MOTION CONTROL NextMove PCI--2 Motion Controller Installation Manual 01/10 MN1933
Contents 1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2.1 NextMove PCI-2 features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2.2 Receiving and inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 2.2.1 2.3 3 Units and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.6.5 4.7 4.7.1 4.8 5 CAN wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27 Reset states . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28 System watchdog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-28 Connection summary - minimum system wiring . . . . . . . . . . . . . 4-29 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1.1 6.1.2 6.2 NextMove PCI-2 indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2.1 6.2.2 6.2.3 6.3 Status LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CAN LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reset LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Problem solving . . . . . . . . . . . .
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1 1 www.baldormotion.com General Information LT0226A03 Copyright Baldor (c) 2010. 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.
www.baldormotion.com 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.
2 2 www.baldormotion.com Introduction 2.1 NextMove PCI-2 features NextMove PCI-2 is a high speed multi-axis intelligent motion controller for use in PCI bus based PC systems. NextMove PCI-2 features the Mint motion control language. Mint 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, Mint includes a wide range of powerful commands for complex applications.
www.baldormotion.com H Mint WorkBench This is the user interface for communicating with the NextMove PCI-2. Installing Mint WorkBench will also install firmware for NextMove PCI-2. H ActiveX control The ActiveX control allows PC applications to communicate with the NextMove PCI-2. This manual is intended to guide you through the installation of NextMove PCI-2. The chapters should be read in sequence. The Basic Installation section describes the mechanical installation of the NextMove PCI-2.
www.baldormotion.com 2.2 Receiving and inspection When you receive your NextMove PCI-2, 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 PCI-2. 2. Remove the NextMove PCI-2 from the shipping container but do not remove its anti-static bag until you are ready to install it. The packing materials may be retained for future shipment. 3.
www.baldormotion.com 2.3 Units and abbreviations The following units and abbreviations may appear in this manual: V ............... W .............. A ............... Ω ............... mΩ . . . . . . . . . . . . . μF . . . . . . . . . . . . . . pF . . . . . . . . . . . . . . mH . . . . . . . . . . . . . Volt (also VAC and VDC) Watt Ampere Ohm milliohm microfarad picofarad millihenry Φ............... ms . . . . . . . . . . . . . . μs . . . . . . . . . . . . . . ns . . . . . . . . . . . . . .
3 3 www.baldormotion.com 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-2. This section describes the mechanical and electrical installation of the NextMove PCI-2. 3.1.1 Location requirements It is essential that you read and understand this section before beginning the installation.
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www.baldormotion.com 3.2 Installation NextMove PCI-2 can be installed into an AT style personal computer that has a free 7 inch PCI card slot. You will need a small cross-head screwdriver to fit the card. 3.2.1 Installing the NextMove PCI-2 card NOTICE Before touching the card, 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 card. 1. 2. 3. 4. 5. 6. 7.
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4 4 www.baldormotion.com Input / Output 4.1 Introduction This section describes the digital and analog input and output capabilities of the NextMove PCI-2. The following conventions will be used to refer to the inputs and outputs: I/O . . . . . . . . . . . . . . DIN . . . . . . . . . . . . . DOUT . . . . . . . . . . . AIN . . . . . . . . . . . . . AOUT . . . . . . . . . . .
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www.baldormotion.com 4.3 Analog I/O The NextMove PCI-2 provides: H Four 12-bit resolution analog inputs. H Four 16-bit resolution analog outputs. 4.3.
www.baldormotion.com Breakout module NextMove PCI-2 +12V ‘X6’ 100 way cable 10k 120k AIN0- 3 - AIN0+ 2 + 120k 10k + Mint ADC(0) TL084 -12V AGND 1 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. +24 VDC 1.5 kΩ, 0.25 W X6 1 kΩ, 0.
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www.baldormotion.com 4.4 Digital I/O The NextMove PCI-2 provides: H 20 general purpose digital inputs. H 12 general purpose digital outputs. 4.4.1 Digital inputs - overview There are a total of 20 general purpose digital inputs. Inputs can be configured in Mint for any of the following functions: H Forward limit (end of travel) input on any axis. H Reverse limit (end of travel) input on any axis. H Home input on any axis. H Drive error input on any axis.
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www.baldormotion.com Breakout module ‘X1’ DIN12 2 Common2 12 NextMove PCI-2 100 way cable Vcc 3k3 Mint INX(12) TLP280 DGND Active high: DINx = 12-24 VDC (±20%) Common2 = 0 V Active low: DINx = 0 V Common2 = 12-24 VDC (±20%) Figure 6 - Digital input circuit - DIN12 shown 4.4.
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www.baldormotion.com 4.4.5 Digital outputs - overview There are a total of 12 general purpose digital outputs. An output can be configured in Mint as a general purpose output, a drive enable output or a general error output. Outputs can be shared between axes and are programmable, using the Mint keyword OUTPUTACTIVELEVEL, to determine their active level. Two types of output are available, depending on the NextMove PCI-2 model: H Current sourcing PNP (PCI201-50x). H Current sinking NPN (PCI201-51x).
www.baldormotion.com Each opto-isolated output is designed to source current from the customer supplied 12-24 V supply (USR V+) as shown in Figure 8. The use of shielded cable is recommended. The CGND must be connected to the host PC’s GND. See section 4.5.2 for details about connecting the USR V+ supply. NextMove PCI-2 Voltage regulator Breakout module Fuse ‘X4’ 1.
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www.baldormotion.com 4.5.1.1 Encoder input frequency The maximum encoder input frequency is approximately 10 million quadrature counts per second. This is equivalent to a frequency for the A and B signals of 2.5 MHz. However, the maximum achievable frequency is affected by the length of the encoder cables, as shown in Table 3: Maximum cable length Frequency meters feet 1.3 MHz 2 6.56 500 kHz 10 32.8 250 kHz 20 65.6 100 kHz 50 164.0 50 kHz 100 328.1 20 kHz 300 984.2 10 kHz 700 2296.
www.baldormotion.com 4.5.2 Power - X9 10 Location Pin 1 Breakout module, connector X9 Name 1 Vcc 2 Vcc 3 Encoder V+ 4 Encoder V+ 5 GND 6 GND 7 USR V+ 8 USR V+ 9 CGND 10 CGND Description +5 V supply source from the host PC Power to the encoder connectors Digital ground from the host PC Customer power supply Customer power supply ground The power connector X9 provides a single connection point for external power supplies. Access is also provided to the host PC’s 5 V supply.
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www.baldormotion.com 4.6 CAN The CAN bus is a serial based network originally developed for automotive applications, but now used for a wide range of industrial applications. It offers low-cost serial communications with very high reliability in an industrial environment; the probability of an undetected error is 4.7x10-11. It is optimized for the transmission of small data packets and therefore offers fast update of I/O devices (peripheral devices) connected to the bus.
www.baldormotion.com 4.6.1 CANopen connector - X17 Location Breakout module, connector X17 1 6 5 9 Pin Name Description 1 Shield Cable shield 2 CAN1- CAN channel 1 negative 3 CAN1 GND CAN1 Ground / earth reference 4 - (NC) 5 - (NC) 6 - (NC) 7 CAN1+ CAN channel 1 positive 8 (NC) - 9 CAN1 V+ CAN1 power (12-24 VDC) CANopen connections are made using the breakout module connector X17. This is a 9-pin male D-type connector with CiA standard DS102 pin configuration.
www.baldormotion.com Baldor HMI Operator Panel CANopen D-type 7 Power supply terminal block 24V 0V 2 6 Breakout module X17 Twisted pairs CAN+ CAN- TR 0V 24V 1 2 7 Breakout module X17 End node 7 7 Twisted pairs 2 2 3 3 3 9 9 9 TR 2 5 Figure 13 - Typical CANopen network connections Note: The NextMove PCI-2 CAN channel is opto-isolated, so a voltage in the range 12-24 VDC must be applied to pin 5 of the CAN connector.
www.baldormotion.com 4.6.3 Baldor CAN connector - X18 Location Breakout module, connector X18 Pin Name 1 8 Description 1 - (NC) 2 - (NC) 3 - (NC) 4 CAN2 0V Ground/earth reference for CAN signal 5 CAN2 V+ CAN remote node power V+ (12-24 VDC) 6 (NC) - 7 CAN2+ CAN channel 2 positive 8 CAN2- CAN channel 2 negative Baldor CAN connections are made using the RJ45 breakout module connector X18.
www.baldormotion.com Baldor CAN Operator Panel J3 4 1 Operator Panel supply 0V 3 2 24V 1 TR JP3 2 4 5 Breakout module ‘X18’ J1 / J2 Twisted pair CAN+ CAN0V 24V 7 8 4 TR 5 Figure 14 - Baldor CAN operator panel connections The NextMove PCI-2 CAN channel is opto-isolated, so a voltage in the range 12-24 VDC must be applied to pin 5 of the CAN connector. From this supply, an internal voltage regulator provides the 5 VDC required for the isolated CAN circuit.
www.baldormotion.com 4.6.5 CAN wiring A very low error bit rate over CAN can only be achieved with a suitable wiring scheme, so the following points should be observed: H The two-wire data bus line may be routed parallel, twisted and/or shielded, depending on EMC requirements. Baldor recommend a twisted pair cable with the shield/screen connected to the connector backshell, in order to reduce RF emissions and provide immunity to conducted interference.
www.baldormotion.com 4.7 Reset states During power up, NextMove PCI-2 is held in a safe non-operational state known as hardware reset. It will also go into hardware reset if the 5 VDC supply drops below approximately 4.75 VDC, to prevent uncontrolled operation due to the electronics losing power. When NextMove PCI-2 is in hardware reset for any reason, most of the controlled interfaces fall into known states. It is also possible for NextMove PCI-2 to be in a state known as software reset.
www.baldormotion.com 4.8 Connection summary - minimum system wiring As a guide, Figure 15 shows an example of the typical minimum wiring required to allow the NextMove PCI-2 and a single axis drive amplifier to work together. Details of the connector pins are shown in Table 4.
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5 5 www.baldormotion.com Operation 5.1 Introduction The software provided includes a number of applications and utilities to allow you to configure, tune and program the NextMove PCI-2. The Baldor Motion Toolkit CD containing the software can be found separately within the packaging. 5.1.1 Installing the driver software - Windows 95, 98 and ME 1. Turn on the PC. During the start process, Windows will detect the newly installed NextMove PCI-2 card. 2.
www.baldormotion.com 5.1.2 Installing the driver software - Windows NT Windows NT does not support ‘plug and play’ so there will be no indication that a new card has been installed. The device driver for NextMove PCI-2 must be installed from the Baldor Motion Toolkit CD. 1. Insert the CD into the drive. The CD should auto-run and display the opening page. If auto-run is disabled, browse the CD and double click the file start.exe. 2.
www.baldormotion.com 5.1.4 Installing Mint Machine Center and Mint WorkBench You will need to install Mint Machine Center (MMC) and Mint WorkBench to configure and tune the NextMove PCI-2. Any previous version of Mint WorkBench must be uninstalled before proceeding with this installation: 1. Insert the CD into the drive. 2. After a few seconds the setup wizard should start automatically. If the setup wizard does not appear, select Run...
www.baldormotion.com 5.2 Mint Machine Center The Mint Machine Center (MMC) is used to view the network of connected controllers in a system. Individual controllers and drives are configured using Mint WorkBench. Note: If you have only a single NextMove PCI-2 connected to your PC, then MMC is probably not required. Use Mint WorkBench (see section 5.3) to configure the NextMove PCI-2.
www.baldormotion.com 5.2.1 Starting MMC 1. On the Windows Start menu, select Programs, Mint Machine Center, Mint Machine Center. 2. In the controller pane, ensure that Host is selected. In the information pane, click Scan. 3. When the search is complete, click once on ‘NextMove PCI-2’ in the controller pane to select it.
www.baldormotion.com 4. The NextMove PCI-2 will not yet be running any firmware, so this must now be installed. Click the Firmware tab at the bottom of the information pane. 5. In the table, click the most recent build of firmware. If no firmware is listed, click Install System File... and locate a suitable .msx file. These are available on www.baldormotion.com/supportme. 6. Click Download to Controller.
www.baldormotion.com 5.3 Mint WorkBench Mint WorkBench is a fully featured application for commissioning the NextMove PCI-2. The main Mint 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’; hold the mouse pointer over the button (don’t click) and its description will appear.
www.baldormotion.com 5.3.1 Help file Mint WorkBench includes a comprehensive help file that contains information about every Mint keyword, how to use Mint WorkBench and background information on motion control topics. The help file can be displayed at any time by pressing F1. On the left of the help window, the Contents contains a number of topics . The tab shows the tree structure of the help file.
www.baldormotion.com 5.3.2 Starting Mint WorkBench Note: If you have already used MMC to install firmware and start an instance of Mint WorkBench, go straight to section 5.4 to continue configuration. 1. On the Windows Start menu, select Programs, Mint Machine Center, Mint WorkBench. 2. In the opening dialog box, click Start New Project... .
www.baldormotion.com 3. In the Select Controller dialog, go to the drop down box near the top and select Do not scan serial ports. Click Scan to search for the NextMove PCI-2. When the search is complete, click ‘NextMove PCI-2’ in the list to select it, then click Select. 4. A dialog box will appear to tell you that the NextMove PCI-2 currently has no firmware. Click Yes to search for firmware.
www.baldormotion.com 5. In the Choose Firmware dialog, click the Controller Type drop down box and select ‘NextMove PCI-2’. In the table, click the most recent build of firmware and then click Download to Controller. The firmware will be downloaded to the NextMove PCI-2. (A dialog box may be displayed to tell you that Mint WorkBench has detected the new firmware. Click OK to continue). Mint WorkBench reads back data from the NextMove PCI-2. When this is complete, Fine-tuning mode is displayed.
www.baldormotion.com 5.4 Configuring an axis The NextMove PCI-2 is capable of controlling servo and stepper axes. This section describes how to configure both types of axis. 5.4.1 Selecting the axis type An axis can be configured as either a servo axis or a stepper axis. The factory preset configuration sets all axes as unassigned (off), so it is necessary to configure an axis as either stepper or servo before it can be used.
www.baldormotion.com 5.4.2 Selecting a scale Mint defines all positional and speed related motion keywords in terms of encoder quadrature counts (for servo motors) or steps for stepper motors. The number of quadrature counts (or steps) is divided by the SCALEFACTOR allowing you to use units more suitable for your application. The unit defined by setting a value for scale is called the user unit (uu). Consider a motor with a 1000 line encoder. This provides 4000 quadrature counts for each revolution.
www.baldormotion.com 5.4.3 Setting the drive enable output The drive enable output allows NextMove PCI-2 to enable the external drive amplifier to allow motion, or disable it 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. If an output is shared, an error on any of the axes sharing the output will cause all of them to be disabled. The drive enable output can either be a digital output or the relay. 1.
www.baldormotion.com 4. If you are going to use the relay, drag the grey Relay0 icon to the grey X axis icon on the right of the screen. To configure multiple axes to use the relay, repeat this step for the other axes. If you are using a digital output, drag the bright blue OUT icon to the grey X axis icon on the right of the screen. To configure multiple axes with the same drive enable output, repeat this step for the other axes. 5. Click Apply at the bottom of the screen.
www.baldormotion.com 5.5 Servo axis - testing and tuning This section describes the method for testing and tuning a servo axis. The drive amplifier must already have been tuned for basic current or velocity control of the motor. To test a stepper axes, go straight to section 5.9. 5.5.1 Testing the demand output This section tests the operation and direction of the demand output for axis 0.
www.baldormotion.com 5.5.2 An introduction to closed loop control This section describes the basic principles of closed loop control. If you are familiar with closed loop control go straight to section 5.6.1. When there is a requirement to move an axis, the NextMove PCI-2 control software translates this into a demand output voltage. This is used to control the drive amplifier which powers the motor. An encoder or resolver on the motor is used to measure the motor’s position.
www.baldormotion.com The remaining gain terms are Velocity Feed forward (KVELFF) and Acceleration Feed forward (KACCEL) described below. In summary, the following rules can be used as a guide: H KPROP: Increasing KPROP will speed up the response and reduce the effect of disturbances and load variations. The side effect of increasing KPROP is that it also increases the overshoot, and if set too high it will cause the system to become unstable.
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www.baldormotion.com 5.6 Servo axis - tuning for current control 5.6.1 Selecting servo loop gains All servo loop parameters default to zero, meaning that the demand output will be zero at power up. Most drive amplifiers can be set to current (torque) control mode or velocity control mode; check that the drive amplifier will operate in the correct mode. The procedure for setting system gains differs slightly for each. To tune an axis for velocity control, go straight to section 5.8.
www.baldormotion.com 3. Click in the KPROP box and enter a value that is approximately one quarter of the value of KDERIV. If the motor begins to vibrate, decrease the value of KPROP or increase the value of KDERIV until the vibration stops. Small changes may be all that is necessary. 4. In the Move Type drop down box, check that the move type is set to Step. 5. Click in the Distance box and enter a distance for the step move.
www.baldormotion.com 5.6.2 Underdamped response If the graph shows that the response is underdamped (it overshoots the demand, as shown in Figure 20) 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. Measured position Demand position Figure 20 - Underdamped response 9. Click in the KDERIV and/or KPROP boxes and make the required changes.
www.baldormotion.com 5.6.3 Overdamped response If the graph shows that the response is overdamped (it reaches the demand too slowly, as shown in Figure 21) 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. Demand position Measured position Figure 21 - Overdamped response 10. Click in the KDERIV and/or KPROP boxes and make the required changes. The ideal response is shown in section 5.6.4.
www.baldormotion.com 5.6.4 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 22.
www.baldormotion.com 5.7 Servo axis - eliminating steady-state errors In systems where precise positioning accuracy is required, it is often necessary to position within one encoder count. Proportional gain, KPROP, is not normally able to achieve this because a very small following error will only produce a small demand for the drive amplifier which may not be enough to overcome mechanical friction (this is particularly true in current controlled systems).
www.baldormotion.com 5.8 Servo axis - tuning for velocity control Drive amplifiers designed for velocity control incorporate their own velocity feedback term to provide system damping. For this reason, KDERIV (and KVEL) can be set to zero. Correct setting of the velocity feed forward gain KVELFF is important to get the optimum response from the system. The velocity feed forward term takes the instantaneous velocity demand from the profile generator and adds this to the output block (see Figure 19).
www.baldormotion.com The analog demand output is controlled by a 12-bit DAC, which can create output voltages in the range -10 V to +10 V. This means a maximum output of +10 V corresponds to a DAC value of 2048. The value of KVELFF is calculated by dividing 2048 by the number of quadrature counts per servo loop, so: KVELFF = = 2048 / 200 10.24 5. Click in the KVELFF box and enter the value. The calculated value should give zero following error in normal operation.
www.baldormotion.com 9. Using the check boxes below the graph, select the Measured velocity and Demand velocity traces. Demand velocity Measured velocity Figure 23 - 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. If the trace for Measured velocity appears below the trace for Demand velocity, increase the value of KVELFF.
www.baldormotion.com 5.8.2 Adjusting KPROP The KPROP term can be used to reduce following error. Its value will usually be much smaller than the value used for an equivalent current controlled system. A fractional value, for example 0.1, will probably give the best response. 1. Click in the KPROP box and enter a starting value of 0.1. 2. Click Go. The NextMove PCI-2 will perform the move and the motor will turn.
www.baldormotion.com Demand position Measured position Figure 24 - 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 24.
www.baldormotion.com 5.9 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. 5.9.1 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. 1. Check that the Drive enable button is pressed. 2. In the Toolbox, click the Edit & Debug icon. 3.
www.baldormotion.com 5.10 Digital input/output configuration The Digital I/O window can be used to setup other digital inputs and outputs. 5.10.1 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.
www.baldormotion.com 4. Now drag the IN1 icon onto the 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-2. Note: If required, multiple inputs can be configured before clicking Apply. 5.10.2 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 5.4.3).
www.baldormotion.com 5.11 Saving setup information When power is removed from the NextMove PCI-2 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. 1. In the Toolbox, click the Edit & Debug icon. 2. On the main menu, choose File, New File. A new program editing window will appear. 3.
www.baldormotion.com 4. On the main menu, choose File, Save File. Locate a folder, enter a filename and click Save. 5.11.1 Loading saved information 1. In the Toolbox, click the Edit & Debug icon. 2. On the main menu, choose File, Open File... Locate the file and click Open. A Startup block should be included in every Mint program, so that whenever a program is loaded and run the NextMove PCI-2 will be correctly configured. Remember that every drive/motor combination has a slightly different response.
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6 6 www.baldormotion.com Troubleshooting 6.1 Introduction This section explains common problems and their solutions. If you want to know the meaning of the LED indicators, see section 6.2. 6.1.1 Problem diagnosis If you have followed all the instructions in this manual in sequence, you should have few problems installing the NextMove PCI-2. If you do have a problem, read this section first. In Mint WorkBench, use the Error Log tool to view recent errors and then check the help file.
www.baldormotion.com 6.2 NextMove PCI-2 indicators 6.2.1 Status LEDs The backplate of the NextMove PCI-2 contains two LEDs, S1 and S2, which represent general status information. The LEDs may illuminate red or green and can be continuous or flashing. S1 S2 LED State(s) Meaning Both off NextMove PCI-2 is not powered. Both red In hardware reset (see section 4.7). Both green, cycling In software reset, with no errors (see section 4.7).
www.baldormotion.com 6.3 Problem solving The following sections describe some common problems and their solutions. 6.3.1 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. Problem Check Cannot detect NextMove PCI-2 Check that the NextMove PCI-2 driver has been installed. See section 5.1.1. Cannot communicate with the controller.
www.baldormotion.com Problem Check Motor runs uncontrollably when controller is switched on and servo loop gains are applied or when a move is set in progress. Motor then stops after a short time. Check that the axis’ corresponding encoder and demand signals are connected to the same axes of motion. Check the demand to the drive is connected with the correct polarity. Check that for a positive demand signal, a positive increase in axis position is seen.
7 7 www.baldormotion.com Specifications 7.1 Introduction This section provides technical specifications of the NextMove PCI-2 7.1.1 Input power and mechanical specifications Description Value Input power (from host PC) +3.3 V at 1000 mA +5 V at 350 mA ±12 V at 250 mA Additional current will be required when powering the encoders from the host PC’s +5 V supply. See section 4.5.2.
www.baldormotion.com 7.1.3 Analog outputs (X7) Unit Description Type Value Bipolar Output voltage range VDC ±10 Output current (max) mA 1 Output DAC resolution bits 12, 14 or 16 (includes sign bit) Equivalent resolution ±4.9 mV (12-bit) ±1.2 mV (14-bit) ±305 μV (16-bit) Update interval μs 200 - 2000 (same as LOOPTIME; default = 1000) 7.1.
www.baldormotion.com 7.1.5 Digital inputs (X3) Unit Description Type Value Non-isolated Input voltage (maximum) VDC Input voltage (Active high) 30 VDC Nominal Minimum Input voltage (Active low) 24 12 VDC Nominal Maximum 0 7 Input current (approximate, per input) mA 7 Sampling interval ms 1 Unit Value mA 50 7.1.6 Digital outputs (X4) Description Output current (maximum, each output) Update interval Immediate 7.1.
www.baldormotion.com 7.1.8 Encoder inputs (X12 - X16) Description Unit Encoder input Maximum input frequency (A and B channels) Value A/B Differential, Z index MHz Output power supply to encoders Total, if sourced from host PC Total, if sourced from user supply 2.5 5 V, 500 mA max. 30 V, 3 A max. Maximum recommended cable length 30.5 m (100 ft) 7.1.
www.baldormotion.com 7.1.12 Environmental Description Unit Operating temperature range Storage temperature range Maximum humidity Vibration Min Max °C 0 +45 °F +32 +113 °C 0 +70 °F +32 +158 % 93% for temperatures up to 31 °C (87 °F), non-condensing, decreasing linearly to 50% relative humidity at 45 °C (113 °F) (non-condensing). 1 G, 10-150 Hz See also section 3.1.1.
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A A www.baldormotion.com Accessories A.1 Introduction NextMove PCI-2 is supplied with the ability to control up to 8 axes. The NextMove PCI-2 expansion card allows control of a further 4 axes. A.1.1 NextMove PCI-2 expansion card In addition to providing a further 4 physical axes, the NextMove PCI-2 expansion card provides 20 digital inputs, 12 digital outputs, 4 analog inputs, 4 analog outputs (demand outputs) and a relay. However, there are no CAN functions.
www.baldormotion.com A description of the catalog numbers are shown in the following table: Catalog number Description PCI202-504 NextMove PCI-2 expansion card with PNP digital outputs, 4 axis PCI202-514 NextMove PCI-2 expansion card with NPN digital outputs, 4 axis OPT225-504 Single expansion interconnect card to connect NextMove PCI-2 to one expansion card. OPT225-505 Dual expansion interconnect card to connect NextMove PCI-2 to two expansion cards.
www.baldormotion.com The Mint WorkBench Axis Config Wizard automatically lists the available channels, which are summarized in the following table: Main NextMove PCI-2 card model NextMove PCI-2 PCI 2 hardware channels (no expansion card) Additional hardware channels... ...with one expansion card exp1 stepper ...with two expansion cards exp1 exp2 serv. step. serv. step.
www.baldormotion.com A.1.3 Expansion card status LEDs The back plate of the NextMove PCI-2 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 State(s) Meaning Both off The expansion card is not powered. Both red In hardware reset (see section 4.7). Both green, flashing alternately In software reset, with no errors (see section 4.7).
www.baldormotion.com A.1.4 NextMove PCI-2 breakout module Breakout modules are available for use with the NextMove PCI-2 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). For further details of each connector, see section 4.
www.baldormotion.com A.1.5 NextMove PC system adapter The NextMove PC adapter takes the output from the 100-pin connector of NextMove PCI-2 and converts it to be compatible with the NextMove PC cable, allowing for machine conversion from NextMove PC to NextMove PCI-2 with minimal change to the physical wiring of the machine. Catalog number Description OPT026-506 Allows NextMove PCI-2 to connect to a NextMove PC system.
www.baldormotion.com A.1.8 Feedback cables The Baldor cables listed in Table 6 connect the ‘Encoder Out’ signal from a drive amplifier (for example MicroFlex, FlexDriveII, Flex+DriveII or MintDriveII), to the encoder input connectors on the NextMove PCI-2 breakout board. One cable is required for each servo axis. See section 4.5.1.1 for the connector pin configuration.
www.baldormotion.com A.1.9 Baldor CAN nodes Digital I/O can be expanded easily on NextMove PCI-2 using the Baldor CAN (CAN2) connection. This provides a high speed serial bus interface to a range of I/O devices, including: H inputNode 8: 8 opto-isolated digital inputs. H relayNode 8: 8 relay outputs. H outputNode 8: 8 opto-isolated digital outputs with short circuit and over current protection. H ioNode 24/24: 24 opto-isolated input and 24 opto-isolated outputs.
www.baldormotion.com A.1.10 HMI panels A range of programmable HMI (Human Machine Interface) panels are available with serial or CANopen communication. Some have color and/or touchscreen capabilities, and all may be programmed using the dedicated HMI Designer software. Catalog number Description KPD-KG420-20 4x20 character/graphic display, serial interface KPD-KG420-30 4x20 character/graphic display, 12 function keys, serial interface KPD-TS03M-10 3.
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B B www.baldormotion.com Mint Keyword Summary B.1 Introduction The following table summarizes the Mint keywords supported by the NextMove PCI-2. Note that due to continuous developments of the NextMove PCI-2 and the Mint language, this list is subject to significant change. Check the latest Mint help file for full details of new or changed keywords. B.1.1 Keyword listing Keyword Description ABORT To abort motion on all axes. ABORTMODE To control the default action taken in the event of an abort.
www.baldormotion.com Keyword Description AUXDAC To set or read the auxiliary DAC outputs. AUXENCODER To set or read the auxiliary encoder input. AUXENCODERMODE To make miscellaneous changes to the auxiliary encoders. AUXENCODERPRESCALE To scale down the auxiliary encoder input. AUXENCODERSCALE To set or read the scale factor for the auxiliary encoder input. AUXENCODERVEL To read the velocity of the auxiliary encoder input.
www.baldormotion.com Keyword Description CAM Perform a cam profile. CAMAMPLITUDE To modify the amplitude of a cam profile. CAMBOX To start or stop a CAMBox channel. CAMBOXDATA To load data associated with a CAMBox channel. CAMEND To define an end point in the cam table if multiple cams are required. CAMINDEX Returns the currently executing cam segment number. CAMPHASE Allows a cam profile to be shifted forwards or backwards over a fixed number of cam segments.
www.baldormotion.com Keyword Description CIRCLEA To perform a circular move with absolute co-ordinates. CIRCLER To perform a circular move with relative co-ordinates. COMMS Accesses the reserved comms array. COMMSMODE Selects comms use over either RS485 or CANopen. COMPAREENABLE Enables/disables the position compare control of a specific digital output. COMPARELATCH Reads the state of the position compare latch. COMPAREMODE Enables and disables the position compare on an axis.
www.baldormotion.com Keyword Description DECELTIME To set the deceleration rate on the axis. DEFAULT To return axis motion variables to their power-up state. DEFAULTALL To return all axis motion variables to their power-up state. DPREVENT To interrupt the host PC and generate a trappable event, using the Dual Port RAM (DPR). DPRFLOAT Read and write a 32-bit floating point value to Dual Port RAM (DPR). DPRLONG Read and write a 32-bit integer value to Dual Port RAM (DPR).
www.baldormotion.com Keyword Description FASTAUXLATCHMODE Sets the default action to be taken to clear the auxiliary encoder’s fast position latch. FASTAUXSELECT To select which of the fast position capture inputs will capture an auxiliary encoder channel. FASTENABLE Manually clears the encoder’s fast position latch. FASTENCODER To return the instantaneous encoder value that was recorded on the fast interrupt. FASTLATCH To read the axis fast interrupt latch.
www.baldormotion.com Keyword Description GEARINGMODE To turn gearing compensation on or off. GLOBALERROROUTPUT Allows the user to specify a global error output which will be deactivated in the event of an error. GO To begin synchronized motion. GROUP To set or read whether a node is a member of a group. GROUPCOMMS To write to the comms arrays of all the nodes within a specified group. GROUPMASTER To set a node as the master of a group or to return the node ID of the group master.
www.baldormotion.com Keyword Description HTAKINT Specifies the integral gain term used in the Hold To Analog (HTA) force loop. HTAKPROP Specifies the proportional gain term used in the Hold To Analog (HTA) force loop. IDLE Indicates if a move has finished executing and the axis has finished moving. IDLEMODE To control the checks performed when determining if an axis idle. IDLEPOS Reads or sets the idle following error limit. IDLESETTLINGTIME To read the time taken for an axis to become idle.
www.baldormotion.com Keyword Description KDERIV To set the servo loop derivative gain on the servo axes. KEYS To remap the layout of the keys on a Baldor CAN KeypadNode. KINT To set the servo loop integral gain. KINTLIMIT To restrict the overall effect of the integral gain KINT. KINTMODE To control when integral action will be applied in the servo loop. KNIFE Loads a tangential knife move on the specified axis. KNIFEAXIS Specifies the master axis that the knife axis should follow.
www.baldormotion.com Keyword Description MISCERRORDISABLE To enable or disable miscellaneous errors calling the error event. MOVEA To set up a positional move to an absolute position. MOVEBUFFERFREE To return the number of free spaces in the move buffer for the specified axis. MOVEBUFFERID To attach or read back a 16-bit identifier from the move buffer. MOVEBUFFERIDLAST To read a 16-bit identifier from the move buffer.
www.baldormotion.com Keyword Description OUTPUTACTIVELEVEL To set the active level on the digital outputs. OUTX To set or read an individual digital output. PLATFORM To return the platform type. POS To set or read the current axis position. POSDEMAND To set or read the instantaneous position demand. POSREMAINING To indicate the remaining move distance. POSROLLOVER To count the number of wraps of the axis position value.
www.baldormotion.com Keyword Description REMOTEEMERGENCYMESSAGE Returns the error code from the last emergency message received from a particular CANopen node. REMOTEERROR Reads the CANopen error register information reported within the last emergency message received from a specific node. REMOTEESTOP To control the emergency stop state of a remote CAN node. REMOTEIN To read the state of all the digital inputs on a remote CAN node.
www.baldormotion.com Keyword Description REMOTESTATUS To set or read the status register on a remote CAN node. RESET To clear motion errors, set the position to zero and re-enable the drive. RESETALL To perform a reset on all axes. SCALEFACTOR To scale axis encoder counts, or steps, into user defined units. SOFTLIMITFORWARD To set the forward software limit position on a specified axis.
www.baldormotion.com Keyword Description TERMINALDEVICE To set or read the device type associated with a given terminal. TERMINALMODE To set or read handshaking modes for a terminal. TERMINALPORT To set or read the communication port associated with a given terminal. TIMEREVENT To set or read the rate of the timer event. TORQUE To execute torque control (constant current) on a servo axis. TRIGGERCHANNEL To specify the input used for triggering, when triggering on an axis source or encoder.
C Date: 24/02/05 Manufacturer: Address: C www.baldormotion.
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Index A Abbreviations, 2-4 Accessories, A-1 Analog I/O, 4-4 analog inputs, 4-4 analog outputs, 4-6 B Baldor CAN nodes, A-8 Basic Installation, 3-1 location requirements, 3-1 NextMove PCI-2 card, 3-3 other requirements, 3-2 Breakout module, A-5 C Calculating KVELFF, 5-26 CAN interface Baldor CAN, 4-25 Baldor CAN connector, 4-25 Baldor CAN nodes, A-8 CANopen, 4-23 CANopen connector, 4-23 introduction, 4-22 LEDs, 6-2 opto-isolation, 4-27 power input, 4-20 specifications, 7-4 terminator, 4-27 wiring, 4-27 Ca
Expansion card, A-1 axis numbering, A-2 status LEDs, A-4 F Features, 2-1 Feedback, 4-17, 7-4 cables, A-7 H Help file, 5-8 HMI panels, A-9 I Indicators, 6-2 CAN LEDs, 6-2 reset LED, 6-2 status LEDs, 6-2 Input / Output, 4-1 100-pin edge connector, 4-1 analog inputs, 4-4, 7-1 analog outputs, 4-6, 7-2 Baldor CAN - X18, 4-25 CAN connection, 4-22 CANopen - X17, 4-23 connection summary, 4-29 digital inputs, 4-8, 7-2, 7-3 digital inputs - X1, 4-10 digital inputs - X2, 4-11 digital inputs - X3, 4-12 digital outpu
tuning for current control, 5-20 tuning for velocity control, 5-26 Specifications, 7-1 analog inputs, 7-1 analog outputs (demands), 7-2 CAN interface, 7-4 digital inputs, 7-2, 7-3 digital outputs, 7-3 encoder inputs, 7-4 environmental, 7-5 mechanical, 7-1 power, 7-1 relay, 7-3 relay output, 7-3 stepper outputs, 7-4 Status LEDs, 6-2 Stepper axis, 5-31 control outputs - X10, 4-21 testing the output, 5-31 System watchdog, 4-28 servo axis, 5-16 stepper axis, 5-31 Troubleshooting, 6-1 CAN LEDs, 6-2 communicatio
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Comments 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 Hawkley Drive Bristol BS32 0BF United Kingdom. Alternatively, you can e-mail your comments to: manuals@baldor.co.uk Comment: continued...
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