National Instruments Impact Driver 7602 User Manual

USER GUIDE  
MID-7604/7602 POWER DRIVE  
This user guide describes the electrical and mechanical aspects of the  
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  
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.  
322454C-01  
Copyright © 1999, 2001 National Instruments Corp. All rights reserved.  
July 2001  
 
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.  
European Union - Compliance to EU Directives  
Readers in the EU must refer to the Manufacturer's Declaration of Conformity (DoC) for information** pertaining to the CE  
Mark compliance scheme. The Manufacturer includes a DoC for most every hardware product except for those bought for  
OEMs, if also available from an original manufacturer that also markets in the EU, or where compliance is not required as for  
electrically benign apparatus or cables.  
*
Certain exemptions may apply in the USA, see FCC Rules §15.103 Exempted devices, and §15.105(c). Also available in  
sections of CFR 47.  
** The CE Mark Declaration of Conformity will contain important supplementary information and instructions for the user or  
installer.  
Conventions  
This guide uses the following conventions:  
This icon denotes a note, which alerts you to important information.  
This icon denotes a caution, which advises you of precautions to take to  
avoid injury, data loss, or a system crash.  
This icon denotes a temperature caution, which advises you of precautions  
to take to avoid a burn hazard.  
This icon denotes a warning, which advises you of precautions to take to  
avoid being electrically shocked.  
bold  
Bold text denotes items that you must select or click on in the software,  
such as menu items and dialog box options. Bold text also denotes  
parameter names.  
italic  
Italic text denotes emphasis, a cross reference, or an introduction to a key  
concept. This font also denotes text that is a placeholder for a word or value  
that you must supply.  
monospace  
Text in this font denotes text or characters that you should enter from the  
keyboard, sections of code, programming examples, and syntax examples.  
This font is also used for the proper names of disk drives, paths, directories,  
programs, subprograms, subroutines, device names, functions, operations,  
variables, filenames and extensions, and code excerpts.  
© National Instruments Corporation  
3
MID-7604/7602 Power Drive  
 
 
Introduction  
National InstrumentsMID-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 Instrumentsmotion controllers.  
The MID-7604/7602 can drive a broad range of stepper motors with its  
rugged microstepping bipolar chopper driver and user-selectable  
current-per-phase settings. In all configurations, power supplies are built-in  
and use standard 230/115 VAC for operation. Electronics are fan-cooled to  
assure reliable operation.  
The MID-7604/7602 simplifies field wiring through separate encoder, limit  
switch, and motor power removable screw terminal connector blocks for  
each axis. The terminal blocks do not require special wiring tools for  
installation. The MID-7604/7602 connects to National Instruments’  
motion controllers via a 68-pin, high-density interconnect cable.  
The MID-7604/7602 has four levels of amplifier inhibit/disable protection  
for motion system shutdown. The front panel contains both enable and  
power switches for direct motor inhibiting and system power-down  
operations. The MID-7604/7602 also has a host bus power interlock that  
activates an internal driver inhibit signal if the host computer is shut down  
or the motion controller interface cable is disconnected. The inhibit input  
from the back panel connectors also inhibits the stepper drives when  
activated.  
The MID-7604/7602 is packaged in a rugged, lightweight enclosure that  
can be used as a benchtop unit, panel mounted using a panel-mount kit, or  
rack mounted using a 19-inch standard rack kit.  
What You Need to Get Started  
To set up and use your MID-7604/7602 accessory, you must have the  
following items:  
MID-7604/7602 power drive  
MID-7604/7602 Power Drive User Guide  
Power cord (IEC type)  
Panel-mount kit (part number 187243-01)  
MID-7604/7602 Power Drive  
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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  
Caution The following paragraphs contain important safety information you must follow  
when installing and operating the device.  
Do not operate the device in a manner not specified in the documentation.  
Misuse of the device may result in a hazard and may compromise the safety  
protection built into the device. If the device is damaged, turn it off and do  
not use it until service-trained personnel can check its safety. If necessary,  
return the device to National Instruments for repair.  
Keep away from live circuits. Do not remove equipment covers or shields  
unless you are trained to do so. If signal wires are connected to the device,  
hazardous voltages can exist even when the equipment is turned off. To  
avoid a shock hazard, do not perform procedures involving cover or shield  
removal unless you are qualified to do so. Disconnect all field power prior  
to removing covers or shields.  
If the device is rated for use with hazardous voltages (>30 Vrms, 42.4 Vpk,  
or 60 Vdc), it may require a safety earth-ground connection wire. See the  
device specifications for maximum voltage ratings.  
Because of the danger of introducing additional hazards, do not install  
unauthorized parts or modify the device. Use the device only with the  
chassis, modules, accessories, and cables specified in the installation  
instructions. All covers and filler panels must be installed while operating  
the device.  
Do not operate the device in an explosive atmosphere or where flammable  
gases or fumes may be present. Operate the device only at or below the  
pollution degree stated in the specifications. Pollution consists of any  
foreign mattersolid, liquid, or gasthat may reduce dielectric strength  
or surface resistivity. Pollution degrees are listed below.  
Pollution Degree 1No pollution or only dry, nonconductive  
pollution occurs. The pollution has no effect.  
© National Instruments Corporation  
5
MID-7604/7602 Power Drive  
 
 
Pollution Degree 2Normally only nonconductive pollution occurs.  
Occasionally, nonconductive pollution becomes conductive because of  
condensation.  
Pollution Degree 3Conductive 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. The unit must be completely dry and free from contaminants before  
returning it to service.  
You must insulate signal connections for the maximum voltage for which  
the device is rated. Do not exceed the maximum ratings for the device.  
Remove power from signal lines before connection to or disconnection  
from the device.  
The MID 7604/7602 drive is not a measurement device. However, if you  
want to make a measurement of the circuits or devices connected to the  
drive, operate the device only at or below the installation category stated in  
the specifications. Installation categories are listed below.  
Installation Category IVfor measurements performed at the source  
of the low-voltage (<1000 V) installation. Examples include electricity  
meters, measurements on primary overcurrent protection devices, and  
ripple-control units.  
Installation Category IIIfor measurements performed in the building  
installation. Examples include measurements on distribution boards,  
circuit-breakers, wiring (including cables), bus bars, junction boxes,  
switches, socket outlets in the fixed installation, equipment for  
industrial use, and some other types of equipment, such as stationary  
motors permanently connected to the fixed installation.  
Installation Category IIfor measurements performed on circuits  
directly connected to the low-voltage installation. Examples include  
measurements on household appliances, portable tools, and other  
similar equipment.  
Installation Category Ifor measurements performed on circuits not  
directly connected to mains1. Examples include measurements on  
circuits not derived from mains, and specially-protected (internal)  
mains-derived circuits.  
1
Mains is defined as the electricity supply system to which the equipment concerned is designed to be connected for either  
powering the equipment or for measurement purposes.  
MID-7604/7602 Power Drive  
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The following is a diagram of a sample installation.  
Warning 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.  
Caution The bottom surface of the MID-7604/7602 can get very hot to the touch under  
certain conditions. To avoid a burn hazard, refer to the Output Current Settings section in  
the Front Panel DIP Switch Settings section of this guide for the appropriate current setting  
and safety hazards.  
Front Panel Switches  
Figure 1 shows the front panel of your MID-7604/7602. The DIP switches  
are shown with the detachable metal cover plate removed.  
AXIS CONFIGURATION  
LINE VOLTAGE SELECT  
AC POWER  
FUSE  
ENABLE  
FAULTS  
INHIBITS  
LIMITS  
ON  
ON  
ON  
ON  
1
2
3
4
+
5V  
ON  
OFF  
AXIS  
ON  
OFF  
1
2
3
4
5
6
7
8
9
10  
1
2
3
4
Main Input Fuse  
5
6
7
Enable Switch  
Axis 1 DIP Switch Bank  
Axis 2 DIP Switch Bank  
8
9
Axis 3 DIP Switch Bank*  
Axis 4 DIP Switch Bank*  
Line Voltage Select Switch  
Power Switch  
10 LED Status Array  
Green Power LED  
Figure 1. MID-7604/7602 Front Panel  
Note Items followed by an asterisk (*) are available on the MID-7604 only.  
© National Instruments Corporation  
7
MID-7604/7602 Power Drive  
 
   
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. If the  
ENABLE switch is in the inhibit position (off), the stepper drivers are  
inhibited, and the yellow LEDs (the middle row of the LED status array)  
for all axes illuminate. See the Front Panel LEDs section of this guide for  
more information.  
Both the AC POWER and ENABLE switches can inhibit the stepper  
drivers. However, as long as the AC POWER switch is on, only the stepper  
driver output stages are disabled. The remaining circuitry remains active,  
including the quadrature encoder circuit.  
Caution You must change the MID-7604/7602 main input fuse on the front panel if you  
change the line voltage from the factory setting. Refer to the Specifications section of this  
guide for fuse specifications.  
Back Panel Connector Wiring  
Figure 2 shows connectors located on the back panel of your  
MID-7604/7602.  
7
8
9
10  
15  
16  
17  
18  
6
1
2
3
4
5
11 12  
13 14  
1
2
3
4
5
6
Motion Controller Connector  
Analog Input Connector  
Analog Output Connector  
Trigger Connector  
Breakpoint Connector  
AC Power  
Encoder  
Limit  
Motor  
Connectors  
Connectors  
11 Axis 1  
12 Axis 2  
13 Axis 3*  
14 Axis 4*  
Connectors  
15 Axis 1  
16 Axis 2  
17 Axis 3*  
18 Axis 4*  
7
8
9
Axis 1  
Axis 2  
Axis 3*  
10 Axis 4*  
Figure 2. MID-7604/7602 Back Panel Connectors  
Note Items followed by an asterisk (*) are available on the MID-7604 only.  
MID-7604/7602 Power Drive  
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Caution 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.  
Warning 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.  
1. Use the interface cable to connect the motion controller to the  
MID-7604/7602. Wire the motor power, limit switch, encoder, and I/O  
terminal blocks as described in this guide and to your specific system  
requirements.  
2. Use the LINE VOLTAGE SELECT switch to configure the  
MID-7604/7602 for 115 VAC, 60 Hz or 230 VAC, 50 Hz operation.  
For proper operation, you must set this switch to match your power  
source.  
Caution You must change the MID-7604/7602 main input fuse on the front panel if you  
change the line voltage from the factory setting. Refer to the Specifications section of this  
guide for fuse specifications.  
3. Finally, install the power cord into the back panel AC connector and  
plug it in to a correctly rated power source.  
Host Bus Interlock Circuit  
The MID-7604/7602 has a host bus interlock circuit that monitors the  
presence of +5 V from the host computer and disables the MID-7604/7602  
when the voltage is not present or falls out of tolerance. This circuit shuts  
down the stepper drives for all axes by activating the inhibit when the host  
computer is disconnected from the MID-7604/7602 or inadvertently shut  
down. Activation of the host bus interlock circuitry illuminates the yellow  
LEDs (middle row) of the LED status array for all axes. See the Front Panel  
LEDs section of this guide for more information.  
Front Panel LEDs  
The front panel LEDs consist of a single green LED to indicate if the main  
power is active and an LED status array of 3 rows by 4 columns that  
provides a variety of status information. Refer to Figure 1 for the location  
of the front panel LEDs.  
© National Instruments Corporation  
9
MID-7604/7602 Power Drive  
 
   
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. Front Panel LED Indicators  
Status  
Motor Axis  
Driver Fault Output (red)  
Driver Inhibit (yellow)  
Limit Status (green)  
1
1
1
2
2
2
3
3
3
4
4
4
Driver Fault Output LEDs  
The top row of LEDs indicates the status of the stepper drivers. An LED  
illuminates red when an overcurrent condition or a problem with the motor  
bus voltage on that axis occurs.  
Driver Inhibit LEDs  
MID-7604/7602 Power Drive  
The middle row of LEDs indicates whether or not a motor axis is inhibited.  
An axis is inhibited and the LED illuminates yellow in the following  
instances: if the host bus interlock circuitry is activated from the back panel,  
if the ENABLE switch on the front panel is in the inhibit position, if the  
motion controllers inhibit signal is low, or if the per-axis inhibit input is  
actively driven.  
The polarity of the per-axis inhibit input is selectable from the front panel  
DIP switches. See the Front Panel DIP Switch Settings section of this guide  
for more information.  
The bottom row of LEDs indicates whether or not a limit switch is currently  
active. The LED illuminates green if either the forward or reverse limit  
switch is active for each axis. You can select the polarity for the limit status  
LEDs from the front panel DIP switches. See the Front Panel DIP Switch  
Settings section in this guide for more information.  
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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. The DIP switch banks for axes 1 and 2 contain a global DIP  
switch, switch 10, which sets the polarity of the inhibit input and the  
polarity of the limit status LED, respectively. Figure 3 shows the DIP  
switch bank layout.  
1
2
O
N
1
2
3
4
5
3
6
7
8
9
10  
4
1
2
3
Peak Current Output Switches  
Microstep Rate Switches  
Current Reduction Switch  
4
Global Polarity Switch (unused on  
axes 3 and 4 DIP switch banks)  
Figure 3. DIP Switch Bank Layout  
© National Instruments Corporation  
11  
MID-7604/7602 Power Drive  
 
   
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. Microstep Rate DIP Switch Setting  
Binary Selections  
Decimal Selections  
Switch  
Microsteps/Step  
Switch  
Microsteps/Step  
O
N
O
N
2 (half step)  
5
6
7
8
9
6
6
7
7
8
8
9
9
O
N
O
N
4
8
10  
(factory default)  
6
7
8
9
O
N
O
N
25  
50  
6
6
7
7
8
8
9
9
6
6
6
7
7
7
8
8
8
9
9
9
O
N
O
N
16  
32  
64  
128  
256  
O
N
O
N
125  
6
6
7
7
8
8
9
9
O
N
O
N
250  
6
6
7
7
8
8
9
9
O
N
O
N
Do not use  
Do not use  
6
6
7
7
8
8
9
9
O
N
O
N
6
7
8
9
MID-7604/7602 Power Drive  
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Output Current Settings  
The MID-7604/7602 can provide 0.201.4 A peak (0.141 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  
Peak Output (A)  
O
N
O
N
1.40  
0.35  
1
2
3
4
1
1
1
1
1
1
2
2
2
2
2
2
3
3
3
3
3
3
4
4
4
4
4
4
O
N
O
N
1.20  
1.00  
0.85  
0.70  
0.60  
0.55  
0.30  
0.28  
0.27  
0.25  
0.24  
0.23  
0.20  
1
2
3
4
O
N
O
N
1
1
2
2
3
3
4
4
O
N
O
N
O
N
O
N
1
1
2
2
3
3
4
4
O
N
O
N
O
N
O
N
1
1
2
2
3
3
4
4
1
1
2
2
3
3
4
4
O
N
O
N
0.50  
(factory default)  
If you are connecting multiple motors to your MID-7604/7602, verify that  
the total power dissipated by the motors at any given time is less than the  
total power the drive can provide. If the total power requirement exceeds  
the capability of the drive at any point, the drive will provide less power to  
the motors than desired until the total power requirement drops back down.  
The MID-7604/7602 may overheat under continuous operation with loads  
that exceed specified limits.  
Caution A fire safety hazard exists when the total power dissipated by the motors exceeds  
80 W continuous for a sustained period of time.  
© National Instruments Corporation  
13  
MID-7604/7602 Power Drive  
 
   
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. Make a  
reasonable estimation of the maximum power your motors will require at  
any given time and verify that this value is less than 80 W continuous.  
You can configure the MID-7604/7602 stepper drivers in a current  
reduction mode on a per-axis basis. This configuration is useful to  
minimize motor heating when you are not stepping. With current reduction  
enabled, the current decreases by 50% when no stepping has occurred for  
approximately 500 ms. DIP switch 5 controls current reduction on a  
per-axis basis. When this DIP switch is on, current reduction is enabled.  
When this DIP switch is off, current reduction is disabled. The factory  
default setting is current reduction enabled.  
Table 4 shows the available settings for DIP switch 5.  
Table 4. Current Reduction DIP Switch Settings  
Switch Setting  
Operation  
O
N
Current reduction enabled  
(factory default)  
5
O
N
Current reduction disabled  
5
MID-7604/7602 Power Drive  
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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. Table 5 shows the DIP switch setting for the inhibit  
input polarity selection.  
Table 5. Inhibit Input Polarity DIP Switch Settings  
Axis 1 Switch Setting  
Operation  
O
N
Active-high  
10  
O
N
Active-low  
(factory default)  
10  
Limit Status LED Polarity Setting  
The MID-7604/7602 has a DIP switch that globally sets the polarity for the  
Limit Status LED. DIP switch 10 on the axis 2 DIP switch bank controls  
this setting. Refer to Figures 1 and 3 for the location of this switch.  
The factory default setting is active-low. Typically, you set the switch to  
match your controllers polarity setting, so that if either the reverse or  
forward limits for an axis are active, the green status LED (on the bottom  
row) for the axis illuminates. This DIP switch alters only the polarity for  
the LEDs, and not the actual limit to the motion controller. Table 6 shows  
the DIP switch setting for the Limit Status LED polarity selection.  
Table 6. Limit Status LED DIP Switch Settings  
Axis 2 Switch Setting  
Operation  
O
N
Active-high  
10  
O
N
Active-low  
(factory default)  
10  
© National Instruments Corporation  
15  
MID-7604/7602 Power Drive  
 
       
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.  
Note The dotted loop indicates a shielded cable. A line above a signal indicates that the  
signal is active-low.  
Phase A  
1
2
3
4
Phase A  
Case Ground  
Phase B  
Phase B  
5
Stepper Motor  
Shield  
Figure 4. Typical Full-Coil Stepper Motor (2-Phase Type)  
Terminal Block Pin Assignment  
Warning 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.  
Use shielded, 20 AWG wire or larger for the motor power cable.  
If available, you should connect a case ground wire to pin 3  
(Ground/Shield) to avoid ground loops and signal noise problems.  
Case ground connects to the motor housing, and not to the motor power  
terminals.  
The MID-7604/7602 contains bipolar chopper drivers. You must wire the  
stepper motors in a 4-wire configuration as shown in Figure 4. You must  
isolate unused lead wires and leave them disconnected. Refer to the Stepper  
Motor Configurations section in this guide for additional information on  
connecting 6- and 8-wire motors and on the alternate half-coil  
configuration.  
MID-7604/7602 Power Drive  
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Caution Never connect unused center taps or winding terminals to pin 3 (ground) or to  
each other.  
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 kpullup resistors to  
+5 VDC.  
Figure 5 shows the typical encoder wiring pin assignment for single-ended  
signal input.  
Encoder A  
Encoder B  
1
2
3
4
5
6
7
8
Encoder Index  
+5 V  
Digital Ground  
Figure 5. Typical Single-Ended Encoder Wiring Pin Assignment  
Figure 6 shows the typical encoder wiring pin assignment for differential  
line driver signal inputs.  
Encoder A  
Encoder A  
Encoder B  
1
2
3
4
5
6
7
8
Encoder B  
Encoder Index  
Encoder Index  
+5 V  
Digital Ground  
Figure 6. Typical Differential Line Driver Encoder Wiring Pin Assignment  
© National Instruments Corporation  
17  
MID-7604/7602 Power Drive  
 
     
If the encoder cable length is greater than 10 ft, use encoders with line  
driver outputs for your applications. Power for a +5 V encodergenerated  
by a power supply inside the MID-7604/7602is available on pin 7.  
Note If you require other encoder power voltages, reference an external power supply to  
the Digital Ground signal on the 8-pin encoder terminal block.  
The MID-7604/7602 supports differential inputs for Phase A, Phase B, and  
Index signals. You can easily accommodate encoders with various phase  
relationships by swapping the signals and/or connecting them to the  
inverting inputs as specific applications require. The Index signal must  
occur when both Phase A and Phase B signals are low, as shown in  
Figure 7. If the Index polarity is inverted, try reversing the Index and Index  
signals on differential encoders or using the Index input on single-ended  
encoders.  
Figure 7 shows the proper encoder phasing for CW (forward) motor  
rotation.  
Phase A  
Phase B  
Index  
Figure 7. Encoder Signal Phasing, CW Rotation  
Closed-loop stepper applications require consistent directional polarity  
between the motor and encoder for correct operation. The National  
Instruments motion control standard directional polarity is as follows:  
Positive = forward = clockwise (CW) facing motor shaft  
Negative = reverse = counter-clockwise (CCW) facing motor shaft  
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Figure 8 shows clockwise and counter-clockwise motor rotation.  
CW  
CCW  
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.  
Drain  
Shield  
Encoder A  
Encoder A  
Encoder B  
Encoder B  
Encoder Index  
Encoder Index  
+5 V  
Digital  
Ground  
Figure 9. Shielded Twisted Pairs  
Note If you use an unshielded cable, noise can corrupt the encoder signals, resulting in  
lost counts, reduced accuracy, and other erroneous encoder and controller operation.  
© National Instruments Corporation  
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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  
1
2
3
Inhibit Input  
4
Inhibit Output  
5
Digital Ground  
6
Figure 10. Limit Switch Terminal Block Pin Assignment  
(Passive Limit Switch Connection Example)  
The inhibit output signal is asserted low from the MID-7604/7602 when an  
axis is inhibited. This signal can be useful for actuating mechanical brakes  
or for monitoring an axis status. An axis is inhibited if the host bus interlock  
circuitry is activated, if the ENABLE switch on the front panel is in the  
inhibit position, if the motion controllers inhibit signal is low, or if the  
per-axis inhibit input is actively driven.  
The MID-7604/7602 stepper drive remains in a reset state for 500 ms after  
the inhibit is deasserted. Therefore, you can lose steps if you attempt to  
issue a start motion command within 500 ms from the deassertion of the  
stepper drive inhibit. A Kill command asserts the inhibit signal from the  
controller and a Halt command deasserts the inhibit signal from the  
controller. The yellow LEDs (middle row) on the front panel illuminate if  
an axis is currently inhibited (killed state). Execute a halt stop to de-assert  
the inhibit signal from the controller, after which you must wait at least  
500 ms before executing a start.  
Breakpoint and Trigger Terminal Blocks  
Both the breakpoint and trigger connectors use a 6-pin removable terminal  
block.  
The trigger terminal block provides access to the trigger input lines,  
shutdown input line, and digital ground. The breakpoint terminal block  
provides access to the breakpoint output lines, +5 V supplied by the  
MID-7604/7602, and digital ground. Figures 11 and 12 show the  
breakpoint and trigger 6-position terminal block assignments.  
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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  
1
2
3
4
5
6
Digital Ground  
Figure 12. Breakpoint Terminal Block Pin Assignment  
Analog I/O Terminal Blocks  
The MID-7604/7602 has two analog I/O connectors. The analog input  
connector uses a 6-pin removable terminal block, and the analog output  
connector uses a 5-pin removable terminal block.  
The analog input terminal block provides access to four analog-to-digital  
converter channels, an analog reference voltage from the converter circuit,  
and an analog input ground signal. The analog output terminal block  
provides access to four digital-to-analog converter channels with 10 V  
output range and analog output ground. Refer to Figures 13 and 14 for  
terminal block pin assignments.  
Analog Input 1  
Analog Input 2  
Analog Input 3  
1
2
3
4
5
6
Analog Input 4  
Analog Reference (Output)  
Analog Input Ground  
Figure 13. Analog Input Terminal Block Pin Assignment  
Analog Output 1  
Analog Output 2  
Analog Output 3  
1
2
3
4
5
Analog Output 4  
Analog Output Ground  
Figure 14. Analog Output Terminal Block Pin Assignment  
© National Instruments Corporation  
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MID-7604/7602 Power Drive  
 
         
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. MID-7604/7602 with the Strain-Relief Bar Installed  
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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.  
Amplifier/Driver Command Signals  
For stepper drivers, the two industry standards for command signals are  
as follows:  
Step and Direction signals (MID-7604/7602 standard)  
Independent CW and CCW pulses  
The MID-7604/7602 uses stepper drivers that have active-low step and  
direction inputs. You must configure the stepper outputs of your motion  
controller for Step and Direction signals with inverted (active-low) polarity.  
© National Instruments Corporation  
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MID-7604/7602 Power Drive  
 
     
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. A 4-wire motor is the same as  
a 6-wire motor except that the center taps (CT) are not brought out.  
Phase B  
Phase B  
Phase B-CT  
Phase B-CT  
Phase B-CT  
Phase B-CT  
Phase B  
Phase B  
6-wire  
8-wire  
Figure 17. 6-Wire and 8-Wire Stepper Motors  
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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 B  
Phase B-CT  
Phase B-CT  
1
2
3
4
5
Phase A  
Phase A  
Ground  
Phase B  
Phase B  
Motor Case Ground  
Phase B  
Shield  
Figure 18. Series Stepper Motor Wiring (Higher Torque, Lower Speed)  
Alternatively, you can wire 8-wire stepper motors in parallel as shown in  
Figure 19. This configuration produces better high-speed performance but  
requires more current to produce rated torque.  
Phase B  
Phase B-CT  
1
2
3
4
5
Phase A  
Phase A  
Ground  
Phase B  
Phase B  
Phase B-CT  
Motor Case Ground  
Phase B  
Shield  
Figure 19. Parallel Stepper Motor Wiring (Higher Speed, Lower Torque)  
© National Instruments Corporation  
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MID-7604/7602 Power Drive  
 
   
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. With this configuration, it is typically not possible  
to produce the rated torque of the motor without the risk of the motor  
overheating because only half of the windings are being used.  
Phase B  
Phase B-CT  
Phase B-CT  
1
2
3
4
5
Phase A  
Phase A  
Ground  
Phase B  
Phase B  
Motor Case Ground  
Phase B  
Shield  
Figure 20. Half-Coil Stepper Motor Wiring  
Figure 21 shows the wiring for a typical 4-wire motor.  
Phase B  
Phase A  
Phase A  
Ground  
Phase B  
Phase B  
1
2
3
4
5
Motor Case Ground  
Phase B  
Shield  
Figure 21. 4-Wire Motor Wiring  
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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. Consult  
your motion controller specifications to determine the allowable voltage  
range and logic level compatibility of the signal.  
Stepper Amplifiers  
Type ....................................................... IM481H modular hybrid,  
bipolar chopper  
Chopping frequency............................... 20 kHz  
DC-bus motor......................................... 24 VDC nominal  
Current per phase ................................... 0.201.4 A peak (0.141 A RMS)  
(factory setting is 0.50 A peak)  
Microstepping selections........................ ×2, 4, 8, 16, 32, 64, 128, 256  
×5, 10, 25, 50, 125, 250  
(factory default is ×10  
microsteps/step)  
Continuous power output rating  
(all axes combined) ................................ 80 W continuous  
Encoder Interface  
Inputs...................................................... Quadrature, incremental  
Differential input threshold.................... 0.3V (typical)  
Single ended input threshold.................. TTL/CMOS  
Voltage range ......................................... 05 VDC  
Noise filter (RC time constant) .............. 100 ns  
Maximum quadrature frequency............ 1 MHz  
Limit and Home Switch Inputs  
Compatibility ......................................... Signal pass-through  
© National Instruments Corporation  
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MID-7604/7602 Power Drive  
 
 
Inhibit Inputs  
Inhibit Output  
Trigger Input  
Voltage range..........................................012 VDC  
Inhibit low voltage..................................0.8 V  
Inhibit high voltage.................................2 V  
Voltage range..........................................05 VDC  
Output low voltage .................................0.5 V at 64 mA  
Output high voltage ................................2.4 V at 32 mA  
Noise filter (RC time constant)...............100 ns  
Compatibility..........................................Signal pass-through  
Breakpoint Output  
Analog Input  
Compatibility..........................................Signal pass-through  
Noise filter (RC time constant)...............10 µs  
Compatibility..........................................Signal pass-through  
Analog Output  
Shutdown Input  
Compatibility..........................................Signal pass-through  
Compatibility..........................................Signal pass-through  
Included Connectors  
Encoders .................................................8-position mini-combicon  
3.81 mm plug (1 per axis)  
Limits......................................................6-position mini-combicon  
3.81 mm plug (1 per axis)  
Motors.....................................................5-position combicon  
5.08 mm plug (1 per axis)  
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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 ............................................... Detachable AC power cord  
(IEC standard type)  
Motion I/O.............................................. 68-pin female high density  
VHDCI type  
Power Supply  
Input voltage .......................................... 115/230 VAC 10%, 4763 Hz  
Installation category............................... II  
Input fuse  
115 VAC (factory default).............. 3 A Type F  
(Bussmann #GMA-3)  
230 VAC......................................... 1.5 A Type F  
(Bussmann #GMA-1.5)  
Input fuse dimensions ............................ 5 × 20 mm  
Host Bus Voltage Interlock  
Undervoltage threshold.......................... 4 VDC  
Physical  
Length .................................................... 30.7 cm (12.1 in.)  
Width...................................................... 25.4 cm (10 in.)  
Height..................................................... 4.3 cm (1.7 in.)  
Weight.................................................... 4.5 kg (10 lb.)  
© National Instruments Corporation  
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MID-7604/7602 Power Drive  
 
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 ...............................................CE, C-Tick and FCC Part 15  
(Class A) Compliant  
Electrical emissions ................................EN 55011 Class A @ 10 meters  
FCC Part 15A above 1 GHz  
Electrical immunity ................................Evaluated to EN 61326:1998,  
Table 1  
Note This device should only be operated with shielded cabling for full EMC & EMI  
compliance. Refer to the Declaration of Conformity (DoC) for this product for any  
additional regulatory compliance information. The DoC for this product is available via the  
following web site: http://digital.ni.com/hardref.nsf. This site lists the DoCs  
by product family. Select the appropriate product family, followed by your product and a  
link to the DoC will appear in Adobe Acrobat format. Click on the Acrobat icon to  
download or read the DoC.  
Safety  
Meets the requirements of the following standards for safety for electrical  
equipment for measurement, control, and laboratory use:  
EN 61010-1:1993/A2:1995, IEC 61010-1:1990/A2:1995  
UL 3101-1:1993, UL 3111-1:1994, UL 3121-1:1998  
CAN/CSA C22.2 No. 1010.1:1992/A2:1997  
UL Recognized to UL 508C, power conversion equipment, File # E208822  
MID-7604/7602 Power Drive  
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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.  
Worldwide Support  
National Instruments has offices located around the world to help address  
your support needs. You can access our branch office Web sites from the  
Worldwide Offices section of ni.com. Branch office Web sites provide  
up-to-date contact information, support phone numbers, e-mail addresses,  
and current events.  
If you have searched the technical support resources on our Web site  
and still cannot find the answers you need, contact your local office or  
National Instruments corporate. For telephone support in the United States,  
dial 512 795 8248. For telephone support outside the United States, contact  
your local branch office:  
Australia 03 9879 5166, Austria 0662 45 79 90 0, Belgium 02 757 00 20,  
Brazil 011 284 5011, Canada (Calgary) 403 274 9391,  
Canada (Montreal) 514 288 5722, Canada (Ottawa) 613 233 5949,  
Canada (Québec) 514 694 8521, Canada (Toronto) 905 785 0085,  
China (Shanghai) 021 6555 7838, China (ShenZhen) 0755 3904939,  
Denmark 45 76 26 00, Finland 09 725 725 11, France 01 48 14 24 24,  
Germany 089 741 31 30, Greece 30 1 42 96 427, Hong Kong 2645 3186,  
India 91805275406, Israel 03 6120092, Italy 02 413091,  
Japan 03 5472 2970, Korea 02 596 7456, Malaysia 603 9596711,  
Mexico 5 280 7625, Netherlands 0348 433466,  
New Zealand 09 914 0488, Norway 32 27 73 00, Poland 0 22 528 94 06,  
Portugal 351 1 726 9011, Singapore 2265886, Spain 91 640 0085,  
Sweden 08 587 895 00, Switzerland 056 200 51 51,  
Taiwan 02 2528 7227, United Kingdom 01635 523545  
© National Instruments Corporation  
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