User's Manual

ManualsBrandsNational Instruments ManualsOtherMID-7604/7602

National Instruments™, NI™, and ni.com™ are trademarks of National Instruments Corporation. Product and company names mentioned herein are

trademarks or trade names of their respective companies.

USER GUIDE

MID-7604/7602 P

OWER

RIVE

This user guide describes the electrical and mechanical aspects of the

MID-7604/7602 power drive and how to use the MID-7604/7602 with your

motion controller.

Contents

Compliance ............................................................................................. 2

Conventions ............................................................................................ 3

Introduction............................................................................................. 4

What You Need to Get Started ............................................................... 4

Safety Information .................................................................................. 5

Front Panel Switches............................................................................... 7

Back Panel Connector Wiring................................................................. 8

Host Bus Interlock Circuit ...................................................................... 9

Front Panel LEDs.................................................................................... 9

Driver Fault Output LEDs ............................................................... 10

Driver Inhibit LEDs ......................................................................... 10

Limit Status LEDs ........................................................................... 10

Front Panel DIP Switch Settings............................................................. 11

Microstepping Selection .................................................................. 12

Output Current Settings ................................................................... 13

Inhibit Input Polarity Setting ........................................................... 15

Limit Status LED Polarity Setting................................................... 15

Back Panel Connector Wiring................................................................. 16

Motor Power Terminal Blocks ........................................................ 16

Encoder Terminal Blocks ................................................................ 17

Limit Switch Terminal Blocks......................................................... 20

Breakpoint and Trigger Terminal Blocks ........................................ 20

Analog I/O Terminal Blocks............................................................ 21

Accessories for Optional Use.................................................................. 22

Strain-Relief Bar .............................................................................. 22

Panel-Mount Kit (Included)............................................................. 23

Amplifier/Driver Command Signals....................................................... 23

Stepper Motor Configurations ................................................................ 24

Specifications .......................................................................................... 27

Summary of content (31 pages)

PAGE 1
USER GUIDE MID-7604/7602 POWER DRIVE This user guide describes the electrical and mechanical aspects of the MID-7604/7602 power drive and how to use the MID-7604/7602 with your motion controller. Contents Compliance ............................................................................................. 2 Conventions ............................................................................................ 3 Introduction ..............................................................................
PAGE 2
Technical Support Resources ..................................................................31 NI Web Support................................................................................31 Worldwide Support ..........................................................................31 Compliance FCC/Canada Radio Frequency Interference Compliance* Determining FCC Class The Federal Communications Commission (FCC) has rules to protect wireless communications from interference.
PAGE 3
• • Connect the equipment into an outlet on a circuit different from that to which the receiver is connected. Consult the dealer or an experienced radio/TV technician for help. Canadian Department of Communications This Class B digital apparatus meets all requirements of the Canadian Interference-Causing Equipment Regulations. Cet appareil numérique de la classe B respecte toutes les exigences du Règlement sur le matériel brouilleur du Canada.
PAGE 4
Introduction National Instruments’ MID-7604/7602 power drive is a complete power amplifier and system interface for use with four or two axes of simultaneous stepper motion control. Ideally suited to industrial and laboratory applications, the MID-7604/7602 has everything you need to connect motors, encoders, limit switches, I/O, and other motion hardware to National Instruments’ motion controllers.
PAGE 5
❑ One of the following shielded cable assemblies, as applicable: – SH68-C68-S (part number 186381-02) – SHC68-C68-S (part number 186380-02) Detailed specifications for the MID-7604/7602 are in the Specifications section in this guide. Safety Information The following paragraphs contain important safety information you must follow when installing and operating the device. Caution Do not operate the device in a manner not specified in the documentation.
PAGE 6
• Pollution Degree 2—Normally only nonconductive pollution occurs. Occasionally, nonconductive pollution becomes conductive because of condensation. • Pollution Degree 3—Conductive pollution or dry, nonconductive pollution occurs. Nonconductive pollution becomes conductive because of condensation. Clean the device and accessories by brushing off light dust with a soft, nonmetallic brush. Remove other contaminants with a stiff, nonmetallic brush.
PAGE 7
The following is a diagram of a sample installation. The stepper motor connectors on this drive are energized when the unit is powered on. Disconnect the MID-7604/7602 unit from the power outlet before connecting wires to or disconnecting wires from the stepper connectors. Strip back the insulation of the stepper wires to the stepper connectors no more than 7 mm. Failure to do so could result in electric shock leading to serious bodily injury or death.
PAGE 8
The two rocker switches on the MID-7604/7602 front panel are the AC POWER and ENABLE. Figure 1 shows the location of these switches. The AC POWER switch energizes the motor bus (+24 V) and the logic (+5 V) power supplies. When switched on, the green power LED labeled +5 V illuminates. If this LED fails to illuminate, check the power cord and main input fuse on the front panel. The ENABLE switch enables or inhibits the stepper drivers.
PAGE 9
Be sure to turn off the ENABLE switch and the main AC power to your MID-7604/7602 and host computer before connecting the accessory to your motion controller. Caution The stepper motor connectors on this drive are energized when the unit is powered on. Disconnect the MID-7604/7602 unit from the power outlet before connecting wires to or disconnecting wires from the stepper connectors. Strip back the insulation of the stepper wires to the stepper connectors no more than 7 mm.
PAGE 10
If the DC power supplies are active, the green power LED illuminates. If this LED fails to illuminate, check the power cord and the main input fuse on the front panel. The LED status array is arranged by motor axes. Each of the four columns represents an axis, and each of the three rows represents a particular status. Table 1 summarizes the axis and status to which each LED in the 3 × 4 array corresponds. Table 1.
PAGE 11
Front Panel DIP Switch Settings The MID-7604/7602 front panel has a detachable metal plate that when removed provides access to four 10-position DIP switch banks. Refer to Figure 1 for the location of these switches. Use the first nine DIP switches on each 10-position DIP switch bank to configure the microstep rate, peak output current, and current reduction for each axis.
PAGE 12
Microstepping Selection The MID-7604/7602 uses bipolar chopper, two-phase microstepping drivers with a broad range of microstep rates. The factory default setting is 10-times microstepping (2,000 steps/rev with standard 1.8º stepper motors). Table 2 shows the DIP switch settings for all possible microstep settings. DIP switches 6 through 9 control the microstep rate on a per-axis basis. Table 2.
PAGE 13
Output Current Settings The MID-7604/7602 can provide 0.20–1.4 A peak (0.14–1 A RMS), depending on the peak output current DIP switch settings for each axis. DIP switches 1 through 4 control the peak output current. Table 3 shows the DIP switch settings for all possible peak output current settings. Table 3. Peak Output Current DIP Switch Setting Switch Peak Output (A) Switch 1.40 O N 1 2 3 4 1.20 O N 1 2 3 4 1.00 O N 0.28 O N 1 2 3 4 1 2 3 4 0.85 O N 0.27 O N 1 2 3 4 1 2 3 4 0.
PAGE 14
To determine the maximum total power dissipation of all of the motors combined, add up the maximum power each motor can dissipate. If this value is less than or equal to 80 W continuous, you will not exceed the capabilities of the MID-7604/7602. If the value is greater than 80 W continuous, you may still be within the operating capabilities of the MID-7604/7602, since it is unlikely you will run all of your motors simultaneously at their maximum levels.
PAGE 15
Inhibit Input Polarity Setting The MID-7604/7602 has a DIP switch that globally sets the polarity for the inhibit input for all axes. DIP switch 10 on the axis 1 DIP switch bank controls this setting. Refer to Figures 1 and 3 for the location of this switch. The factory default setting of DIP switch 10 is active-low. If the inhibit input is active, the axis is inhibited and the yellow status LED (middle row) illuminates for the axis.
PAGE 16
Back Panel Connector Wiring Motor Power Terminal Blocks Each axis on the MID-7604/7602 has a separate 5-position removable screw terminal block for motor power wiring. Figure 4 shows a typical stepper motor configuration pin assignment. The dotted loop indicates a shielded cable. A line above a signal indicates that the signal is active-low. Note Phase A Phase A Case Ground Phase B Phase B Stepper Motor 1 2 3 4 5 Shield Figure 4.
PAGE 17
Never connect unused center taps or winding terminals to pin 3 (ground) or to each other. Caution Encoder Terminal Blocks For quadrature incremental encoder signals, each MID-7604/7602 axis has a separate 8-position removable screw terminal block. Where applicable, the MID-7604/7602 accepts two types of encoder signal inputs: single-ended (TTL) or differential line driver. You can accommodate open-collector output encoders by using 2.2 kΩ pullup resistors to +5 VDC.
PAGE 18
If the encoder cable length is greater than 10 ft, use encoders with line driver outputs for your applications. Power for a +5 V encoder—generated by a power supply inside the MID-7604/7602—is available on pin 7. If you require other encoder power voltages, reference an external power supply to the Digital Ground signal on the 8-pin encoder terminal block. Note The MID-7604/7602 supports differential inputs for Phase A, Phase B, and Index signals.
PAGE 19
Figure 8 shows clockwise and counter-clockwise motor rotation. W C W C C Figure 8. Clockwise and Counter-Clockwise Motor Rotation When connecting the encoder wiring to your MID-7604/7602, use shielded wire of at least 24 AWG. Analog noise filters filter the encoder inputs in the MID-7604/7602. You must use cables with twisted pairs and an overall shield for improved noise immunity and enhanced encoder signal integrity. Figure 9 shows twisted pairs in a shielded cable.
PAGE 20
Limit Switch Terminal Blocks For end-of-travel limit, home, inhibit input, and inhibit output connections, MID-7604/7602 axes have a separate, 6-position removable screw terminal connector block. Figure 10 shows the limit switch terminal block pin assignments. Forward Limit Home Input Reverse Limit Inhibit Input Inhibit Output Digital Ground 1 2 3 4 5 6 Figure 10.
PAGE 21
Trigger Input 1 Trigger Input 2 Trigger Input 3 Trigger Input 4 Shutdown Input Digital Ground 1 2 3 4 5 6 Figure 11. Trigger Terminal Block Pin Assignment Breakpoint Output 1 Breakpoint Output 2 Breakpoint Output 3 Breakpoint Output 4 +5 V Digital Ground 1 2 3 4 5 6 Figure 12. Breakpoint Terminal Block Pin Assignment Analog I/O Terminal Blocks The MID-7604/7602 has two analog I/O connectors.
PAGE 22
Accessories for Optional Use Strain-Relief Bar The strain-relief bar provides strain relief for wiring to the back panel terminals of the MID-7604/7602. The arms of the strain-relief bar attach to the sides of the MID-7604/7602 with the thumb nuts facing upward, as shown in Figure 15. Using the provided screws, attach the strain-relief bar to the rear set of screwholes on the side panels of the MID-7604/7602. Strain-Relief Bar Figure 15.
PAGE 23
Panel-Mount Kit (Included) The panel-mount kit allows you to mount the MID-7604/7602 inside a cabinet or enclosure. Using the provided screws, attach the panel-mount kit to the rear and front set of screw holes on the side panels of the MID-7604/7602, as shown in Figure 16. Panel-Mount Bracket Figure 16. MID-7604/7602 with the Panel-Mount Kit Installed Note The strain-relief bar and panel-mount kit cannot be installed at the same time.
PAGE 24
Stepper Motor Configurations This section describes the various industry-standard winding configurations for stepper motors and shows how to connect them to a MID-7604/7602. The MID-7604/7602 is compatible with all configurations of two-phase stepper motors. Note The MID-7604/7602 is not compatible with 5-lead unipolar stepper motors or 5-phase stepper motors. 2-phase stepper motors come in 4-, 6-, and 8-wire variations. Figure 17 shows a 6-wire and an 8-wire stepper motor.
PAGE 25
For maximum flexibility, you can connect 8-wire stepper motors in either a series or parallel configuration. Connecting the windings in series as shown in Figure 18 produces the most torque per amp, but has the disadvantage of higher inductance and poorer high-speed performance. Phase A Phase A-CT Phase A-CT Phase A Phase B 1 2 3 4 5 Phase B-CT Phase B-CT Motor Case Ground Phase B Phase A Phase A Ground Phase B Phase B Shield Figure 18.
PAGE 26
Notice that an 8-wire motor wired in series is virtually identical to a 6-wire motor and typically has the same high-torque but low-speed characteristics. While a parallel configuration is not possible with a 6-wire motor, you can usually obtain high-speed performance with the half-coil connection shown in Figure 20. This configuration sacrifices low-speed torque for better high-speed performance.
PAGE 27
Specifications The following specifications apply only to the MID-7604/7602. To obtain a system specification, you must account for your motion controller. Refer to your controller specifications to determine overall system specifications. Some signals have compatibility defined as signal pass-through, which means the MID-7604/7602 may have passive filtering on these signals but will not affect the voltage range or current handling capability.
PAGE 28
Inhibit Inputs Voltage range..........................................0–12 VDC Inhibit low voltage..................................0.8 V Inhibit high voltage.................................2 V Inhibit Output Voltage range..........................................0–5 VDC Output low voltage .................................0.5 V at 64 mA Output high voltage ................................2.4 V at 32 mA Trigger Input Noise filter (RC time constant)...............100 ns Compatibility ......................
PAGE 29
Breakpoints ............................................ 6-position mini-combicon 3.81 mm plug (1 total) Triggers .................................................. 6-position mini-combicon 3.81 mm plug (1 total) Analog input........................................... 6-position mini-combicon 3.81 mm plug (1 total) Analog output......................................... 5-position mini-combicon 3.81 mm plug (1 total) AC power ...............................................
PAGE 30
Environment Operating temperature ............................ 0 to 40 ºC (32 to 104 ºF) Storage temperature ................................–20 to 70 ºC (–4 to 158 ºF) Humidity .................................................10 to 90% RH, noncondensing Maximum altitude...................................2000 m Pollution degree ......................................2 Usage ......................................................Indoor use only Electromagnetic Compatibility EMC/EMI ...........................
PAGE 31
Technical Support Resources NI Web Support National Instruments Web support is your first stop for help in solving installation, configuration, and application problems and questions. Online problem-solving and diagnostic resources include frequently asked questions, knowledge bases, product-specific troubleshooting wizards, guides, drivers, software updates, and more. Web support is available through the Technical Support section of ni.com.