Baldor Nextmove ESB User manual

NextMove ESB
Motion Controller
MOTION CONTROL
Installation Manual
1/04 MN1924

Contents i
MN1924
Contents
1 General Information 1-1.................................
2 Introduction 2-1........................................
2.1 NextMove ESB features 2-1.................................
2.2 Receiving and inspection 2-3................................
2.2.1 Identifying the catalog number 2-3....................................
2.3 Units and abbreviations 2-4..................................
3 Basic Installation 3-1....................................
3.1 Introduction 3-1............................................
3.1.1 Location requirements 3-1..........................................
3.1.2 Mounting the NextMove ESB 3-2.....................................
3.1.3 Other requirements for installation 3-3................................
4 Input / Output 4-1......................................
4.1 Introduction 4-1............................................
4.1.1 Connector locations 4-2............................................
4.2 Analog I/O 4-3.............................................
4.2.1 Analog inputs 4-3..................................................
4.2.2 Analog outputs 4-5.................................................
4.3 Digital I/O 4-7..............................................
4.3.1 Digital inputs 4-7..................................................
4.3.2 Digital outputs 4-12.................................................
4.4 Other I/O 4-13..............................................
4.4.1 Stepper control outputs 4-13..........................................
4.4.2 Encoder inputs 0-2 4-14.............................................
4.4.3 USB port 4-15.....................................................
4.4.4 Serial port 4-16.....................................................
4.4.5 Using RS232 4-16..................................................
4.4.6 Multidrop using RS485 / RS422 4-17..................................
4.4.7 Connecting serial Baldor HMI Operator Panels 4-18......................
4.5 CAN 4-19..................................................
4.5.1 CAN connector 4-19................................................
4.5.2 CAN wiring 4-20....................................................
4.5.3 CANopen 4-21.....................................................
4.5.4 Baldor CAN 4-22...................................................
4.6 Connection summary - minimum system wiring 4-24.............

ii Contents MN1924
5 Operation 5-1..........................................
5.1 Introduction 5-1............................................
5.1.1 Connecting the NextMove ESB to the PC 5-1..........................
5.1.2 Installing WorkBench v5 5-1.........................................
5.1.3 Starting the NextMove ESB 5-1......................................
5.1.4 Preliminary checks 5-2.............................................
5.1.5 Power on checks 5-2...............................................
5.2 WorkBench v5 5-3..........................................
5.2.1 Help file 5-3......................................................
5.2.2 Starting WorkBench v5 5-4..........................................
5.3 Configuring an axis 5-6.....................................
5.3.1 Selecting a scale 5-6...............................................
5.3.2 Setting the drive enable output 5-7...................................
5.3.3 Testing the drive enable output 5-9...................................
5.4 Stepper axis - testing 5-10....................................
5.4.1 Testing the output 5-10..............................................
5.5 Servo axis - testing and tuning 5-11............................
5.5.1 Testing the demand output 5-11.......................................
5.5.2 An introduction to closed loop control 5-13..............................
5.6 Servo axis - tuning for current control 5-16......................
5.6.1 Selecting servo loop gains 5-16.......................................
5.6.2 Underdamped response 5-18.........................................
5.6.3 Overdamped response 5-19..........................................
5.6.4 Critically damped response 5-20......................................
5.7 Servo axis - eliminating steady-state errors 5-21.................
5.8 Servo axis - tuning for velocity control 5-22.....................
5.8.1 Calculating KVELFF 5-22............................................
5.8.2 Adjusting KPROP 5-25..............................................
5.9 Digital input/output configuration 5-27..........................
5.9.1 Digital input configuration 5-27........................................
5.9.2 Digital output configuration 5-28.......................................
5.10 Saving setup information 5-29.................................
5.10.1 Loading saved information 5-30.......................................
6 Troubleshooting 6-1....................................
6.1 Introduction 6-1............................................
6.1.1 Problem diagnosis 6-1..............................................
6.1.2 SupportMe feature 6-1.............................................
6.2 NextMove ESB indicators 6-2................................
6.2.1 Status display 6-2.................................................
6.2.2 Communication 6-3................................................
6.2.3 Motor control 6-4..................................................

Contents iii
MN1924
6.2.4 WorkBench v5 6-5.................................................
6.2.5 CANopen 6-6.....................................................
6.2.6 Baldor CAN 6-8...................................................
7 Specifications 7-1......................................
7.1 Introduction 7-1............................................
7.1.1 Input power 7-1...................................................
7.1.2 Analog inputs 7-1..................................................
7.1.3 Analog outputs 7-1.................................................
7.1.4 Digital inputs 7-2..................................................
7.1.5 Digital outputs - general purpose 7-2..................................
7.1.6 Relay output 7-2...................................................
7.1.7 Encoder inputs 7-2................................................
7.1.8 Stepper control outputs 7-3..........................................
7.1.9 Serial RS232/RS485 port 7-3........................................
7.1.10 CAN interface 7-3.................................................
7.1.11 Environmental 7-3.................................................
7.1.12 Weights and dimensions 7-4........................................
Appendices
A General A-1............................................
A.1 Axis renumbering A-1.......................................
A.2 Feedback cables A-3.......................................
B CE Guidelines B-1......................................
B.1 Outline B-1................................................
B.1.1 EMC Conformity and CE marking B-1.................................
B.1.2 NextMove ESB compliance B-1......................................
B.1.3 Use of CE compliant components B-2.................................
B.1.4 EMC installation suggestions B-2.....................................
B.1.5 Wiring of shielded (screened) encoder cables B-2.......................

iv Contents MN1924

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General Information 1-1MN1924
LT0189A02 Copyright Baldor (c) 2004. All rights reserved.
This manual is copyrighted and all rights are reserved. This document or attached software may not,
in whole or in part, be copied or reproduced in any form without the prior written consent of BALDOR.
BALDOR makes no representations or warranties with respect to the contents hereof and specifically
disclaims any implied warranties of fitness for any particular purpose. The information in this
document is subject to change without notice.
BALDOR assumes no responsibility for any errors that may appear in this document.
Minttis a registered trademark of Baldor.
Windows 95, Windows 98, Windows ME, Windows NT, Windows 2000 and Windows XP are
registered trademarks of the Microsoft Corporation.
Limited Warranty:
For a period of two (2) years from the date of original purchase, BALDOR will repair or replace without
charge controls and accessories which our examination proves to be defective in material or
workmanship. This warranty is valid if the unit has not been tampered with by unauthorized persons,
misused, abused, or improperly installed and has been used in accordance with the instructions and/or
ratings supplied. This warranty is in lieu of any other warranty or guarantee expressed or implied.
BALDOR shall not be held responsible for any expense (including installation and removal),
inconvenience, or consequential damage, including injury to any person or property caused by items of
our manufacture or sale. (Some countries and U.S. states do not allow exclusion or limitation of
incidental or consequential damages, so the above exclusion may not apply.) In any event,
BALDOR’s total liability, under all circumstances, shall not exceed the full purchase price of the
control. Claims for purchase price refunds, repairs, or replacements must be referred to BALDOR with
all pertinent data as to the defect, the date purchased, the task performed by the control, and the
problem encountered. No liability is assumed for expendable items such as fuses. Goods may be
returned only with written notification including a BALDOR Return Authorization Number and any
return shipments must be prepaid.
Baldor UK Ltd
Mint Motion Centre
6 Bristol Distribution Park
Hawkley Drive
Bristol, BS32 0BF
Telephone: [phone]
Fax: [phone]
Email: [e-mail]
Web site: www.baldor.co.uk
Baldor ASR GmbH
Telephone: [phone]
Fax: [phone]
Baldor ASR AG
Telephone: [phone]
Fax: [phone]
Email: [e-mail]
Australian Baldor Pty Ltd
Baldor Electric Company
Telephone: [phone]
Fax: [phone]
Email: [e-mail]
Web site: www.baldor.com
A
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B
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Telephone: [phone]
Fax: [phone]
Baldor Electric (F.E.) Pte Ltd
Telephone: [phone]
Fax: [phone]
Baldor Italia S.R.L
Telephone: [phone]
Fax: [phone]
1General Information 1

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1-2 General Information MN1924
Safety Notice
Only qualified personnel should attempt to start-up, program or troubleshoot this equipment.
This equipment may be connected to other machines that have rotating parts or parts that are
controlled by this equipment. Improper use can cause serious or fatal injury.
Precautions
WARNING: Do not touch any circuit board, power device or electrical connection before you
first ensure that no high voltage is present at this equipment or other equipment to
which it is connected. Electrical shock can cause serious or fatal injury.
WARNING: Be sure that you are completely familiar with the safe operation and programming
of this equipment. This equipment may be connected to other machines that have
rotating parts or parts that are controlled by this equipment. Improper use can
cause serious or fatal injury.
WARNING: The stop input to this equipment should not be used as the single means of
achieving a safety critical stop. Drive disable, motor disconnect, motor brake and
other means should be used as appropriate.
WARNING: Improper operation or programming may cause violent motion of the motor shaft
and driven equipment. Be certain that unexpected motor shaft movement will not
cause injury to personnel or damage to equipment. Peak torque of several times
the rated motor torque can occur during control failure.
CAUTION: The safe integration of this equipment into a machine system is the responsibility
of the machine designer. Be sure to comply with the local safety requirements at
the place where the machine is to be used. In Europe these are the Machinery
Directive, the Electromagnetic Compatibility Directive and the Low Voltage
Directive. In the United States this is the National Electrical code and local codes.
CAUTION: Electrical components can be damaged by static electricity. Use ESD
(electrostatic discharge) procedures when handling this drive.

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Introduction 2-1MN1924
2.1 NextMove ESB features
NextMove ESB is a high performance multi-axis intelligent controller for servo and stepper
motors.
NextMove ESB features the MintMT motion control language. MintMT is a structured form of
Basic, custom designed for stepper or servo motion control applications. It allows you to get
started very quickly with simple motion control programs. In addition, MintMT includes a wide
range of powerful commands for complex applications.
Standard features include:
HControl of 4 stepper and 3 servo axes.
HPoint to point moves, software cams and gearing.
H20 general purpose digital inputs, software configurable as level or edge triggered.
H11 general purpose digital outputs.
H2 differential analog inputs with 12-bit resolution.
H4 single-ended analog outputs with 12-bit resolution.
HUSB serial port.
HRS232 or RS485 serial port (model dependent).
HCANopen or proprietary Baldor CAN protocol for communication with MintMT controllers
and other third party devices.
HProgrammable in MintMT.
2Introduction 2

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2-2 Introduction MN1924
Included with NextMove ESB is the Baldor Motion Toolkit CD. This contains a number of
utilities and useful resources to get the most from your MintMT controller. These include:
HMint WorkBench v5
This is the user interface for communicating with the NextMove ESB. Installing Mint
WorkBench v5 will also install firmware for NextMove ESB.
HPC Developer Libraries
Installing Mint WorkBench v5 will install ActiveX interfaces that allow PC applications to be
written that communicate with the NextMove ESB.
This manual is intended to guide you through the installation of NextMove ESB.
The chapters should be read in sequence.
The Basic Installation section describes the mechanical installation of the NextMove ESB.
The following sections require knowledge of the low level input/output requirements of the
installation and an understanding of computer software installation. If you are not qualified in
these areas you should seek assistance before proceeding.
Note: You can check that you have the latest firmware and WorkBench v5 releases by
visiting the website www.supportme.net.

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Introduction 2-3MN1924
2.2 Receiving and inspection
When you receive your NextMove ESB, there are several things you should do immediately:
1. Check the condition of the packaging and report any damage immediately to the carrier
that delivered your NextMove ESB.
2. Remove the NextMove ESB from the shipping container and remove all packing material. The
container and packing materials may be retained for future shipment.
3. Verify that the catalog number of the NextMove ESB you received is the same as the
catalog number listed on your purchase order. The catalog/part number is described in
the next section.
4. Inspect the NextMove ESB for external damage during shipment and report any damage
to the carrier that delivered it.
5. If the NextMove ESB is to be stored for several weeks before use, be sure that it is stored
in a location that conforms to the storage humidity and temperature specifications shown
in section 3.1.1.
2.2.1 Identifying the catalog number
Different models of NextMove ESB are available. As a reminder of which product has been
installed, it is a good idea to write the catalog number in the space provided below.
NextMove ESB catalog number: NSB002-501 or NSB002-502
Installed in: ________________________ Date: ______
A description of the catalog numbers are shown in the following table:
Catalog
number Description
NSB002-501 NextMove ESB controller with USB and RS232 serial connections
NSB002-502 NextMove ESB controller with USB and RS485 serial connections

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2-4 Introduction MN1924
2.3 Units and abbreviations
The following units and abbreviations may appear in this manual:
V Volt (also VAC and VDC)...............
WWatt..............
A Ampere...............
ΩOhm...............
mΩmilliohm.............
µF microfarad..............
pF picofarad..............
mH millihenry.............
Φphase...............
ms millisecond..............
µs microsecond..............
ns nanosecond..............
mm millimeter.............
m meter...............
in inch...............
ft feet...............
lbf-in pound force inch (torque)............
Nm Newton meter (torque).............
ADC Analog to Digital Converter............
ASCII American Standard Code for Information Interchange...........
AWG American Wire Gauge............
CAL CAN Application Layer............
CAN Controller Area Network............
CDROM Compact Disc Read Only Memory.........
CiA CAN in Automation International Users and Manufacturers Group e.V..............
CTRL+E on the PC keyboard, press Ctrl then Eat the same time..........
DAC Digital to Analog Converter............
DS301 CiA CANopen Application Layer and Communication Profile..........
DS401 CiA Device Profile for Generic I/O Devices..........
DS403 CiA Device Profile for HMIs..........
EDS Electronic Data Sheet............
EMC Electromagnetic Compatibility............
HMI Human Machine Interface.............
ISO International Standards Organization.............
Kbaud kilobaud (the same as Kbit/s in most applications)...........
LCD Liquid Crystal Display............
MB megabytes.............
Mbps megabits/s...........
(NC) Not Connected............
RF Radio Frequency..............

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Basic Installation 3-1MN1924
3.1 Introduction
You should read all the sections in Basic Installation.
It is important that the correct steps are followed when installing the NextMove ESB.
This section describes the mechanical installation of the NextMove ESB.
3.1.1 Location requirements
You must read and understand this section before beginning the installation.
CAUTION: To prevent equipment damage, be certain that input and output signals
are powered and referenced correctly.
CAUTION: To ensure reliable performance of this equipment be certain that all
signals to/from the NextMove ESB are shielded correctly.
CAUTION: Avoid locating the NextMove ESB immediately above or beside heat
generating equipment, or directly below water steam pipes.
CAUTION: Avoid locating the NextMove ESB in the vicinity of corrosive substances
or vapors, metal particles and dust.
The safe operation of this equipment depends upon its use in the appropriate environment.
The following points must be considered:
HThe NextMove ESB is designed to be mounted indoors, permanently fixed and located.
HThe NextMove ESB must be secured by the slots in the metal case.
HThe NextMove ESB must be installed in an ambient temperature of 0°C to 45°C (32°F to
113°F).
HThe NextMove ESB must be installed in relative humidity levels of less than 80% for
temperatures up to 31°C (87°F) decreasing linearly to 50% relative humidity at 45°C
(113°F), non-condensing.
HThe NextMove ESB must be installed where the pollution degree according to IEC664
shall not exceed 2.
HThere shall not be abnormal levels of nuclear radiation or X-rays.
3Basic Installation 3

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3-2 Basic Installation MN1924
3.1.2 Mounting the NextMove ESB
CAUTION: Before touching the unit be sure to discharge static electricity from your
body and clothing by touching a grounded metal surface. Alternatively,
wear an earth strap while handling the unit.
Ensure you have read and understood the location requirements in section 3.1.1. Mount the
NextMove ESB using the supplied M4 screws. For effective cooling, the NextMove ESB must
be mounted on a smooth non-flammable vertical surface. Orientation must be as shown in
Figure 1, with the two slots in the metal carrier / heat sink assembly at the bottom.
135 (5.3) 124 (4.9)
170 (6.7)
245 (9.65)
All dimensions shown as
mm (inches)
43 (1.7)
Mounting keyhole and slot detail
A
BC
A4.5mm
B10mm
C11mm
A
Drawings not to scale
Figure 1 - Package dimensions
There must be at least 20mm (0.8 in) clearance between the NextMove ESB and neighboring
equipment to allow sufficient cooling by natural convection. Remember to allow additional
space around the edges to accommodate the mating connectors and associated wiring. For
example, 70mm (2.8 in) clearance will be required for connection of the serial port cable.

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Basic Installation 3-3MN1924
3.1.3 Other requirements for installation
HThe NextMove ESB requires +24V power supply capable of supplying 2A continuously.
If digital outputs are to be used, a supply will be required to drive them - see section 4.3.2.
HA PC that fulfills the following specification:
Minimum specification Recommended specification
Processor Intel Pentium 133MHz Intel PentiumII 400MHz or faster
RAM 32MB 128MB
Hard disk space 40MB 60MB
CD-ROM ACD-ROMdrive
Serial port USB port
or
RS232 or RS485 serial port (depending on NextMove ESB model)
Screen 800 x 600, 256 colors 1024 x 768, 16-bit color
Mouse A mouse or similar pointing device
Operating
system
Windows 95, Windows NT Windows 98*, Windows ME*,
Windows NT*, Windows 2000 or
Windows XP
* For USB support, Windows 2000 or Windows XP is required. Software installation will be
described later, in section 5.
HA serial cable (connected as shown in section 4.4.4) or USB cable.
HYour PC operating system user manual might be useful if you are not familiar with Windows.

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3-4 Basic Installation MN1924

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Input / Output 4-1MN1924
4.1 Introduction
This section describes the input and output capabilities of the NextMove ESB.
The following conventions will be used to refer to the inputs and outputs:
I/O Input / Output..............
DIN Digital Input.............
DOUT Digital Output...........
AIN Analog Input.............
AOUT Analog Output...........
4Input / Output 4

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4-2 Input / Output MN1924
4.1.1 Connector locations
Tightening torque for terminal block
connections is 0.3Nm (2.65 lbf-in)
X12 AIN 0-1
& relay
X7 Encoder2
X6 Encoder1
X4 DOUT 8-10
X2 STEP 0-1
AIN0+
AIN0-
AGND
AIN1+
AIN1-
Shield
REL COM
REL NC
REL NO
REL COM
CREF2
CREF1
CREF0
!RSTIN
USR GND
USR V+
USR V+
DOUT10
DOUT9
DOUT8
Shield
DIR1+
DIR1-
STEP1+
STEP1-
DGND
Shield
DIR0+
DIR0-
STEP0+
STEP0-
DGND
Serial
Required mating connectors:
Sauro CTF10008
Sauro CTF12008
Sauro CTF02008
9-pin D-type plug (male)
9-pin D-type socket (female)
RJ45 plug
USB type B plug
1
2
3
4
5
6
7
8
9
10
12
11
10
9
8
7
6
5
4
3
2
1
10
9
8
7
6
5
4
3
2
1
X11 DOUT 0-7
DOUT0
DOUT1
DOUT2
DOUT3
DOUT4
DOUT5
DOUT6
DOUT7
USR V+
USR GND
1
2
3
4
5
6
7
8
9
10
X10 DIN 0-3
(fast interrupts)
DIN3
Shield
CREF0
DIN2
Shield
CREF0
DIN1
Shield
CREF0
DIN0
1
2
3
4
5
6
7
8
9
10
X9 DIN 4-11
DIN11
DIN10
DIN9
DIN8
DIN7
DIN6
DIN5
DIN4
CREF1
Shield
1
2
3
4
5
6
7
8
9
10
X8 DIN 12-19
DIN19
DIN18
DIN17
DIN16
DIN15
DIN14
DIN13
DIN12
CREF2
Shield
1
2
3
4
5
6
7
8
9
10
X13 AOUT 0-3
(demands)
DEMAND0
AGND
Shield
DEMAND1
AGND
Shield
DEMAND2
AGND
Shield
DEMAND3
AGND
Shield
1
2
3
4
5
6
7
8
9
10
11
12
X3 STEP 2-3
Shield
DIR3+
DIR3-
STEP3+
STEP3-
DGND
Shield
DIR2+
DIR2-
STEP2+
STEP2-
DGND
12
11
10
9
8
7
6
5
4
3
2
1
X5 Encoder0
X1 +24V in +24V
0V
2
1
CANUSB

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Input / Output 4-3MN1924
4.2 Analog I/O
The NextMove ESB provides:
HTwo 12-bit resolution analog inputs.
HFour 12-bit resolution analog outputs.
4.2.1 Analog inputs
The analog inputs are available on connector X12, pins 1 & 2 (AIN0) and 4 & 5 (AIN1).
HDifferential inputs.
HVoltage range: ±10V.
HResolution: 12-bit with sign (accuracy ±4.9mV @ ±10V input).
HInput impedance: 120kΩ.
HSampling frequency: 4kHz maximum, 2kHz if both inputs are enabled.
The analog inputs pass through a differential buffer and second order low-pass filter with a
cut-off frequency of approximately 1kHz.
Both inputs are normally sampled at 2kHz. However, an input can be disabled by setting
ADCMODE to4(_acOFF). With one input disabled, the remaining input will be sampled at 4kHz.
In MintMT, analog inputs can be read using the ADC keyword. See the MintMT help file for full
details of ADC,ADCMODE and other related ADC... keywords.
NextMove ESB
-
+
AIN0+
AIN0-
AGND
MintMT
ADC.0
-
+
120k
120k
15k
10k 10k
22nF
10nF
2
3
1
+12V
-12V
‘X12’
Figure 2 - Analog input, AIN0 shown
For differential inputs connect input lines to AIN+ and AIN-. Leave AGND unconnected.

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4-4 Input / Output MN1924
AIN0
(ADC.0)
X12
AIN0
(ADC.0)
1
2
3
X12
AIN0-
Differential connection Single ended connection
AIN0+ 1
2
3
AIN0+
GND
Figure 3 - AIN0 analog input wiring
AIN0
1kΩ,0.25W
potentiometer
(ADC.0)2
1
X12
1.5kΩ, 0.25W
0V
+24VDC
3
Figure 4 - Typical input circuit to provide 0-10V (approx.) input from a 24V source