MOTION CONTROL NextMove ST Motion Controller Installation Manual 2/03 MN1921
Contents 1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 3 2.1 NextMove ST features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 2.2 Receiving and inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 2.3 Units and abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.1.1 5.1.2 5.1.3 5.1.4 5.1.5 5.2 WorkBench v5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2.1 5.2.2 5.3 5.6 5-1 5-1 5-1 5-1 5-2 5-3 5-3 5-4 5-6 5-6 5-8 5-8 5-9 5.5.1 5.5.2 5-9 5-10 Digital input configuration . . . . . . . . . . . . . . . . . . . . .
1 General Information 1 LT0184A00 Copyright Baldor (c) 2002. 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.
Safety Notice Only qualified personnel should attempt the start-up procedure or troubleshoot this equipment. This equipment may be connected to other machines that have rotating parts or parts that are controlled by this equipment. Improper use can cause serious or fatal injury. Precautions WARNING: Do not touch any circuit board, power device or electrical connection before you first ensure that no high voltage is present at this equipment or other equipment to which it is connected.
2 Introduction 2 2.1 NextMove ST features NextMove ST is a high performance multi-axis intelligent controller for stepper motors. NextMove ST features the MintMT motion control language. MintMT is a structured form of Basic, custom designed for stepper or servo motion control applications. It allows you to get started very quickly with simple motion control programs. In addition, MintMT includes a wide range of powerful commands for complex applications.
Included with NextMove ST is the Baldor Motion Toolkit CD. This contains a number of utilities and useful resources to get the most from you MintMT controller. These include: H Mint WorkBench v5 This is the user interface for communicating with the NextMove ST. Installing Mint WorkBench will also install firmware for NextMove ST. H PC Developer Libraries Installing Mint WorkBench will install ActiveX interfaces that allow PC applications to be written that communicate with the NextMove ST.
2.3 Units and abbreviations The following units and abbreviations may appear in this manual: V ............... W .............. A ............... Ω ............... µF . . . . . . . . . . . . . . pF . . . . . . . . . . . . . . mH . . . . . . . . . . . . . Volt (also VAC and VDC) Watt Ampere Ohm microfarad picofarad millihenry Φ............... ms . . . . . . . . . . . . . . µs . . . . . . . . . . . . . . ns . . . . . . . . . . . . . . phase millisecond microsecond nanosecond Kbaud . . . . . . . . . . .
2-4 Introduction MN1921
3 Basic Installation 3 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 ST. This section describes the mechanical installation of the NextMove ST. 3.1.1 Location requirements You must read and understand this section before beginning the installation. CAUTION: To prevent equipment damage, be certain that input and output signals are powered and referenced correctly.
3.1.2 Mounting the NextMove ST 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 ST by the four slots in the metal carrier/heatsink assembly. M5 bolts or screws are recommended. 140 (5.51) 53 (2.09) 6.5 (0.26) Slot detail 263 (10.
3.1.3 Other requirements for installation H The NextMove ST requires a power supply as described in section 4.2.
3-4 Basic Installation MN1921
4 Input / Output 4 4.1 Introduction This section describes the digital and analog input and output capabilities of the NextMove ST. The following conventions will be used to refer to the inputs and outputs: I/O . . . . . . . . . . . . . . DIN . . . . . . . . . . . . . DOUT . . . . . . . . . . . AIN . . . . . . . . . . . . . AOUT . . . . . . . . . . .
4.1.
4.2 Power connections The NextMove ST can accept AC or DC power supplies, and has connections for separate drive and logic supplies. However, the NextMove ST can operate from a single combined supply if necessary. Supply connection Recommended supply voltage Supply voltage range Power requirement 24VDC 12-35VDC 60W 24VAC 12-30VAC 60VA 24VDC 12-35VDC (must not exceed 6A) 150W 24VAC 12-30VAC (must not exceed 6A RMS) 150VA 24VDC 12-35VDC (must not exceed 8.
4.2.2 Operation using separate drive and logic supplies For improved noise immunity, the ±12V and +5V supplies used for the control card and internal circuitry can be derived from a separate logic supply. To operate the NextMove ST using separate drive and logic supplies, do not link power input connector pins. Connect power as shown in Figure 3.
4.3 Stepper outputs The NextMove ST provides three 37VDC (max), 2A stepper axes drive outputs, operating at 10Hz to 200kHz. Logic level outputs are provided to control a fourth stepper axis. If required, the output current for individual axes can be derated. This can only be achieved by making precise alterations to the NextMove ST circuitry. Please contact Baldor Technical Support for details. 4.3.
4.3.1.2 Connecting a 6-wire motor Six-wire unipolar motors can be used with the NextMove ST. Six-wire motors are similar to eight-wire motors except the coils in each phase have a permanent center tap connection. Connections are shown in Figure 6. If the motor turns in the wrong direction, reverse the connections from one of the phase outputs AB or CD, but not both. Always leave the common center tap wires unconnected.
4.3.1.3 Connecting a 8-wire motor Eight-wire (universal) motors can be used with the NextMove ST. Connections are shown in Figures 7 and 8. If the motor turns in the wrong direction, reverse the connections from one of the phase outputs AB or CD, but not both. Eight-wire motors can be connected in two ways, depending on the required torque and speed characteristics.
4.3.2 Stepper axes 0-3 logic outputs DGND DIR3 STEP3 BOOST3 DGND DIR2 STEP2 BOOST2 DGND DIR1 STEP1 BOOST1 DGND DIR0 STEP0 BOOST0 NextMove ST ULN2003 Step Output STEP0 74AHCT244 GND DGND J3 Figure 9 - Stepper output pin header J3, and output circuit (STEP0 shown) To allow external stepper amplifiers to be used, all of the stepper output signals from the NextMove ST control card are output on a 16-pin header, J3, mounted on the card.
4.4 Analog I/O The NextMove ST provides: H Two 12-bit resolution analog inputs. H One 0-11V analog output. 4.4.1 Analog inputs H Differential inputs. H Voltage range: ±10V. H Resolution: 12-bit with sign (accuracy ±4.9mV @ ±10V input). H Input impedance: 120kΩ. H Sampling frequency: 4kHz maximum, 2kHz if both inputs are enabled. The analog inputs pass through a differential buffer and second order Butterworth filter with a cut-off frequency of approximately 1kHz.
4.4.2 Analog output H Single ended output. H Voltage range: 0-11V. H Output current: 30mA maximum. The analog output provides an independent opto-isolated 0-11V output for controlling an additional axis or other external equipment. The output is controlled using the AUXDAC keyword - see the MintMT help file. Output offset voltage can be controlled by the variable resistor R35, located just behind the SOUT and SGND pins of the Misc connector. NextMove ST MintMT AUXDAC.
4.5 Digital I/O The NextMove ST provides: H 24 general purpose digital inputs. H 16 general purpose digital outputs. Note: It is recommended to use separate shielded cables for the digital inputs. The shield should be connected to the input connector’s shield pin. 4.5.1 Digital inputs The digital inputs are available across a range of connectors, as shown in section 4.1.1. All digital inputs have a common specification: H General purpose 5V TTL digital inputs with internal pull-up resistors.
Using a digital input as a LIMIT or HOME input An input can be configured as a Limit or Home input for any axis, using the LIMITFORWARDINPUT, LIMITREVERSEINPUT or HOMEINPUT keywords. Typically, limit and home inputs will be grounded by normally closed switches. When a limit or home switch is activated, the switch will become open-circuit. If two or more limit switches are to be used they can be connected in series.
4.5.2 Digital outputs The digital outputs are available across a range of connectors, as shown in section 4.1.1. H 16 general purpose digital outputs H Update frequency: Immediate There are 16 general purpose digital outputs, arranged in two groups; DOUT0-DOUT7 and DOUT8-DOUT15. Each group is driven by a ULN2803 device. The outputs are designed to sink current from an external supply (typically 24VDC), but have no overcurrent or short circuit protection.
4.5.3 Error output The NextMove ST control card has an internal error output connected directly to the enable inputs of the ST L297 stepper controllers (see section 4.3.1). The error output must therefore be used to enable the axes. There are a number of methods for controlling the error output. 4.5.3.1 RELAY keyword Because the NextMove ST control card is used in products that include a hardware relay, the error output may be controlled directly by the RELAY keyword.
4.6 Other I/O 4.6.
RS232 NextMove ST (DCE) COM RXD 2 2 RXD TXD 3 3 TXD GND 5 5 GND RTS 7 7 RTS CTS 8 8 CTS 9-- pin Computer COM Port (DCE / DTE) Connect overall shield to connector backshell. Figure 15 - RS232 serial port connections The maximum recommended cable length is 3m (10ft) at 57.6Kbaud. When using lower baud rates, longer cable lengths may be used up to maximum of 15m (49ft) at 9600 baud. A suitable cable is available from Baldor, catalog number CBL001-501. 4.6.
4.6.3 CAN communication The CAN connection is made using the RJ45 connector on the NextMove ST control card. Location NextMove ST control card Pin Name Description 1 CAN+ CAN channel positive 2 CAN- CAN channel negative 3 (NC) - 1 4 CAN 0V Ground/earth reference for CAN signals 8 5 CAN V+ CAN power V+ (12-24V) 6 - (NC) 7 - (NC) 8 - (NC) Description Opto-isolated CAN interface using a RJ45 connector.
The CAN channel is opto-isolated. A voltage in the range 12-24V must be applied to pin 5 of the CAN connector. An internal voltage regulator provides the 5V required for the isolated CAN circuit. Practical operation of the CAN channel is limited to 500Kbit/s owing to the propagation delay of the opto-isolators. JP1 The CAN channel must be terminated by a 120Ω resistor connected between CAN+ and CAN- at both ends of the network and nowhere else.
4.7 Connection summary - minimum system wiring As a guide, Figure 17 shows an example of the typical minimum wiring required to allow the NextMove ST to control a single stepper motor. The diagram shows the logic supply being derived from the main Drive supply (see section 4.2.1).
4-20 Input / Output MN1921
5 Operation 5 5.1 Introduction The software provided includes a number of applications and utilities to allow you to configure, tune and program the NextMove ST. The Baldor Motion Toolkit CD containing the software can be found separately within the packaging. 5.1.1 Connecting the NextMove ST to the PC Connect the serial cable between a PC serial port (often labeled as “COM”) to the NextMove ST RS232 connector. WorkBench v5 can scan all the COM ports, so you can use any port.
5.1.5 Power on checks If at any time the status display shows a digit and a flashing decimal point, this indicates that the NextMove ST has detected a fault - see section 6. 1. Turn on the Logic supply (if separate from the Drive supply). 2. Turn on the Drive supply. 3. After a brief test sequence, ( followed by ), the Status display should show the node number, for example , the factory default. If the display is not lit then re-check the power supply connections.
5.2 WorkBench v5 WorkBench v5 is a fully featured application for programming and controlling the NextMove ST. The main WorkBench window contains a menu system, the Toolbox and other toolbars. Many functions can be accessed from the menu or by clicking a button - use whichever you prefer. Most buttons include a ‘tool-tip’; hold the mouse pointer over the button (don’t click) and its description will appear. 5.2.
5.2.2 Starting WorkBench v5 1. On the Windows Start menu, select Programs, WorkBench v5, WorkBench v5. WorkBench v5 will start, and the Tip of the Day dialog will be displayed. You can prevent the Tip of the Day dialog appearing next time by removing the check mark next to Show tips at startup. Click Close to continue. 2. In the small opening dialog box, click Start New Project...
3. In the Select Controller dialog, go to the drop down box near the top and select the PC serial port to which the NextMove ST is connected. If you are unsure which PC serial port is connected to the drive, select Scan all serial ports. Click Scan to search for the NextMove ST. When the search is complete, click NextMove ST in the list to select it, and click the Select button.
5.3 Configuring an axis The NextMove ST is capable of controlling up to four stepper axes. This section describes the basic setup for these axes. Commands typed in the Command window have immediate effect - they do not need to be separately downloaded to the NextMove ST. 5.3.1 Selecting a scale When controlling stepper motors, MintMT defines all positional and speed related motion keywords in terms of steps.
5. Click Apply. This immediately sets the scaling factor for the selected axis, which will remain in the NextMove ST until another scale is defined or power is removed from the NextMove ST.
5.4 Stepper axis - testing This section describes the method for testing a stepper axis. The stepper control is an open loop system so no tuning is necessary. 5.4.1 Testing the output This section tests the operation and direction of the output. It is recommended that the system is initially tested and tuned with the motor shaft disconnected from other machinery. 1. Check that the Drive enable button is pressed (down). 2. In the Toolbox, click the Edit & Debug icon. 3. Click in the Command window. 4.
5.5 Digital input/output configuration The Digital I/O window can be used to setup other digital inputs and outputs. 5.5.1 Digital input configuration The Digital Inputs tab allows you to define how each digital input will be triggered, and if it should be assigned to a special purpose function such as a Home or Limit input. 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. In the Toolbox, click the Digital I/O icon.
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 ST. Note: If required, multiple inputs can be configured before clicking Apply. 5.5.2 Digital output configuration The Digital Outputs tab allows you to define how each digital output will operate and if it is to be configured as an error output. Remember to click Apply to send the changes to the NextMove ST.
5.6 Saving setup information When power is removed from the NextMove ST all data, including configuration parameters, is lost. You should therefore save this information in a file, which can be loaded when the 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.
4. On the main menu, choose File, Save File. Locate a folder, enter a filename and click Save. 5.6.1 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 ST will be correctly configured.
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 ST. If you do have a problem, read this section first. In WorkBench v5, use the Error Log tool to view recent errors and then check the help file.
6.2 NextMove ST 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 MintMT 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. The NextMove ST is in Torque mode.
Axis disabled. The axis/drive must be enabled before operation can continue. See section 5.4.1. Click the Drive enable button in WorkBench v5. Suspend. The SUSPEND command has been issued and is active. Motion will be ramped to zero demand whilst active. Reverse software or hardware limit. A reverse software limit has been activated. See AXISERROR and/or AXISSTATUS to determine which applies. Forward software or hardware limit. A forward software limit has been activated.
6.2.3 Communication If the problem is not listed below please contact Baldor Technical Support. Symptom Check Cannot detect NextMove ST Check that the NextMove ST is powered. Check that the serial lead is wired correctly and properly connected. Check that no other application on the PC is attempting to use the same serial port. Cannot communicate with the controller. Verify that WorkBench v5 is loaded and that NextMove ST is the currently selected controller.
7 Specifications 7 7.1 Introduction This section provides technical specifications of the NextMove ST. 7.1.
7.1.3 Analog inputs Description Unit Type Value Differential Common mode voltage range VDC ±10 kÙ 120 Input ADC resolution bits 12 (includes sign bit) Equivalent resolution (±10V input) mV ±4.9 ìs 500 (both inputs enabled) 250 (one input disabled) Input impedance Sampling interval 7.1.4 Analog output Description Unit Type Value Single ended Output voltage range VDC 0-11V Output current (max) mA 1 Update interval Immediate 7.1.
7.1.6 Digital outputs Description Load supply voltage (maximum) Unit V Output current (DOUT0-DOUT7) Per output, one output on Per output, all outputs on mA Output current (DOUT8-DOUT15) Per output, one output on Per output, all outputs on mA Value 50 500 150 500 150 Update interval Immediate 7.1.7 Stepper axis 0-2 drive outputs Description Unit Value Maximum output frequency kHz 200 VDC 40 A 2 Output voltage Output current (maximum, per axis) 7.1.
7.1.9 CAN interface Description Unit Value Signal 2-wire, isolated Channels 1 Protocols CANopen Baldor CAN (with optional firmware) Bit rates Kbit/s 10, 20, 50, 100, 125, 250, 500 7.1.10 Environmental Description Unit Operating temperature range Min Max °C 0 +40 °F +32 +104 Maximum humidity Maximum installation altitude (above m.s.l.
Index A E Abbreviations, 2-3 Analog I/O, 4-9 analog inputs, 4-9 analog output, 4-10 Auxiliary encoder, 4-12 Environmental, 3-1, 7-4 Error output, 4-14 DRIVEENABLEOUTPUT keyword, 4-14 GLOBALERROROUTPUT keyword, 4-14 RELAY keyword, 4-14 B F Basic Installation, 3-1 location requirements, 3-1 mounting, 3-2 Features, 2-1 C CAN interface connection, 4-17 specifications, 7-4 Configuration axis, 5-6 digital inputs, 5-9 digital outputs, 5-10 selecting a scale, 5-6 testing an axis, 5-8 Connectors CAN, 4-17 l
J Jumper settings CAN terminator, 4-18 error output, 4-14 L LED indicators status display, 6-2 surface mount, 6-3 Loading saved information, 5-12 O Operation, 5-1 connecting to the PC, 5-1 installing WorkBench v5, 5-1 power on checks, 5-2 preliminary checks, 5-1 starting, 5-1 P Power sources, 3-3, 4-3, 7-1 using a single drive supply, 4-3 using separate drive and logic supplies, 4-4 Precautions, 1-2 R Receiving and Inspection, 2-2 RELAY keyword, 4-14 RS232 port, 4-15 S Safety Notice, 1-2 Saving setup i
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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