ABB NextMove e100 motion controller

ABB NextMove e100 motion controller

Product Overview and Models

1. Core competencies

Onboard local: 4-channel stepper output, 3-channel servo analog command output; Expand remote axes through Ethernet POWERLINK, with a maximum control of 16 axes for the entire machine.

Sports functions: point motion, software electronic cam, electronic gear, complex path, spline curve interpolation.

IO resources: 20 digital inputs; 12 digital outputs; 1 relay output; 2-channel 12 bit differential analog input; 4-channel 12 bit analog output; 3-channel RS-422 incremental encoder input.

Communication interfaces: USB1.1, RS232/RS422-485 serial port, dual port Ethernet (TCP/IP+POWERLINK), CANopen.

2. Model differentiation

Model suffix step output type

NXE100-16xxDx RS-422 differential pulse direction output

NXE100-16xxSx open collector (single ended) pulse direction output

X represents the hardware version and does not affect functionality; The number represents the maximum number of axes (08/12/16).

3. Safety prerequisite requirements

Only qualified electrical engineers are allowed to install and debug; The panel STOP input cannot be used as the only means of safety emergency stop, and an independent hardware emergency stop circuit must be configured.

ESD electrostatic protection, release human static electricity before taking out the equipment.

The operation of the equipment will drive the rotating mechanism. During the debugging phase, it is necessary to disconnect the mechanical load to prevent accidental injury.

Medical implant equipment personnel should stay away from motors and power cables to avoid electromagnetic hazards.

Receiving inspection and mechanical installation

Receiving inspection: check for damage to the appearance of the packaging; Verify the ordered model; Save the packaging for repair; Long term storage must meet temperature and humidity specifications.

environmental conditions

Working temperature: 0~45 ℃; Humidity ≤ 80% @ 31 ℃, linearly decreases to 50% RH@45 ℃, no condensation; Pollution level 2.

It is prohibited to install it next to heating equipment, under steam pipelines, in environments with corrosive gases, dust, and metal debris.

Installation method

Install M4 screws vertically on a flat non combustible metal backplate; Reserved elongated circular holes on the metal base plate.

Shell dimensions: width 250   mm, height 140   mm, depth 40.3   mm; leave at least 20   mm of convective heat dissipation gap around the perimeter; Reserve 70mm wiring space on the connector side.

Power supply requirements: 24   VDC, continuous 2A; recommended maximum 4A fuse, independent power supply.

Minimum configuration for PC debugging host: 1GHz CPU, 512MB memory, 2GB hard drive, Windows XP and above; Supports USB/serial/Ethernet. EPL network recommends configuring a dedicated network card on the PC.

I/O Hardware Interface Detailed Explanation

Terminal block tightening torque: 0.25 N · m; It is recommended to use shielded twisted pair cables for all simulations, encoders, and high-speed signals, with shielded single ended grounding.

3.1 Analog I/O

Analog input X12 (AIN0, AIN1)

Differential input, ± 10V, 12 bit with sign; Input impedance 120k Ω;

Dual input simultaneously enables maximum sampling of 2kHz; Close one channel, the other channel can reach 4kHz; Built in second-order 1kHz low-pass filter; Mint keyword ADC reading.

Analog output X13 (Demand0-3)

Four independent bipolar ± 10V DC, 12 bits; Maximum output of 2.5mA per channel; update rate 1kHz; The minimum load is ≥ 4k Ω.

Demand0-2 is assigned by default to the local servo axis for speed command output, and can be used as a general DA output when not assigned; Mint keyword DAC.

3.2 Digital Input (DIN0-19, X8/X9/X10)

There are a total of 20 optocoupler isolation DIs, divided into 3 independent common reference terminals CREF0/CREF1/CREF2; The software can be configured with high/low effectiveness.

DIN0-DIN3: High speed interrupt input, hardware lockable position, trigger delay of 1 µ s; suitable for origin and mark capture; ⚠ It is not recommended to directly connect the mechanical switch as it may shake and trigger incorrectly. The cable must be shielded.

DIN4-19 ordinary DI, sampling rate 1kHz; The edge triggered pulse should be at least ≥ 1ms.

Software can allocate limit, stop, and fault inputs;

⚠ Important: The origin signal of EPL remote drive must be wired to the drive body and cannot be connected to the DI of e100 controller; EPL remote drive enable should not be directly output with DO, but should be coordinated with the instantaneous+delayed contact logic of emergency stop.

3.3 Digital Output and Relays

DOUT0-11 (X11, X4): UDN2982 driver, powered by an external 24V user power supply;

DO0-7: Total current upper limit of 500mA, maximum single channel 350mA;

DO8-11: Total current upper limit of 500mA, maximum single channel 350mA;

Overload will trigger the self recovery fuse, which takes several minutes to recover; Inductive loads must be connected in parallel with freewheeling diodes.

DOUT12 relay output (X12): Isolation relay, normally powered on, connected to COM-NO; Power failure/fault COM-NC connection; Configurable global fault output.

3.4 Step pulse output

Dx differential version (X2, X3): RS-422 DS26LS31; Output frequency: 60Hz~5MHz; Step/Dir differential signal.

Sx collector open circuit version (X2, X3): ULN2803; Output frequency 60Hz -500kHz; Onboard+5V output, with a total current of no more than 600mA for all 5V peripherals.

Mint keyword STEPPERDLAY sets the pulse direction delay; FREQ controls the output frequency.

3.5 Encoder Input X5/X6/X7 (3-channel incremental encoder)

RS-422 differential A/B/Z phase; The controller provides 5V power supply for the encoder;

The cable length directly limits the maximum counting frequency; The longer the cable, the lower the allowed frequency, with a recommended maximum length of 30.5m;

The maximum orthogonal count is 20Mcount/s.

3.6 Node ID dip switch

2 hexadecimal dialing codes HI/LO, set Ethernet POWERLINK node ID (0-255)

ID   240 (F0): EPL management host node (only 1 allowed in the entire network)

ID 1-239: Controlled Slave Node

ID   0/241-255: Reserved and prohibited from use; The firmware does not run during FF, but it can still be downloaded.

3.7 Communication Interface

USB（Type‑B）：USB1.1， Used for debugging PC Mint WorkBench; The longest cable is 5m; self powered equipment.

9-pin serial port RS232/RS422-485 (hardware jumper switching)

The highest baud rate is 115.2 kbaud; Support multi-point 4-wire RS422 multi slave network; Can be connected to Baldor/Abb HMI panels.

Both ends of the RS422 bus must be connected to a 120 Ω terminal resistor, and the middle node must not be connected to a terminal resistor.

Dual port Ethernet RJ45 E1/E2

Built in Hub, supporting daisy chain EPL real-time bus (100Mbit/s Ethernet POWERLINK); Simultaneously supporting TCP/IP.

⚠ EPL real-time network prohibits the use of ordinary switches, only Hub or EPL dedicated routers can be used; Each node introduces a delay of approximately 500ns.

Controller IP: 192.168.100.XXX, with the last XXX equal to the hardware dial-up decimal node number.

CANopen (9-pin D-Sub, optically isolated)

Compliant with CiA DS-301 and DS-402 driver specifications; Can be used as a master/slave station;

Terminal resistance of 120 Ω at both ends of the bus; The baud rate determines the maximum bus length; The interface requires external 12-24V isolated power supply.

3.8 Minimum System Wiring Example

The manual provides two sets of minimum wiring schematics:

Local servo axis: 24V power supply; Simulate instruction output; Encoder feedback; Relay output is used as a driving enable; USB connected to PC.

EPL remote axis (MicroFlex e100 driver): Ethernet communication only; Relay hardware enablement; No need for analog output and local encoder.

Software operation, debugging, and axis configuration

4.1 PC Software Suite

Mint WorkBench: Core tool; Axis configuration, parameter tuning, Mint program editing and download, oscilloscope Scope, automatic tuning Autotune, help document (F1).

Mint Machine Center (MMC): Network scanning, browsing all USB/serial/EPL/CANopen controllers and drivers; Open the corresponding WorkBench with one click; Support network redirection (PC can access remote drivers on EPL network through USB).

4.2 Power on process

The wiring is completed, and the motor disconnects the mechanical load; Check grounding and power supply;

Self check after 20-30 seconds of power on; Status green light flashing=normal; Red light flashing=malfunction;

USB driver automatic installation; Ethernet needs to modify the IP address of the PC network card to 192.168.100. x in the same network segment.

4.3 Axis Configuration Classification

Local axis: onboard stepper output/± 10V analog servo output, using onboard encoder interface;

Remote axis: MicroFlex e100/MotiFlex e100 driver on Ethernet POWERLINK bus; The axis configuration is stored on the drive side; Connect the origin and limit IO to the drive terminal.

4.4 Local axis debugging steps

Step axis: Test the pulse direction output and set the electronic gear ratio scale.

Local servo axis (simulating ± 10V command)

Test Demand simulation instruction output; Closed loop control debugging;

Servo loop parameters: proportional gain KPROP, speed feedforward KVELF;

Three response states: under damping (oscillation), over damping (slow response), and critical damping (optimal);

Adjust and eliminate steady-state position errors; Support two-stage tuning of current loop and speed loop.

Digital IO: Configure input edges/levels; Output level polarity.

Fault diagnosis

LED status indicator lights: Status light, CAN indicator light, and Ethernet indicator light, respectively indicating operation, bus communication, and faults.

SupportMe tool: One click collection of controller diagnostic logs for submitting fault information to ABB technical support.

Fault classification: communication fault, motor motion fault, Mint program abnormality, EPL, CANopen bus fault.