in the Scale box and type a value. 5. Click Apply. This immediately sets the scaling factor for the selected axis which will remain in the NextMove PCI until another scale is defined or power is removed from the NextMove PCI. MN1903 Operation 5-9...

  • Page 52: Setting The Drive Enable Output

    5.3.4 Setting the drive enable output The drive enable output allows NextMove PCI to disable the drive in the event of an error. Each axis can be configured with its own drive enable output, or can share an output with other axes.

  • Page 53: Testing The Drive Enable Output

    5. Click Apply at the bottom of the screen. This sends the output configuration to the NextMove PCI. 5.3.5 Testing the drive enable output 1. On the main WorkBench v5 toolbar, click the Drive enable button. Click the button again.

  • Page 54: Servo Axis - Testing And Tuning

    5.4 Servo axis - testing and tuning This section describes the method for testing and tuning a servo axis. To test a stepper axes, go straight to section 5.8. 5.4.1 Testing the drive command output This section tests the operation and direction of the axis command output. It is recommended that the motor is disconnected for this test.

  • Page 55: An Introduction To Closed Loop Control

    [ Demand stopped so you stopped too, but not quite level ]. The NextMove PCI tries to correct the error, but because the error is so small the amount of torque demanded might not be enough to overcome friction.
  • Page 56 This problem is overcome by using a term called Integral gain (KINT). This sums the error over time, so that the motor torque is gradually increased until the positional error is reduced to zero [ like a person gradually pushing harder and harder on your car until they’ve pushed it level with Demand].
  • Page 57 Figure 11 - The NextMove PCI servo loop MN1903 Operation 5-15...

  • Page 58: Servo Axis - Tuning For Current Control

    5.5 Servo axis - tuning for current control 5.5.1 Selecting servo loop gains All servo loop parameters default to zero, meaning that the demand output will be zero at power up. Most servo amplifiers can be set to current (torque) control mode or velocity control mode;...
  • Page 59 0.15 seconds. 7. Click Go. The NextMove PCI will perform the move and the motor will turn. As the soon as the move is completed, WorkBench v5 will download captured data from the NextMove PCI. The data will then be displayed in the Capture window as a graph.
  • Page 60 5.5.2 Underdamped response If the graph shows that the response is underdamped (it overshoots the demand, as shown in Figure 12) then the value for KDERIV should be increased to add extra damping to the move. If the overshoot is excessive or oscillation has occurred, it may be necessary to reduce the value of KPROP.
  • Page 61 5.5.3 Overdamped response If the graph shows that the response is overdamped (it reaches the demand too slowly, as shown in Figure 13) then the value for KDERIV should be decreased to reduce the damping of the move. If the overdamping is excessive, it may be necessary to increase the value of KPROP.
  • Page 62 5.5.4 Critically damped response If the graph shows that the response reaches the demand quickly and only overshoots the demand by a small amount, this can be considered an ideal response for most systems. See Figure 14. Demand position Measured position Figure 14 - Critically damped (ideal) response 5-20 Operation MN1903...

  • Page 63: Servo Axis - Eliminating Steady-State Errors

    0.1. 2. Click in the KINTLIMIT box and enter a value of 5. With NextMove PCI, the action of KINT and KINTLIMIT can be set to operate in various modes: Never - the KINT term is never applied Always - the KINT term is always applied Smart - the KINT term is only applied when the demand is zero or constant.

  • Page 64: Servo Axis - Tuning For Velocity Control

    (+10V) is applied to the drive. The setting for LOOPTIME. The factory preset setting is 1ms. The number of encoder lines for the attached motor. Baldor BSM motors use either 1000 or 2500 line encoders. The servo loop formula uses speed values expressed in quadrature counts per servo loop. To calculate this figure: 1.
  • Page 65 8. Click Go. The NextMove PCI will perform the move and the motor will turn. As the soon as the move is completed, WorkBench v5 will download captured data from the NextMove PCI. The data will then be displayed in the Capture window as a graph.
  • Page 66 9. Using the check boxes below the graph, select the Measured velocity and Demand velocity traces. Demand velocity Measured velocity Figure 15 - Correct value of KVELFF It may be necessary to make changes to the calculated value of KVELFF. If the trace for Measured velocity appears above the trace for Demand velocity, reduce the value of KVELFF.

  • Page 67: Adjusting Kprop

    0.1. 2. Click Go. The NextMove PCI will perform the move and the motor will turn. As the soon as the move is completed, WorkBench v5 will download captured data from the NextMove PCI. The data will then be displayed in the Capture window as a graph.
  • Page 68 Demand position Measured position Figure 16 - Correct value of KPROP The two traces will probably appear with a small offset from each other. Adjust KPROP by small amounts until the two traces appear on top of each other (approximately), as shown in Figure 16.

  • Page 69: Stepper Axis - Testing

    5.8 Stepper axis - testing This section describes the method for testing a stepper axis. The stepper control is an open loop system so no tuning is necessary. 5.8.1 Testing the drive command output This section tests the operation and direction of the axis command output. It is recommended that the system is initially tested and tuned with the motor shaft disconnected from other machinery.

  • Page 70: Digital Input/Output Configuration

    5.9 Digital input/output configuration The Digital I/O window can be used to setup other digital inputs and outputs. 5.9.1 Digital input configuration The Digital Inputs tab allows you to define how each digital input will be triggered and, optionally, if it is to be allocated to a special function, for example the Forward Limit. In the following example, digital input 1 will be set to trigger on a falling edge, and allocated to the forward limit input of axis 0: 1.

  • Page 71: Digital Output Configuration

    Fwd Limit icon This will setup IN1 as the Forward Limit input of axis 0. 5. Click Apply to send the changes to the NextMove PCI. Note: If required, multiple inputs can be configured before clicking Apply. 5.9.2 Digital output configuration The Digital Outputs tab allows you to define how each digital output will operate and if it is to be allocated to a drive enable output (see section 5.3.4).

  • Page 72: Saving Setup Information

    5.10 Saving setup information When power is removed from the NextMove PCI all data, including configuration and tuning parameters, is lost. You should therefore save this information in a file, which can be loaded when the card is next used. Alternatively, the information can be included in program files as part of the Startup block.

  • Page 73: Loading Saved Information

    A Startup block should be included in every Mint program, so that whenever a program is loaded and run the NextMove PCI will be correctly configured. Remember that every drive/motor combination has a slightly different response. If the same program is used on a different NextMove PCI installation, the Startup block will need to be changed.
  • Page 74 5-32 Operation MN1903...

  • Page 75: Troubleshooting

    If you have followed all the instructions in this manual in sequence, you should have few problems installing the NextMove PCI. If you do have a problem, read this section first. In WorkBench v5, use the Error Log tool to view recent errors and then check the help file. If you cannot solve the problem or the problem persists, the SupportMet feature can be used.

  • Page 76: Nextmove Pci Indicators

    6.2 NextMove PCI indicators 6.2.1 Status and CAN LEDs The backplate of the NextMove PCI contains four LEDs. S1 and S2 represent general status information. C1 and C2 are CAN traffic indicators. The LEDs may illuminate red or green and can be continuous or flashing.

  • Page 77: Communication

    6.2.2 Communication If the problem is not listed below please contact Baldor Technical Support. An oscilloscope will be useful for many of the electrical tests described below. Symptom Check Cannot detect NextMove Check that the NextMove PCI driver has been installed.
  • Page 78 Symptom Check Motor runs uncontrollably Check that the axis’ corresponding encoder and demand when controller is switched signals are connected to the same axes of motion. Check on and servo loop gains are the demand to the drive is connected with the correct applied or when a move is polarity.

  • Page 79: Specifications

    Specifications 7.1 Introduction This section provides technical specifications of the NextMove PCI 7.1.1 Mechanical specifications Description Value Input power +5V at 1200mA (from host PC) ±12V at 250mA Additional current will be required when powering the encoders from the host PC’s +5V supply.

  • Page 80: Analog Outputs (Drive Demand/Command - X7)

    7.1.3 Analog outputs (Drive Demand/Command - X7) Description Unit Value Type Bipolar Output voltage range ±10 Output current (max) Output DAC resolution bits (includes sign bit) Equivalent resolution ±1.22 Update interval Immediate 7.1.4 Digital inputs (X1 & X2) Description Unit Value Type Opto-isolated, AC inputs...

  • Page 81: Digital Outputs (X4)

    7.1.6 Digital outputs (X4) Description Unit Value Output current (maximum, each output) Update interval Immediate 7.1.7 Relay output (X8) Description Unit Value Contacts Normally closed Contact rating (resistive) 1A @ 24VDC 0.5A @ 125VAC Maximum carrying current Maximum switching power 62.5VA, 30W Maximum switching voltage 125VAC, 60VDC...

  • Page 82: Stepper Outputs (X10 & X11)

    Bit rate Kbit/s 10, 20, 50, 100, 125, 250, 500, 800, 1000 Protocol CANopen 7.1.11Baldor CAN interface (X18) Description Unit Value Signal 2-wire Channels Bit rate Kbit/s 10, 20, 50, 125, 250, 500, 800, 1000 Protocol Baldor CAN 7-4 Specifications MN1903...

  • Page 83: A Accessories

    Accessories A.1 Introduction NextMove PCI is supplied with a software license to control 1, 2 ,3, 4 or 8 axes. Similarly, the NextMove PCI Expansion Card is supplied with a software license to control a further 4 or 8 axes. A license cannot be upgraded.

  • Page 84: Axis Numbering When Using Expansion Card(S

    A.1.2 Axis numbering when using expansion card(s) The main NextMove PCI card is available in 1, 2, 3, 4, or 8 axis variants. The expansion card is available in 4 or 8 axis variants. However, using a 8 axis main card and a 8 axis expansion card will not provide 16 axes of control.

  • Page 85: Expansion Card Status Leds

    A.1.3 Expansion card status LEDs The backplate of the NextMove PCI Expansion card contains two LEDs, S1 and S2. These represent general status information. The LEDs may illuminate red or green and can be continuous or flashing. Expansion card LED...
  • Page 86 A.1.4 NextMove PCI Breakout module Breakout modules are available for use with the NextMove PCI and expansion cards, providing one or two part screw-down terminals for the I/O, power and relay connections, with 9-pin D-type connectors for the encoders and steppers. CAN connections are brought out on a CANopen compatible D-type for CAN1 (CANopen) and an RJ45 for CAN2 (Baldor CAN).

  • Page 87: Digital Output Modules

    A.1.5 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: Catalog Description number OPT025-508 NPN - N-channel unprotected MOSFET module for current sinking outputs...

  • Page 88: Baldor Can Nodes

    A.1.8 Baldor CAN nodes Digital I/O can be expanded easily on NextMove PCI using the Baldor CAN (CAN2) connection. This provides a high speed serial bus interface to a range of I/O devices, including: inputNode 8: 8 opto isolated digital inputs.

  • Page 89: Nextmove Pci Can Bracket Board

    A.1.9 NextMove PCI CAN Bracket board This is a compact alternative to using the breakout module when the NextMove PCI controller is being used only as a CAN network manager. Both CAN channels are presented on 9-pin D-type connectors. The board is connected to the NextMove PCI CAN jumpers by a ribbon cable.
  • Page 90 A-8 Accessories MN1903...
  • Page 92 Baldor Electric Company P.O. Box 2400 Ft. Smith, AR 72902-2400 Tel: (479) 646-4711 Fax: (479) 648-5792 www.baldor.com Printed in UK E Baldor UK Ltd LT0166A00...

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