Mint NextMove PCI User manual

MN1277 04.2001
NextMove PCI
Installation Manual
MN1277
Issue 2.3

NextMove PCI Installation Manual
ii MN1277 04.2001
.

Copyright
MN1277 04.2001 iii
Copyright Baldor UK Ltd © 2001. 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 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: [phone]
Fax: [phone]
Web site: www.baldor.co.uk
Sales email: [email protected].uk
Support email: [e-mail]
Baldor Electric Company
Telephone: [phone]
Fax: [phone]
email: [e-mail]
web site: www.baldor.com
Baldor ASR GmbH
Telephone: [phone]
Fax: [phone]
Baldor ASR AG
Telephone: [phone]
Fax: [phone]
Australian Baldor Pty Ltd
Telephone: [phone]
Fax: [phone]
Baldor Electric (F.E.) Pte Ltd
Telephone: [phone]
Fax:[phone]

NextMove PCI Installation Manual
iv MN1277 04.2001

Safety Information
MN1277 04.2001 v
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, start-
up 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
vi 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, start-
up 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
MN1277 04.2001 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

NextMove PCI Installation Manual
viii MN1277 04.2001

Contents
MN1277 04.2001 ix
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

NextMove PCI Installation Manual
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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
MN1277 04.2001 1
1. Read Me First
1Details of the symbols used throughout this document.

NextMove PCI Installation Manual
2MN1277 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 Eat the same time.

Product Overview
MN1277 04.2001 3
2. Product Overview
2A brief overview of NextMove PCI and the software tools available on the
Baldor Motion Toolkit.

NextMove PCI Installation Manual
4MN1277 04.2001
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.
6
4Axesof
closed loop
Servo control
12
NextMove
Motion Controller
8
Inputs 0-4 second function
Hardware position latch &
fast interrupt input
32
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
4
4
5
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
20
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 5
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.

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Hardware Guide
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3. Hardware Guide
3This 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 9
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
1Chassis Shield connection
2DIG_IN_4 Digital input 4 (referenced to Common0-7)
3DIG_IN_5 Digital input 5 (referenced to Common0-7)
4DIG_IN_6 Digital input 6 (referenced to Common0-7)
5DIG_IN_7 Digital input 7 (referenced to Common0-7)
6DIG_IN_8 Digital input 8 (referenced to Common8-19)
7DIG_IN_9 Digital input 9 (referenced to Common8-19)
8DIG_IN_10 Digital input 10 (referenced to Common8-19)
9DIG_IN_11 Digital input 11 (referenced to Common8-19)
10 Chassis Shield connection
11 Common0-7 Common for inputs 0-7
12 Common8-19 Common for inputs 8-19
X1: Digital Inputs 12 to 19
Pin Signal Function
1Chassis Shield connection
2DIG_IN_12 Digital input 12 (referenced to Common8-19)
3DIG_IN_13 Digital input 13 (referenced to Common8-19)
4DIG_IN_14 Digital input 14 (referenced to Common8-19)
5DIG_IN_15 Digital input 15 (referenced to Common8-19)
6DIG_IN_16 Digital input 16 (referenced to Common8-19)
7DIG_IN_17 Digital input 17 (referenced to Common8-19)
8DIG_IN_18 Digital input 18 (referenced to Common8-19)
9DIG_IN_19 Digital input 19 (referenced to Common8-19)
10 Chassis Shield connection
11 n/c Not connected
12 Common8-19 Common for inputs 8-19