Baldor NextMove ST Installation Manual
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Baldor NextMove ST Installation Manual

Baldor NextMove ST Installation Manual

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MOTION CONTROL
NextMove ST
Motion Controller
Installation Manual
1/04
MN1929

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Summary of Contents for Baldor NextMove ST

  • Page 1 MOTION CONTROL NextMove ST Motion Controller Installation Manual 1/04 MN1929...

  • Page 3: Table Of Contents

    ........4-19 4.6.5 Connecting serial Baldor HMI Operator Panels ..... . 4-20 4.6.6...
  • Page 4 ..........5.1.1 Connecting the NextMove ST to the PC ......
  • Page 5 Specifications ........Introduction .
  • Page 6 MN1929 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 www.supportme.net 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. Precautions WARNING: Do not touch any circuit board, power device or electrical connection before you first ensure that no high voltage is present at this equipment or other equipment to...

  • Page 9: Introduction

    NextMove ST is a high performance multi-axis intelligent controller for stepper motors. NextMove ST 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 ST 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 ST. Installing Mint WorkBench v5 will also install firmware for NextMove ST.

  • Page 11: Receiving And Inspection

    4. Inspect the NextMove ST for external damage during shipment and report any damage to the carrier that delivered it. 5. If the NextMove ST is to be stored for several weeks before use, be sure that it is stored in a location that conforms to the storage humidity and temperature specifications shown in section 3.1.1.

  • Page 12: Units And Abbreviations

    www.supportme.net 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

    The NextMove ST is designed to be mounted indoors, permanently fixed and located. The NextMove ST must be secured by the slots in the metal carrier. The NextMove ST must be installed in an ambient temperature of 0°C to 40°C (32°F to 104°F).

  • Page 14: Mounting The Nextmove St

    Ensure you have read and understood the location requirements in section 3.1.1. Mount the NextMove ST by the four slots in the metal carrier / heat sink assembly. M5 bolts or screws are recommended.

  • Page 15: Other Requirements For Installation

    3.1.3 Other requirements for installation The NextMove ST requires a power supply as described in section 4.2. A PC that fulfills the following specification: Minimum specification Recommended specification Processor Intel Pentium 133MHz Intel PentiumII 400MHz or faster 32MB 128MB...
  • Page 16 www.supportme.net 3-4 Basic Installation MN1929...

  • Page 17: Input / Output

    www.supportme.net Input / Output 4.1 Introduction This section describes the digital and analog input and output capabilities of the control card. The following conventions will be used to refer to the inputs and outputs: ....Input / Output .
  • Page 18 www.supportme.net 4.1.1 Connector locations Shield Axis0 Axis2 Output Output Shield PSU Logic PSU Logic Axis1 Power Shield Output PSU Drive PSU Drive Shield Shield Shield AIN0+ -12V OUT Analog Power AIN0- Shield AIN1+ Inputs +12V OUT AIN1- DGND AGND +5V OUT Shield Shield DOUT0...

  • Page 19: Power Connections

    4.2.1 Operation using combined drive and logic supply To operate the NextMove ST using a combined drive and logic supply, it is necessary to connect links between the power input connections as shown in Figure 2. The drive and logic supply inputs have independent bridge rectifiers so polarity is not important.

  • Page 20: Operation Using Separate Drive And Logic Supplies

    For improved noise immunity, the ±12V and +5V supplies used for the control card and internal circuitry can be derived from a separate logic supply. To operate the NextMove ST using separate drive and logic supplies, do not link power input connector pins. Connect power as shown in Figure 3.

  • Page 21: Stepper Outputs

    4.3 Stepper outputs The NextMove ST provides three 37VDC (max), 2A stepper axes drive outputs, operating at 10Hz to 200kHz. Logic level outputs are provided to control a fourth stepper axis. If required, the output current for individual axes can be derated. This can only be achieved by making precise alterations to the NextMove ST circuitry.
  • Page 22 4.3.1.2 Connecting a 6-wire motor Six-wire unipolar motors can be used with the NextMove ST. Six-wire motors are similar to eight-wire motors except the coils in each phase have a permanent center tap connection. Connections are shown in Figure 6. If the motor turns in the wrong direction, reverse the connections from one of the phase outputs AB or CD, but not both.
  • Page 23 4.3.1.3 Connecting a 8-wire motor Eight-wire (universal) motors can be used with the NextMove ST. Connections are shown in Figures 7 and 8. If the motor turns in the wrong direction, reverse the connections from one of the phase outputs AB or CD, but not both. Eight-wire motors can be connected in two ways, depending on the required torque and speed characteristics.

  • Page 24: Stepper Axes 0-3 Logic Outputs

    To allow external stepper amplifiers to be used, all of the stepper output signals from the NextMove ST control card are output on a 16-pin header, J3, mounted on the card. There are four sets of stepper motor control outputs, operating in the range 10Hz to 1MHz. The step (pulse), direction and boost signals from the NextMove ST control card are divided into two groups, each group driven by an ULN2003 open collector Darlington output device.

  • Page 25: Analog I/O

    4.4 Analog I/O The NextMove ST provides: Two 12-bit resolution analog inputs. One 0-11V analog output. 4.4.1 Analog inputs Differential inputs. Voltage range: ±10V. Resolution: 12-bit with sign (accuracy ±4.9mV @ ±10V input). Input impedance: 120kΩ. Sampling frequency: 4kHz maximum, 2kHz if both inputs are enabled.
  • Page 26 AIN0+ Integration of PWM signal and offset adjustment Servo amplifier ±10VDC demand input SGND AIN0- Shield Connect overall shield at one end only Figure 12 - Analog output - typical connection to a Baldor MicroFlex 4-10 Input / Output MN1929...
  • Page 27 Integration of PWM signal and offset adjustment Servo amplifier ±10VDC demand input SGND AIN0- Shield Connect overall shield at one end only Figure 13 - Analog output - typical connection to a Baldor FlexDrive Flex+Drive or MintDrive MN1929 Input / Output 4-11...

  • Page 28: Digital I/O

    4.5 Digital I/O The NextMove ST provides: 24 general purpose digital inputs. 16 general purpose digital outputs. Note: It is recommended to use separate shielded cables for the digital inputs. The shield should be connected to the input connector’s shield pin.
  • Page 29 MicroFlex / equipment output NextMove ST ‘X3’ Status+ DIN0 MintMT 74AHCT14 INX.0 Status- DGND NEC PS2562L-1 Figure 15 - Digital input - typical connections from a Baldor MicroFlex FlexDrive / equipment output NextMove ST User supply ‘X1’ USRV+ DIN0 MintMT 74AHCT14 INX.0...
  • Page 30 An input can be configured as an Error input for any axis, using the ERRORINPUT keyword. This input can be used to stop the NextMove ST in the event of an error occurring elsewhere in the system. The action of an ERROR input can be controlled using the ERRORSWITCH and ERRORINPUTMODE keywords.

  • Page 31: Digital Outputs

    An output can be configured in MintMT as a general purpose output, a drive enable output or a global error output. Outputs can be shared between axes and can be configured using WorkBench v5 (or the OUTPUTACTIVELEVEL keyword) to determine their active level. Load supply NextMove ST Output Load ULN2803 MintMT...

  • Page 32: Error Output

    Figure 18 - Error output jumper JP1 Jumpers JP3, JP4 and JP5 are situated at the edge of the NextMove ST control card, near the end of the 50-pin expansion header. JP4 and JP5 must be fitted to allow correct operation of the error output.

  • Page 33: Other I/O

    USB1.1 specification of the NextMove ST. Ideally, the NextMove ST should be connected directly to a USB port on the host PC. If it is connected to a hub shared by other USB devices, communication could be affected by the activity of the other devices.

  • Page 34: Using Rs232

    Only the TXD, RXD and 0V GND connections are required for communication. Pins 4 and 6 are linked on the NextMove ST. The maximum recommended cable length is 3m (10ft) at 57.6 Kbaud. When using lower baud rates, longer cable lengths may be used up to maximum of 15m (49ft) at 9600 baud.

  • Page 35: Multidrop Using Rs485 / Rs422

    (slave) devices on the network. The network master can be a controller such as NextMove ST, a host application such as WorkBench v5 (or other custom application), or a programmable logic controller (PLC). RS422 may be used for multi-drop applications as shown in Figure 20.

  • Page 36: Connecting Serial Baldor Hmi Operator Panels

    Serial Baldor HMI Operator Panels use a 15-pin male D-type connector (marked PLC PORT), but the NextMove ST Serial connector uses a 9-pin male D-type connector. The NextMove ST may be connected with or without hardware handshaking, as shown in Figure 21:...

  • Page 37: Can

    To determine which firmware is currently installed, start WorkBench v5 and connect to the NextMove ST (see section 5). At the bottom of the WorkBench v5 window, the status bar will show the name of the controller, followed by ‘CANopen’ or ‘Baldor CAN’. If the correct option is not shown, it will be necessary to download alternative firmware by using the Install System File and/or Download Firmware menu items in WorkBench v5.

  • Page 38: Can Wiring

    Baldor are ‘category 5’ and have a maximum current rating of 1A, so the maximum number of NextMove ST units that may be used on one network is limited to ten. Practical operation of the CAN channel is limited to 500Kbit/s owing to the propagation delay of the opto-isolators.

  • Page 39: Canopen

    The configuration and management of a CANopen network must be carried out by a single node acting as the network master. This role can be performed by the NextMove ST when it is configured to be the Network Manager node (node ID 1), or by a third party CANopen master device.

  • Page 40: Baldor Can

    KeypadNode 4 (Baldor part KPD002-505 ) - an operator panel CAN node with 4 x 20 LCD display and 41 key membrane labeled for control of 4 axes (1, 2, 3, 4). A typical Baldor CAN network with a NextMove ST and a Baldor CAN operator panel is shown in Figure 18.
  • Page 41 1 and 2 of the RJ45 connectors. On the Baldor CAN node, jumper JP3 can be used to connect an internal 120Ω terminating resistor, provided the node is at the end of the network. Jumpers JP4 and JP5 can be used to configure the node ID and baud rate.

  • Page 42: Connection Summary - Minimum System Wiring

    As a guide, Figure 25 shows an example of the typical minimum wiring required to allow the NextMove ST to control a single stepper motor. The diagram shows the logic supply being derived from the main Drive supply (see section 4.2.1).

  • Page 43: Operation

    RS232 to RS485 converter, connect this as specified by the manufacturer. WorkBench v5 can scan all the PC’s COM ports, so you can use any port. If you are not using the Baldor serial cable CBL001-501, your cable must be wired in accordance with Figure 19 in section 4.6.3.

  • Page 44: Preliminary Checks

    1. Follow the on-screen instructions to select and install the driver. The driver files are available on the supplied Baldor Motion Toolkit CD. If you are using a copy of the driver located on the hard disk, a floppy disk or another CD, the two driver files should be in the same folder.

  • Page 45: Workbench V5

    5.2 WorkBench v5 WorkBench v5 is a fully featured application for programming and controlling the NextMove ST. 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. Most buttons include a ‘tool-tip’;...

  • Page 46: Starting Workbench V5

    www.supportme.net 5.2.2 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 3. In the Select Controller dialog, go to the drop down box near the top and select the PC serial port to which the NextMove ST is connected. If you are unsure which PC serial port is connected to the drive, select Scan all serial ports. If the NextMove ST is connected using USB, it will be scanned automatically.

  • Page 48: Configuring An Axis

    The unit defined by setting a value for scale is called the user unit (uu). Consider a motor with a 1.8° step angle. The NextMove ST operates in half step mode, so there will be 400 steps per revolution. If SCALEFACTOR is not set, a MintMT command that involves distance, speed, or acceleration may need to use a large number to specify a significant move.

  • Page 49: Setting Relay0 As The Drive Enable Output

    ST L297 stepper controllers (see section 4.3.1). The error output must therefore be used to enable the axes. Because the NextMove ST control card is used in products that include a hardware relay, the error output is referred to as Relay0.

  • Page 50: Stepper Axis - Testing

    www.supportme.net 5.4 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. 5.4.1 Testing the output This section tests the operation and direction of the output. It is recommended that the system is initially tested and tuned with the motor shaft disconnected from other machinery.

  • Page 51: Digital Input/Output Configuration

    www.supportme.net 5.5 Digital input/output configuration The Digital I/O window can be used to setup other digital inputs and outputs. 5.5.1 Digital input configuration The Digital Inputs tab allows you to define how each digital input will be triggered, and if it should be assigned to a special purpose function such as a Home or Limit input.

  • Page 52: 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 ST. Note: If required, multiple inputs can be configured before clicking Apply. 5.5.2 Digital output configuration The Digital Outputs tab allows you to define how each digital output will operate and if it is to be configured as an error output.

  • Page 53: Saving Setup Information

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

  • Page 54: Loading Saved Information

    A Startup block should be included in every Mint program, so that whenever a program is loaded and run the NextMove ST will be correctly configured. If the same program is used on a different NextMove ST installation, remember the Startup block might need to be changed to accommodate a different motor type.

  • Page 55: Troubleshooting

    If you have followed all the instructions in this manual in sequence, you should have few problems installing the NextMove ST. 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.

  • Page 56: Nextmove St Indicators

    Spline. A spline move is being performed. See the SPLINE keyword and related commands. Axis enabled. Torque mode. The NextMove ST is in Torque mode. See the TORQUE keyword and related commands. Hold to Analog. The axis is in Hold To Analog mode. See the HTA keyword and related commands.

  • Page 57: Surface Mount Leds D3, D4, D16 And D20

    LED and LEDDISPLAY keywords. See the MintMT help file for details of each keyword. 6.2.2 Surface mount LEDs D3, D4, D16 and D20 The NextMove ST control card contains a number of surface mount LEDs that indicate hardware status: D3 (yellow): Indicates that the FPGA is being initialized at startup.

  • Page 58: Communication

    6.2.3 Communication If the problem is not listed below please contact Baldor technical support. Symptom Check Cannot detect NextMove ST Check that the NextMove ST is powered. For serial connections, check that the serial cable is wired correctly and properly connected. Check that no other application on the PC is attempting to use the same serial port.

  • Page 59: Canopen

    Check The CANopen bus is ‘passive’ This means that the internal CAN controller in the NextMove ST is experiencing a number of Tx and/or Rx errors, greater than the passive threshold of 127. Check: 12-24V is being applied to pin 5 of the RJ45 CAN connector, to power the opto-isolators.
  • Page 60 MintMT state, check the following: NODESCAN keyword. Only nodes that conform to DS401, DS403 and other Baldor CANopen nodes are supported by the MintMT NODESCAN keyword. Check that the node in question has been assigned a unique node ID.

  • Page 61: Baldor Can

    The Baldor CAN bus is This means that the internal CAN controller in the ‘passive’ NextMove ST is experiencing a number of Tx and/or Rx errors, greater than the passive threshold of 127. Check: 12-24V is being applied to pin 5 of the RJ45 CAN connector, to power the opto-isolators.
  • Page 62 www.supportme.net 6-8 Troubleshooting MN1929...
  • Page 63 Specifications 7.1 Introduction This section provides technical specifications of the NextMove ST. 7.1.1 Input power Description Value Logic power Nominal supply voltage 24VDC / 24VAC Minimum supply voltage 12VDC / 12VAC Maximum supply voltage 35VDC / 30VAC Power consumption...
  • Page 64 www.supportme.net 7.1.3 Analog inputs Description Unit Value Type Differential Common mode voltage range ±10 Input impedance kΩ Input ADC resolution bits 12 (includes sign bit) Equivalent resolution (±10V input) ±4.9 Sampling interval µs 500 (both inputs enabled) 250 (one input disabled) 7.1.4 Analog output Description Unit...
  • Page 65 www.supportme.net 7.1.6 Digital outputs Description Unit Value Load supply voltage (maximum) Output current (DOUT0-DOUT7) Per output, one output on Per output, all outputs on Output current (DOUT8-DOUT15) Per output, one output on Per output, all outputs on Update interval Immediate 7.1.7 Stepper axis 0-2 drive outputs Description Unit...
  • Page 66 7.1.10 CAN interface Description Unit Value Signal 2-wire, isolated Channels Protocols CANopen or Baldor CAN (selected by choice of firmware) Bit rates Kbit/s CANopen 10, 20, 50, 100, 125, 250, 500, 1000 Baldor CAN 10, 20, 50, 125, 250, 500, 1000 7.1.11 Environmental...
  • Page 67 DRIVEENABLEOUTPUT keyword, 4-16 Basic Installation, 3-1 GLOBALERROROUTPUT keyword, 4-16 location requirements, 3-1 RELAY keyword, 4-16 mounting, 3-2 Features, 2-1 CAN interface Baldor CAN, 4-24 CANopen, 4-23 GLOBALERROROUTPUT keyword, 4-16 connector, 4-21 introduction, 4-21 opto-isolation, 4-22 Hardware requirements, 3-3 specifications, 7-4...
  • Page 68 Saving setup information, 5-11 digital input/output configuration, 5-9 Scale, selecting, 5-6 help file, 5-3 Serial port, 4-17 loading saved information, 5-12 connecting serial Baldor HMI panels, 4-20 saving setup information, 5-11 Specifications, 7-1 starting, 5-4 analog inputs, 7-2 MN1929 Index...
  • Page 69 If you have any suggestions for improvements to this manual, please let us know. Write your comments in the space provided below, remove this page from the manual and mail it to: Manuals Baldor UK Ltd Mint Motion Centre 6 Bristol Distribution Park...
  • Page 70 Thank you for taking the time to help us. Comments MN1929...
  • Page 72 Baldor Japan Corporation Baldor Electric Company Tel: +81 45 412 4506 Tel: +1 479 646 4711 Fax: +81 45 412 4507 Fax: +1 479 648 5792 For additional office locations visit www.baldor.com Printed in UK E Baldor UK Ltd LT0203A01...

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