ABB NextMove ESB-2 Debugging and Replacement

Serial 9-pin female socket RS232: 2: RXD, 3: TXD, 5: GND; RS485: 7:TXA, 8:RXA, 5:GND

Attention: If using the driver enable function of digital output, a certain output (or relay) needs to be assigned to Drive Enable Output in the Digital I/O configuration and enabled in the program through the DRIVE ENABLE command.

Axis configuration and debugging process

3.1 Installing Mint WorkBench and Connecting Controllers

Download Mint WorkBench from the ABB official website (or use OPT-SW-001 CD) and install it on a Windows XP or higher version (32/64 bit) PC.

Connect NextMove ESB-2 to a PC using a USB cable or RS232 serial port cable. When connected via USB for the first time, Windows will automatically install the driver ("USB Motion Controller" will appear in Device Manager).

Start Mint WorkBench, select "Start New Project", scan the serial/USB ports, select NextMove ESB-2, and enter Fine tuning mode.

3.2 Axis Config Wizard

Click on the Axis Config icon in the Toolbox.

For each required axis, select "Servo" or "Stepper" in the Configuration column. The system automatically assigns hardware channels (such as Servo Channel 0 corresponding to Demand0 output); Stepper Channel 0 corresponds to STEP0/DIR0.

Click Finish, and the configuration will be downloaded to the controller. If it prompts' Hardware channel required is in use ', it means that the same channel is occupied by multiple axes. Please check and correct it.

3.3 Setting Scale Factor

Convert encoder counts to user units (such as revolutions, millimeters) through SCALEFACTOR. For example: 1000 line encoder x 4=4000 counts/revolution, set SCALEFACTOR (0)=4000, then the user unit 1=1 revolution. Set each axis separately in the Scale tab of the Parameters window.

3.4 Configuring Driver Enable Output

In the Digital Output tab of the Digital I/O window, drag an output (such as DOUT0 or Relay0) onto the Drive Enable OP axis icon on the right side.

Click Apply to enable the output to be assigned. Afterwards, the driver can be enabled through software or hardware buttons.

3.5 Step Axis Test

Ensure that the drive is powered on and enabled effectively.

Enter JOG (0)=200 (speed 200 user units/second) in the command line of the Edit&Debug window. The motor should rotate.

Enter JOG (0)=-200 in reverse, STOP (0) stops.

3.6 Servo axis testing and tuning

3.6.1 Preliminary testing

Ensure that the encoder feedback is correctly connected and oriented. Enter TORQUE (0)=5 at the command line, the motor should rotate and Velocity should display a positive value. If it is a negative value, the encoder A/B channels need to be swapped or the counting direction needs to be reversed using ENCODEMODE; Or use DACMODE to reverse the output polarity.

Use Fine tuning tools for step response testing.

3.6.2 Gain setting under current (torque) control mode

Suitable for drivers operating in current mode (torque loop). The steps are as follows:

Set the initial value of KDERIV to 1 and gradually increase it until there is resistance (such as 50) when turning the motor by hand.

Set KPROP to 1/4 of KDERIV (e.g. 12.5).

Select Move Type as Step, Distance as 1 turn (or 1000 user units), Duration as 0.15 seconds in the Fine tuning window, and click Go.

Observe the response curve:

Underdamped (overshoot): Increase KDERIV or decrease KPROP.

Overdamping (slow rise): Reduce KDERIV or increase KPROP.

Critical damping (fast and without overshoot): Ideal state.

Add an integral gain KINT (e.g. 0.1) to eliminate steady-state errors, and set KINTLIMIT=5% to limit integral saturation.

3.6.3 Gain setting in speed control mode

Suitable for drivers operating in speed mode. Mainly using speed feedforward KVELFF.

Calculate KVELFF: Measure the speed (rpm) of the motor under the+10V command. Formula:

Quadrature counts per servo loop

=rpm sixty×LOOPTIME(s)×counts/rev

Quadrature counts per servo loop= sixty rpm×LOOPTIME(s)×counts/rev

LOOPTIME defaults to 0.001 seconds. If the speed is 3000rpm and the encoder counts 4000 times per revolution, then the count per servo cycle is 3000/60 × 0.001 × 4000=200. The maximum DAC value of 2048 corresponds to 10V, so KVELF=2048/200 ≈ 10.24.

Set KVELFF as the calculated value and KPROP as 0.1, KDERIV=0。

Select Trapezoid move in Fine tuning, with a distance of 10 revolutions, and click Go. Observe the measured velocity and demand velocity curves. If the measured velocity is too low, increase KVELF, and if it is too high, decrease it.

Fine tune KPROP to reduce tracking error (see position curve).

3.7 Save Configuration

In the Edit&Debug window, use "Program → Generate Mint Startup Block" to generate all configuration parameters as startup blocks and save them as. mnt files. Load and run this file on the next power up to restore the complete configuration.

CAN bus communication configuration

4.1 CANopen mode

Hardware requirements: RJ45 connector, pin 5 needs to be connected to 12-24V (for optocoupler isolation power supply). Both ends of the network must be connected to a 120 Ω terminal resistor.

Software settings: Download CANopen firmware (via Install System File on Mint WorkBench). Set BUSBAUD (1)=500000 (500kbit/s) and BUSSIDE (1)=1 (master station) in Mint. Scan the slave station using NOSCAN and establish a connection through CONNECT.