MN1957 NextMove ESB-2
Contents Contents 1 General Information 2 Introduction 2.1 2.2 NextMove ESB-2 features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Receiving and inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 2.3 Units and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 2.2.1 3 Basic Installation 3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 3.1.1 3.1.2 3.1.
5 Operation 5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1 5.1.1 5.1.2 5.1.3 5.1.4 5.1.5 Connecting the NextMove ESB-2 to the PC . . . . . . . . . . . . . . . . . . . . . . . . .5-1 Installing Mint Machine Center and Mint WorkBench . . . . . . . . . . . . . . . . . .5-1 Starting the NextMove ESB-2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1 Preliminary checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.2.5 6.2.6 7 CANopen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Baldor CAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 Specifications 7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 7.1.1 7.1.2 7.1.3 7.1.4 7.1.5 7.1.6 7.1.7 7.1.8 7.1.9 Input power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
iv Contents MN1957
General Information 1 General Information LT0271A03 1 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 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.
Introduction 2 Introduction 2 2.1 NextMove ESB-2 features NextMove ESB-2 is a high performance multi-axis intelligent controller for servo and stepper motors. NextMove ESB-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 Included with NextMove ESB-2 is the Mint Motion Toolkit CD. This contains a number of utilities and useful resources to get the most from your Mint controller. These include: Mint WorkBench This is the user interface for communicating with the NextMove ESB-2. PC Developer Libraries Installing Mint WorkBench will install ActiveX interfaces that allow PC applications to be written that communicate with the NextMove ESB-2.
www.baldormotion.com 2.2 Receiving and inspection When you receive your NextMove ESB-2, there are several things you should do immediately: 1. Check the condition of the shipping container and report any damage immediately to the carrier that delivered your NextMove ESB-2. 2. Remove the NextMove ESB-2 from the shipping container and remove all packing material. The container and packing materials may be retained for future shipment. 3.
www.baldormotion.com 2.3 Units and abbreviations The following units and abbreviations are used in this manual: V. . . . . . . . . . . . . . . . Volt (also VAC and VDC) W . . . . . . . . . . . . . . . Watt A. . . . . . . . . . . . . . . . Ampere Ω . . . . . . . . . . . . . . . Ohm μF. . . . . . . . . . . . . . . microfarad pF. . . . . . . . . . . . . . . picofarad mH . . . . . . . . . . . . . . millihenry Φ . . . . . . . . . . . . . . . phase ms . . . . . . . . . . . . . . millisecond μs . . . . . . . . .
Basic Installation 3 Basic Installation 3 3.1 Introduction You should read all the sections in Basic Installation to ensure safe installation. It is important that the correct steps are followed when installing the NextMove ESB-2. This section describes the mechanical installation of the NextMove ESB-2. 3.1.1 Location requirements You must read and understand this section before beginning the installation.
www.baldormotion.com 3.1.2 Mounting the NextMove ESB-2 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-2 using the supplied M4 screws. For effective cooling, the NextMove ESB-2 must be mounted on a smooth non-flammable vertical surface.
www.baldormotion.com 3.1.3 Other requirements for installation The components you will need to complete the basic installation are: The NextMove ESB-2 requires +24 V power supply capable of supplying 2 A continuously. It is recommended that a separate fused 24 V supply is provided for the NextMove ESB-2, with the fuse rated at 4 A maximum. If digital outputs are to be used, a supply will be required to drive them - see section 4.3.2.
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Input / Output 4 Input / Output 4 4.1 Introduction This section describes the input and output capabilities of the NextMove ESB-2. 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 . . . . . . . . . . .
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www.baldormotion.com 4.2 Analog I/O The NextMove ESB-2 provides: Two 12-bit resolution analog inputs. Four 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). Differential inputs. Voltage range: ±10 V. Resolution: 12-bit with sign. Input impedance: 120 kΩ. Sampling frequency: 4 kHz maximum, 2 kHz if both inputs are enabled.
www.baldormotion.com X12 AIN0+ 1 AIN0- 2 X12 AIN0+ 1 AIN0 (ADC.0) 3 2 AIN0 (ADC.0) 3 GND Differential connection Single ended connection Figure 3: AIN0 analog input wiring +24VDC 1.5 kÙ, 0.25 W X12 1 kÙ, 0.25 W potentiometer 0V 1 2 AIN0 (ADC.0) 3 Figure 4: Typical input circuit to provide 0-10 V (approx.
www.baldormotion.com 4.2.2 Analog outputs The four analog outputs are available on connector X13, as shown in section 4.1.1. Four independent bipolar analog outputs. Output range: ±10 VDC (±0.1%). Resolution: 12-bit. Output current: 2.5 mA maximum per output. Update frequency: 10 kHz maximum (adjustable using the LOOPTIME keyword, factory default 1 kHz). Mint and the Mint Motion Library use analog outputs Demand0 to Demand3 to control drive amplifiers.
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www.baldormotion.com 4.3 Digital I/O The NextMove ESB-2 provides: 20 general purpose digital inputs. 12 general purpose digital outputs. 4.3.1 Digital inputs Digital inputs are available on connectors X8, X9 and X10, as shown in section 4.1.1. The digital inputs are arranged in three groups, each with their own common connection. This allows each group to be configured independently for ‘active high’ or ‘active low’ operation.
www.baldormotion.com 4.3.1.2 DIN4 - DIN11 Digital inputs DIN4 to DIN11 have a common specification: Opto-isolated digital inputs. Sampling frequency: 1 kHz. Digital inputs DIN4 to DIN11 use CREF1 as their common connection. NextMove ESB-2 Vcc X9 100R DIN11 1 CREF1 9 Shield 10 3k3 Mint INX.
www.baldormotion.com 4.3.1.4 Auxiliary encoder inputs - DIN17 (STEP), DIN18 (DIR), DIN19 (Z) DIN17-DIN19 may also be used as an auxiliary encoder input. DIN17 accepts step (pulse) signals and DIN18 accepts direction signals, allowing an external source to provide the reference for the speed and direction of an axis. The step frequency (15 kHz maximum) determines the speed, and the direction input determines the direction of motion.
www.baldormotion.com 4.3.1.5 Typical digital input wiring NextMove ESB-2 X9 User supply 24V DIN4 CREF1 8 9 User supply GND TLP280 Figure 12: Digital input - typical ‘active high’ input connection using a switch User supply 24V NextMove ESB-2 X9 DIN4 CREF1 8 9 TLP280 User supply GND Figure 13: Digital input - typical ‘active low’ input connection using a switch Note: The circuits shown in Figures 12 and 13 are not suitable for use with fast inputs DIN0 to DIN3.
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www.baldormotion.com 4.3.2 Digital outputs The digital outputs are available on connectors X4 and X11, as shown in section 4.1.1. A digital output can be configured in Mint 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 Mint WorkBench (or the OUTPUTACTIVELEVEL keyword) to determine their active level. 4.3.2.
www.baldormotion.com 4.4 Other I/O 4.4.1 Stepper control outputs - models NSB202... / NSB204... The stepper control outputs are available on connectors X2 and X3, as shown in section 4.1.1. There are four sets of stepper motor control outputs, operating in the range 0 Hz to 500 kHz. Each of the step (pulse) and direction signals from the NextMove ESB-2 is driven by DS26LS31 line drivers, providing RS422 differential outputs. It is recommended to use separate shielded cables for the step outputs.
www.baldormotion.com 4.4.2 Stepper control outputs - models NSB203... / NSB205... The stepper control outputs are available on connectors X2 and X3, as shown in section 4.1.1. There are four sets of stepper motor control outputs, operating in the range 0 Hz to 500 kHz. Each of the step (pulse) and direction signals from the NextMove ESB-2 is driven by a ULN2803 open collector Darlington output device. The STEPPERDELAY keyword allows a 0 - 4.
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www.baldormotion.com 4.4.3.1 Encoder input frequency The maximum encoder input frequency is affected by the length of the encoder cables. The theoretical maximum frequency is 10 million quadrature counts per second. This is equivalent to a maximum frequency for the A and B signals of 2.5 MHz. However, the effect of cable length is shown in Table 1: A and B signal frequency Maximum cable length 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.
www.baldormotion.com MicroFlex FlexDriveII Flex+DriveII MintDriveII encoder output CHA+ NextMove ESB-2 X7 Vcc X5 10k 1 1 CHA+ to CPU CHA- 6 6 120R MAX3095 120R MAX3095 120R MAX3095 CHA- Twisted pair Vcc 10k CHB+ 2 2 CHB+ to CPU CHB- 7 7 CHB- Twisted pair Vcc 10k CHZ+ 3 3 CHZ+ to CPU CHZ- 8 8 CHZ- Twisted pair DGND 5 5 DGND 4 Shield Connect overall shield to connector backshells / shield connections.
www.baldormotion.com 4.4.4 Relay connections The relay connections are available on connector X12, as shown in section 4.1.1. The relay outputs are isolated from any internal circuits in the NextMove ESB-2. In normal operation, while there is no error, the relay is energized and REL COM is connected to REL NO. In the event of an error or power loss, the relay is de-energized, and REL COM is connected to REL NC.
www.baldormotion.com 4.4.6 Serial port Location Serial Mating connector: 9-pin female D-type Pin RS232 name 6 9 1 5 RS485 / RS422 name 1 Shield (NC) 2 RXD RXB (input) 3 TXD TXB (output) 4 (NC) (NC) 5 DGND 0V DGND 6 (NC) (NC) 7 RTS TXA (output) 8 CTS RXA (input) 9 DGND (NC) NextMove ESB-2 is available with either an RS232 or RS485 serial port (see section 2.2.1). The port is fully ESD protected to IEC 1000-4-2 (15 kV).
www.baldormotion.com The RS232 port is configured as a DCE (Data Communications Equipment) unit so it is possible to operate the controller with any DCE or DTE (Data Terminal Equipment). Full duplex transmission with hardware handshaking is supported. Only the TXD, RXD and 0V GND connections are required for communication, but since many devices will check the RTS and CTS lines, these must also be connected. Pins 4 and 6 are linked on the NextMove ESB-2.
www.baldormotion.com 4.4.9 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 ESB-2 Serial connector uses a 9-pin male D-type connector.
www.baldormotion.com 4.5 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 4.5.2 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: MN1957 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 4.5.3 CANopen The NextMove ESB-2 must have the CANopen firmware loaded to use this protocol. Baldor have implemented a CANopen protocol in Mint (based on the ‘Communication Profile’ CiA DS-301) which supports both direct access to device parameters and time-critical process data communication.
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www.baldormotion.com 4.5.4 Baldor CAN The NextMove ESB-2 must have the Baldor CAN firmware loaded to use this protocol. Baldor CAN is a proprietary CAN protocol based on CAL. It supports only the following range of Baldor CAN specific I/O nodes and operator panels: InputNode 8 (Baldor part ION001-503) - an 8 x digital input CAN node. OutputNode 8 (Baldor part ION003-503) - an 8 x digital output CAN node. RelayNode 8 (Baldor part ION002-503) - an 8 x relay CAN node.
www.baldormotion.com Note: All CAN related Mint keywords are referenced to either CANopen or Baldor CAN using the ‘bus’ parameter. Although the NextMove ESB-2 has a single physical CAN bus channel that may be used to carry either protocol, Mint distinguishes between the protocols with the ‘bus’ parameter. For Baldor CAN the ‘bus’ parameter must be set to 2. Please refer to the Mint help file for further details on Baldor CAN, Mint keywords and keyword parameters.
www.baldormotion.com 4.6 Connection summary - minimum system wiring As a guide, Figure 30 shows an example of the typical minimum wiring required to allow the NextMove ESB-2 and a single axis drive amplifier to work together. Details of the connector pins are shown in Table 2.
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Operation 5 Operation 5 5.1 Introduction Before powering the NextMove ESB-2 you will need to connect it to the PC using a serial or USB cable and install the supplied PC software Mint WorkBench. This software includes a number of tools to allow you to configure, tune and program the NextMove ESB-2. If you do not have experience of software installation or Windows applications you may need further assistance for this stage of the installation. 5.1.
www.baldormotion.com 5.1.4 Preliminary checks Before you apply power for the first time, it is very important to verify the following: Disconnect the load from the motor until instructed to apply a load. Inspect all power connections for accuracy, workmanship and tightness. Verify that all wiring conforms to applicable codes. Verify that the NextMove ESB-2 is properly earthed/grounded. Check all signal wiring for accuracy. 5.1.
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 ESB-2 connected to your PC, then MMC is probably not required. Use Mint WorkBench (see section 5.4) to configure the NextMove ESB-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 ESB-2' in the controller pane to select it, then double click to open an instance of Mint WorkBench. The NextMove ESB-2 will be already connected to the instance of Mint WorkBench, ready to configure. Go straight to section 5.
www.baldormotion.com 5.3 Mint WorkBench Mint WorkBench is a fully featured application for programming and controlling the NextMove ESB-2. 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’; 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 tab shows the tree structure of the help file; each book contains a number of topics .
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 the PC serial port to which the NextMove ESB-2 is connected. (If you are unsure which PC serial port is connected to the NextMove ESB-2, select Scan all serial ports. During the detection process, a dialog box may be displayed to tell you that Mint WorkBench has detected new firmware. Click OK to continue.) Click Scan to search for the NextMove ESB-2.
www.baldormotion.com 5.4 Configuring an axis The NextMove ESB-2 is capable of controlling 4 servo and 4 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). The number of quadrature counts 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 ESB-2 to disable the drive in the event of an error. Each axis can be configured with its own drive enable output, or can share an output with other axes. 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. In the Toolbox, click the Digital I/O icon. 2.
www.baldormotion.com If you are going to use a digital output, drag the bright blue OUT icon to the grey Drive Enable OP 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. This sends the output configuration to the NextMove ESB-2. See section 5.11 for details about saving configuration parameters. 5.4.4 Testing the drive enable output 1.
www.baldormotion.com 5.5 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. 5.5.1 Testing the output This section tests the operation and direction of the output. It is recommended that the system is initially tested with the motor shaft disconnected from other machinery. 1. Check that the Drive enable button is pressed (down). 2. In the Toolbox, click the Edit & Debug icon. 3.
www.baldormotion.com 5.6 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. 5.6.1 Testing the demand output This section tests the operation and direction of the demand output for axis 0. The example assumes that axis 0 has already been configured as a servo axis, using the default hardware channel 0 (see section 5.4.1).
www.baldormotion.com 5. To repeat the tests for negative (reverse) demands, type: TORQUE(0)=-5 6. This should cause a demand of -5% of maximum output (-0.5 V) to be produced at the DEMAND0 output. Correspondingly, the Spy window's Velocity display should show a negative value. 7. To remove the demand and stop the test, type: STOP(0) This should cause the demand produced at the DEMAND0 output to become 0 V.
www.baldormotion.com 5.6.2 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 5.7.1. When there is a requirement to move an axis, the NextMove ESB-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: 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.
Profile Generator 5-18 Operation Demand Position Demand Velocity + Demand Acceleration - KVELFF Velocity Feedforward KACCEL Acceleration Feedforward KDERIV Derivative Gain KINT Integral Gain KPROP Proportional Gain + + + + + + + - KVEL Velocity Feedback DACLIMITMAX Clip DAC output Power Amp Measured Velocity Measured Position Servo Motor www.baldormotion.
www.baldormotion.com 5.7 Servo axis - tuning for current control 5.7.1 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 5.7.2 Underdamped response If the graph shows that the response is underdamped (it overshoots the demand, as shown in Figure 35) 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 35: Underdamped response 9. Click in the KDERIV and/or KPROP boxes and make the required changes.
www.baldormotion.com 5.7.3 Overdamped response If the graph shows that the response is overdamped (it reaches the demand too slowly, as shown in Figure 36) 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 36: Overdamped response 10. Click in the KDERIV and/or KPROP boxes and make the required changes. The ideal response is shown in section 5.7.4.
www.baldormotion.com 5.7.4 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 37.
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 often 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 34).
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 at constant velocity.
www.baldormotion.com 9. Using the check boxes below the graph, select the Measured velocity and Demand velocity traces. Measured velocity Demand velocity Figure 38: 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 be a good starting figure which can then be increased slowly. 1. Click in the KPROP box and enter a starting value of 0.1. 2. Click Go. The NextMove ESB-2 will perform the move and the motor will turn.
www.baldormotion.com Demand position Measured position Figure 39: Correct value of KPROP The two traces will probably appear with a small offset from each other, which represents the following error. Adjust KPROP by small amounts until the two traces appear on top of each other (approximately), as shown in Figure 39. Note: It may be useful to use the zoom function to magnify the end point of the move. In the graph area, click and drag a rectangle around the end point of the traces.
www.baldormotion.com 5.9 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 5.10 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 if it should be assigned to a special purpose function such as a Home or Limit input. In the following example, digital input 1 will be set to trigger on an active low input, 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 ESB-2. 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 configured as a drive enable output (see section 5.4.3).
www.baldormotion.com 5.11 Saving setup information When power is removed from the NextMove ESB-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 unit is next used. 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. On the main menu, choose Program, Generate Mint Startup Block.
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 ESB-2 will be correctly configured. Remember that every drive/motor combination has a different response.
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Troubleshooting 6 Troubleshooting 6 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 ESB-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 ESB-2 indicators 6.2.1 Status display The Status LED normally displays the unit's node number. To display information about a specific axis, use the LED keyword (see the Mint help file). When a specific axis is selected, the following symbols may be displayed by the Status LED. Some characters will flash to indicate an error. Spline. A spline move is being performed. See the SPLINE keyword and related commands. Axis enabled. Torque mode.
www.baldormotion.com Offset move. The axis is performing an offset move. Positional Move. The axis is performing a linear move. See the MOVEA and MOVER keywords. Stop. A STOP command has been issued or the stop input is active. Axis disabled. The axis/drive must be enabled before operation can continue. See section 5.4.4. Click the Drive enable button in Mint WorkBench. Suspend. The SUSPEND command has been issued and is active. Motion will be ramped to zero demand whilst active.
www.baldormotion.com Symptom Check Cannot communicate with the controller after downloading firmware. After firmware download, always power cycle the controller (remove 24 V power and then reconnect). 6.2.3 Motor control If the problem is not listed below please contact Baldor technical support. Symptom Check Controller appears to be working but will not cause motor to turn. Check that the connections between motor and drive are correct.
www.baldormotion.com Symptom 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. (Servo outputs only) Check that the encoder feedback signal(s) are connected to the correct encoder input(s). 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.
www.baldormotion.com 6.2.4 Mint WorkBench Symptom Check The Spy window does not update The system refresh has been disabled. Go to the Tools, Options menu item, select the System tab and then choose a System Refresh Rate (500 ms is recommended). Firmware download fails Confirm that you have the correct version of firmware. Attempting to download certain older versions of firmware (intended for models without USB), will cause the download to fail. Download the latest version of firmware.
www.baldormotion.com 6.2.5 CANopen Symptom Check The CANopen bus is ‘passive’ This means that the internal CAN controller in the NextMove ESB-2 is experiencing a number of Tx and/or Rx errors, greater than the passive threshold of 127. Check: 12-24 V is being applied to pin 5 of the RJ45 CAN connector, to power the opto-isolators. There is at least one other CANopen node in the network. The network is terminated only at the ends, not at intermediate nodes.
www.baldormotion.com Symptom Check The Manager node cannot scan/recognize a node on the network using the Mint NODESCAN keyword. Assuming that the network is working correctly (see previous symptoms) and the bus is in an ‘Operational’ state, check the following: Only nodes that conform to DS401, DS403 and other Baldor CANopen nodes are supported by the Mint NODESCAN keyword. Check that the node in question has been assigned a unique node ID. The node must support the node guarding process.
www.baldormotion.com 6.2.6 Baldor CAN Symptom Check The Baldor CAN bus is ‘passive’ This means that the internal CAN controller in the NextMove ESB-2 is experiencing a number of Tx and/or Rx errors, greater than the passive threshold of 127. Check: 12-24 V is being applied to pin 5 of the RJ45 CAN connector, to power the opto-isolators. There is at least one other Baldor CAN node in the network, with jumpers JP1 and JP2 in the ‘1' (lower) position.
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Specifications 7 Specifications 7 7.1 Introduction This section provides technical specifications of the NextMove ESB-2. 7.1.1 Input power Value Description Input power Nominal input voltage Power consumption 24 VDC (±20%) 50 W (2 A @24 V approx.) 7.1.2 Analog inputs Description Unit Type Common mode voltage range Value Differential VDC ±10 kΩ 120 Input ADC resolution bits 12 (includes sign bit) Equivalent resolution (±10 V input) mV ±4.
www.baldormotion.com 7.1.4 Digital inputs Unit Description Type Value Opto-isolated VDC USR V+ supply voltage 24 12 30 Nominal Minimum Maximum VDC Input voltage > 12V < 2V Active Inactive Input current Maximum per input, USR V+ = 24 V mA 7 7.1.5 Digital outputs - general purpose Unit Description Value VDC USR V+ supply voltage 24 12 30 Nominal Minimum Maximum Output current Max. source per output, one output on Max.
www.baldormotion.com 7.1.7 Stepper control outputs Models NSB202... / NSB204... Description Unit Output type Value RS422 (differential) step (pulse) and direction Maximum output frequency kHz Output current Maximum, per output pair mA 500 20 Models NSB203... / NSB205... Description Unit Output type Value Open collector step (pulse) and direction Maximum output frequency kHz Output current Maximum sink, per output mA 500 50 7.1.
www.baldormotion.com 7.1.10 CAN interface Unit Description Value Signal 2-wire, isolated Channels 1 Protocols CANopen or Baldor CAN (selected by choice of firmware) Kbit/s Bit rates 10, 20, 50, 100, 125, 250, 500, 1000 10, 20, 50, 125, 250, 500, 1000 CANopen Baldor CAN 7.1.
www.baldormotion.com 7.1.13 Declaration of Conformity EC Declaration of Conformity Date: 14/01/08 Manufacturer: Address: Ref: DE00029-000 Baldor UK Ltd. Mint Motion Centre, 6 Bristol Distribution Park, Hawkley Drive, Bristol, BS32 0BF, United Kingdom.
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Accessories A Accessories A A.1 Introduction A variety of accessories are available to expand the capabilities of the NextMove ESB-2. A.1.1 Feedback cables The Baldor cables listed in Table 3 connect the ‘Encoder Out’ signal from a drive amplifier (for example MicroFlex, FlexDriveII, Flex+DriveII, or MintDriveII) to the ‘ENC 0’ - ‘ENC 4’ encoder input connectors on the NextMove ESB-2. One cable is required for each servo axis. See section 4.4.3 for the connector pin configuration.
www.baldormotion.com A.1.2 Baldor CAN nodes Digital I/O can be expanded easily on NextMove ESB-2 using the Baldor CAN (CAN2) connection. This provides a high speed serial bus interface to a range of I/O devices, including: inputNode 8: 8 opto-isolated digital inputs. relayNode 8: 8 relay outputs. outputNode 8: 8 opto-isolated digital outputs with short circuit and over current protection. ioNode 24/24: 24 opto-isolated input and 24 opto-isolated outputs.
www.baldormotion.com A.1.3 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.
www.baldormotion.com A.1.5 Mint NC (CAD to motion software) The Mint NC software provides machine builders with an extremely rapid and flexible solution for creating contouring and profiling machinery and automation. Mint NC provides a PC-based environment that will import information in industry-standard CAD formats including G-code, HPGL and DXF, and generate the required real-time motion commands.
Mint Keyword Summary B Mint Keyword Summary B B.1 Introduction The following table summarizes the Mint keywords supported by the NextMove ESB-2. Note that due to continuous developments of the NextMove ESB-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 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. AUXENCODERWRAP To set or read the encoder wrap range for the auxiliary encoder input. AUXENCODERZLATCH To read the state of the auxiliary encoder's Z latch.
www.baldormotion.com Keyword Description 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. CAMPHASESTATUS To get the state of the CAMPHASE for a specific axis. CAMSEGMENT To change CAM table data. CAMSTART To define a start point in the cam table if multiple cams are required. CAMTABLE To specify the array names to be used in a cam profile on the specified axis.
www.baldormotion.com Keyword COMPAREPOS Description To write to the position compare registers. CONFIG To set the configuration of an axis for different control types. CONNECT To enable a connection between two remote nodes to be made or broken. CONNECTSTATUS Returns the status of the connection between this node and another node. CONTOURMODE To enable contouring for interpolated moves. CONTOURPARAMETER To set the parameters for contoured moves.
www.baldormotion.com Keyword Description ENCODERZLATCH To get and reset the state of an axis' encoder Z latch. ERRORDECEL To set the deceleration rate on the axis for powered stops, in the event of an error or stop input. ERRORINPUT To set or return the digital input to be used as the error input for the specified axis. ERRORINPUTMODE To control the default action taken in the event of an external error input. ERRORMASK To prevent specific error conditions calling the ONERROR event.
www.baldormotion.com Keyword Description FEEDRATEMODE To control the use of slew speed, acceleration, deceleration and feedrate override. FEEDRATEOVERRIDE Overrides the current speed or feedrate being used. FEEDRATEPARAMETER To set the parameters for the current speed or feedrate being used. FIRMWARERELEASE To read the release number of the firmware. FLY To create a flying shear by following a master axis with controlled acceleration and deceleration.
www.baldormotion.com Keyword Description HOMEPHASE To find the phase of the homing sequence currently in progress. HOMEPOS To read the axis position at the completion of the homing sequence. HOMESPEED To set the speed for the initial seek phase of the homing sequence. HOMESTATUS To set or read the status of a homing sequence. HOMESWITCH To return the state of the home input. HTA Starts the hold to analog mode of motion.
www.baldormotion.com Keyword Description INPUTMODE To set or return the sum of a bit pattern describing which of the user digital inputs should be edge or level triggered. INPUTNEGTRIGGER To set or return the user inputs that become active on negative edges. INPUTPOSTRIGGER To set or return the user inputs that become active on positive edges. INSTATE To read the state of all digital inputs. INSTATEX To read the state of an individual digital input.
www.baldormotion.com Keyword Description LIMITREVERSEINPUT To set the user digital input configured to be the reverse end of travel limit switch input for the specified axis. LOOPTIME To set the servo loop update interval in microseconds. MASTERCHANNEL To set or read the channel of the input device used for gearing. MASTERDISTANCE To set the distance on the master axis over which the slave will travel for a 'segment' in master-slave move types.
www.baldormotion.com Keyword Description NVRAMDEFAULT Clears the contents of non-volatile RAM (NVRAM). OFFSET To perform a positional offset move. OFFSETMODE Define the mode of operation on the OFFSET keyword. OUT To set or read the state of all the outputs on an output bank. 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.
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 RESETALL To perform a reset on all axes. SCALEFACTOR To scale axis encoder counts, or steps, into user defined units. SERIALBAUD To set the baud rate of the RS232 / RS485/422 port. SOFTLIMITFORWARD To set the forward software limit position on a specified axis. SOFTLIMITMODE To set or read the default action taken if a forward or reverse software limit position is exceeded.
www.baldormotion.com Keyword Description TERMINALADDRESS To set or read the node ID for a CAN node associated with a terminal. 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.
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Index Index A digital inputs, 5-30 digital outputs, 5-31 selecting a scale, 5-10 selecting the axis type, 5-9 setting the drive enable output, 5-11 testing and tuning a servo axis, 5-14 testing the drive enable output, 5-11, 5-12 Abbreviations, 2-4 Accessories, A-1 Baldor CAN nodes, A-2 Feedback cables, A-1, B-1 HMI (Human Machine Interface) panels, A-3 Mint NC CAD to Motion software, A-4 Analog inputs, 4-3 Connectors CAN, 4-22 locations, 4-2 serial, 4-19 USB, 4-18 Analog outputs, 4-5 Critically damp
H O Hardware requirements, 3-3 Operation, 5-1 connecting to the PC, 5-1 Installing Mint Machine Center, 5-1 Installing Mint WorkBench, 5-1 installing the USB driver, 5-2 power on checks, 5-2 preliminary checks, 5-2 starting, 5-1 Help file, 5-6 HMI (Human Machine Interface) panels, A-3 I Indicators, 6-2 status display, 6-2 Input / Output, 4-1 analog inputs, 7-1 analog outputs, 4-5, 7-1 CAN connection, 4-22 connection summary, 4-28 connector locations, 4-2 digital inputs, 4-7, 7-2 digital outputs, 4-7, 4
digital inputs, 7-2 digital outputs, 7-2 encoder inputs, 7-3 power, 7-1 relay, 7-2 serial port, 7-3 stepper outputs, 7-3 Status display, 6-2 Stepper axis control outputs, 4-13, 4-14 T Testing servo axis, 5-14 Troubleshooting, 6-1 Baldor CAN, 6-9 CANopen, 6-7 communication, 6-3 help file, 5-6 Mint WorkBench, 6-6 motor control, 6-4 problem diagnosis, 6-1 status display, 6-2 SupportMe, 6-1 Tuning adjusting KPROP, 5-27 calculating KVELFF, 5-24 critically damped response, 5-23 eliminating steady-state errors, 5
Index MN1957
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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