National Instruments Impact Driver MID 7654 User Manual

USER GUIDE  
MID-7654/7652 SERVO POWER MOTOR DRIVE  
Analog I/O Terminal Blocks .................................................... 25  
Step and Direction Terminal Block.......................................... 26  
Cable Installation for CE Compliance............................................. 27  
Accessories Included for Optional Use................................................... 28  
Strain-Relief Bar Installation........................................................... 28  
Panel Mount Kit Installation............................................................ 29  
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.  
322691B-01  
Copyright © 2000, 2001 National Instruments Corp. All rights reserved.  
June 2001  
 
The MID-7654/7652 simplifies your field wiring through separate encoder,  
limit switch, and motor power removable screw terminal connector blocks  
for each axis. The terminal blocks do not require any special wiring tools  
for installation. The MID-7654/7652 connects to National Instruments  
motion controllers via a 68-pin, high-density interconnect cable.  
The MID-7654/7652 has four levels of amplifier inhibit/disable protection  
for motion system shut down. The front panel contains both enable and  
power switches for direct motor inhibiting and system power-down  
operations. The MID-7654/7652 also has a host bus power interlock that  
activates an internal driver inhibit signal if the host computer is shut down  
or if the motion controller interface cable is disconnected. The inhibit input  
from the back panel connectors also inhibits the servo drives when  
activated.  
You can use the MID-7654/7652 enclosure 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-7654/7652 accessory, you must have the  
following items:  
The MID-7654/7652 servo power motor drive with attached rear guard  
MID-7654/7652 Servo Power Motor Drive User Guide  
Power cord (IEC type)  
Strain-relief bar, part number 187407-01 (included)  
Panel-mount kit, part number 187243-01 (included)  
SHC68-C68-S shielded cable assembly, part number 186380-02  
(not included)  
Refer to the Specifications section later in this guide for detailed  
specifications for the MID-7654/7652.  
Safety Information  
Follow these guidelines to ensure your safety and protect your equipment:  
Keep away from live circuits. Do not remove equipment covers or  
shields unless you are trained to do so. Hazardous voltages may 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  
© National Instruments Corporation  
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MID-7654/7652 Servo Power Motor Drive User Guide  
 
   
qualified to do so and disconnect all field power prior to removing  
covers or shields.  
Do not operate damaged equipment. The safety protection features  
built into this device can become impaired if the device becomes  
damaged in any way. If the device is damaged, turn the device off and  
do not use it until service-trained personnel can check its safety.  
If necessary, return the device to National Instruments for service and  
repair to ensure its safety is not compromised.  
Do not operate this equipment in a manner that contradicts the  
information specified in this guide. Misuse of this equipment could  
result in a shock hazard.  
Do not substitute parts or modify equipment. Because of the danger  
of introducing additional hazards, do not install unauthorized parts  
or modify the device. Return the device to National Instruments for  
service and repair to ensure its safety features are not compromised.  
When connecting or disconnecting signal lines to the MID-7654/7652  
terminal block screw terminals, make sure the lines are powered off.  
Potential differences between the lines and the MID-7654/7652  
ground create a shock hazard while you connect the lines.  
Connections that exceed any of the maximum signal ratings on the  
MID-7654/7652 device can create a shock or fire hazard or can  
damage any or all of the motion controllers connected to the  
MID-7654/7652 chassis, the host computer, and the MID-7654/7652  
device. This includes power signals to ground and vice versa. National  
Instruments is not liable for any damages or injuries resulting from  
incorrect signal connections.  
The servo motor connectors on this drive are energized when the unit  
is powered on. The rear guard must be in place at all times while the  
unit is connected to a power outlet. Disconnect the MID-7654/7652  
unit from power outlet before connecting wires to or disconnecting  
wires from the servo motor connectors. Strip back the insulation of  
7 mm. Reattach the rear guard before you reconnect the unit to a power  
outlet. Failure to do so could result in electric shock leading to serious  
bodily injury or death.  
The bottom surface of the MID-7654/7652 can get very hot to the  
touch under certain conditions. To avoid a burn hazard, refer to the  
Setting Continuous and Peak Current Limits section within the Front  
Panel DIP Switch Settings section of this guide for the appropriate  
current setting and safety hazards.  
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Front Panel Switches  
Figure 1 shows the front panel for your MID-7654/7652. The DIP switches  
are shown with the detachable metal cover plate removed.  
4 Axis Servo Motor Drive  
POL  
AXIS 1  
AXIS 2  
AXIS 3  
AXIS 4  
1
2
3
4
5
6
7
8
9
MID-7654  
2 Axis Servo Motor Drive  
POL  
AXIS 1  
AXIS 2  
9
1
2
3
6
7
8
MID-7652  
1
2
3
Polarity DIP Switch Bank  
Axis 1 DIP Switch Bank  
Axis 2 DIP Switch Bank  
4
5
6
Axis 3 DIP Switch Bank*  
Axis 4 DIP Switch Bank*  
LED Status Array  
7
8
9
Enable Switch  
Green Power LED  
Power Switch  
* This DIP switch bank is only available on the MID-7654.  
Figure 1. MID-7654/7652 Front Panel  
There are two rocker switches on the MID-7654/7652 front panel:  
AC POWER and ENABLE. Figure 1 illustrates the location of these  
switches.  
The AC POWER switch energizes the motor bus (+48 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 back panel.  
© National Instruments Corporation  
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MID-7654/7652 Servo Power Motor Drive User Guide  
 
   
The ENABLE switch enables or inhibits the servo amplifiers. If the  
ENABLE switch is in the inhibit position (OFF), the amplifier output stages  
are inhibited and the yellow LEDs 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 servo  
amplifiers. However, as long as the AC POWER switch is on, only the servo  
amplifier output stages are disabled. The remaining circuitry remains  
active, including the quadrature encoder circuit.  
Warning You must change the MID-7654/7652 main input fuse on the rear panel if you  
change the line voltage from the factory setting. Refer to the Specifications section of this  
guide for fuse specifications. Refer to the Modifying the Power Entry Module section for  
more information on handling the power entry module.  
Host Bus Interlock Circuit  
The MID-7654/7652 has a host bus interlock circuit that monitors the  
presence of +5 V from the host computer and disables the MID-7654/7652  
when the voltage is not present or falls out of tolerance. This circuit shuts  
down the servo amplifiers for all axes by activating the inhibit when the  
host computer is disconnected from the MID-7654/7652 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  
5 V power is active. 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.  
An LED status array of 3 rows by 4 columns on the MID-7654 or 3 rows  
by 2 columns on the MID-7652 provides a variety of status information.  
Refer to Figure 1 for the location of the front panel LEDs. 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 axes and statuses to which the different LEDs in the 3 × 4  
or 3 × 2 array correspond.  
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Table 1. Front Panel LED Indicators  
Status Motor Axis  
Amplifier Fault Output (red)  
Amplifier Inhibit (yellow)  
1
1
1
2
2
2
3*  
3*  
3*  
4*  
4*  
4*  
Limit Status (green)  
* These LEDs only appear on the MID-7654.  
Amplifier Fault Output LEDs  
The top row of the LED status array indicates the status of the amplifiers.  
A red LED indicates an overcurrent condition, a short circuit condition, an  
over temperature condition, or a problem with the motor bus voltage on that  
axis.  
Amplifier Inhibit LEDs  
The middle row of the LED status array indicates if a motor axis is  
inhibited. An axis is inhibited and the LED illuminates yellow 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. You  
can select the polarity of the per-axis inhibit input from the front panel DIP  
switches. See the Front Panel DIP Switch Settings section of this guide for  
more information.  
The bottom row of the LED status array indicates if a limit switch is  
currently active. The LED illuminates green when 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 of this guide for more information.  
© National Instruments Corporation  
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MID-7654/7652 Servo Power Motor Drive User Guide  
 
       
Front Panel DIP Switch Settings  
The MID-7654/7652 front panel has a detachable metal plate that, when  
removed, provides access to one 4-position DIP switch bank and either four  
(MID-7654) or two (MID-7652) 9-position DIP switch banks. Refer to  
Figure 1 for the location of these switches.  
Use the DIP switches on the 4-position DIP switch bank to configure the  
inhibit in, inhibit out, and limit status LED polarity as shown in Figure 2.  
The different settings for these switches are described in the following  
sections.  
O
N
1
1
2
2
3
3
4
4
1
2
Inhibit In Polarity Switch  
Inhibit Out Polarity Switch  
3
4
Limit Status LED Polarity Switch  
Reserved  
Figure 2. 4-Position DIP Switch Bank Layout  
Use the DIP switches on each 9-position DIP switch bank to configure the  
continuous current limit, the peak current limit, and the motor inductance  
(low or standard) for each axis, as shown in Figure 3. The different settings  
for these switches are described in the following sections.  
O
N
1
2
3
4
5
6
7
8
9
1
2
3
1
2
Continuous Current Limit Switches  
Peak Current Limit Switches  
3
Motor Inductance Switch  
Figure 3. 9-Position DIP Switch Bank Layout  
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Inhibit Input Polarity Setting  
Use DIP switch 1 on the 4-position DIP switch bank to globally set the  
polarity for the inhibit input for all axes. Refer to Figures 1 and 3 for the  
location of this switch.  
The factory-default setting of DIP switch 1 is active-low. If the inhibit input  
is active, the axis is inhibited and the yellow status LED (middle row)  
corresponding to that axis illuminates. Table 2 shows the DIP switch setting  
for the inhibit input polarity selection.  
Table 2. Inhibit Input Polarity DIP Switch Settings  
Switch Setting  
Operation  
O
N
Active-high  
1
O
N
Active-low  
(factory default)  
1
Inhibit Output Polarity Setting  
Use DIP switch 2 on the 4-position DIP switch bank to globally set the  
polarity for the inhibit output for all axes. Refer to Figures 1 and 3 for the  
location of this switch.  
The factory-default setting of DIP switch 2 is active-high. Table 3 shows  
the DIP switch setting for the inhibit output polarity selection.  
Table 3. Inhibit Output Polarity DIP Switch Settings  
Switch Setting  
Operation  
O
N
Active-high  
(factory default)  
3
O
N
Active-low  
3
© National Instruments Corporation  
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MID-7654/7652 Servo Power Motor Drive User Guide  
 
       
Limit Status LED Polarity Setting  
Use DIP switch 3 on the 4-position DIP switch bank to globally set the  
polarity for the Limit Status LED. Refer to Figures 1 and 3 for the location  
of this switch.  
The factory-default setting is active-high. Typically, you set the switch to  
match your controllers polarity setting, so if either the reverse or forward  
limits for an axis are active, the green status LED (on the bottom row)  
corresponding to that axis illuminates. This DIP switch alters only the  
polarity for the LEDs, not the actual limit to the motion controller. Table 4  
shows the DIP switch setting for the Limit Status LED polarity selection.  
Table 4. Limit Status LED DIP Switch Settings  
Switch Setting  
Operation  
O
N
Active-high  
(factory default)  
2
O
N
Active-low  
2
Setting Continuous and Peak Current Limits  
The MID-7654/7652 uses high-efficiency PWM amplifiers configured as  
torque blocks (current amplifiers or transconductance amplifiers). The  
peak current limit is the maximum current your motor can withstand for  
short periods of time. The continuous current limit is the maximum current  
your motor can withstand indefinitely. The MID-7654/7652 varies the gain  
applied to the input voltage so the maximum input voltage corresponds to  
a current output equal to the peak current limit, Ipeak  
.
Caution To avoid overheating the drive under a motor fault condition, ensure the following  
error trip point is set above zero in the motion controller configuration software. The  
default following error is 32,767.  
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Figure 4 illustrates the command voltage input to current output  
relationship for periods of time less than 2.7 seconds.  
+Ipeak  
+Vmax  
+Icont  
0 V  
0 A  
–Icont  
–Vmax  
Gain Applied  
–Ipeak  
Figure 4. Input Voltage to Output Current Relationship for Periods  
of Time Less Than 2.7 Seconds  
Figure 5 shows the command voltage input to current output relationship  
for periods of time greater than 2.7 seconds. The maximum current output  
corresponds to the continuous current limit, Icont. Therefore, command  
voltages that would result in a higher current output than Icont when the gain  
is applied instead result in a current output of Icont  
.
+Ipeak  
+Vmax  
+Icont  
0 V  
0 A  
Icont  
Vmax  
Gain Applied  
Ipeak  
Figure 5. Input Voltage to Output Current Relationship for Periods  
of Time Greater Than 2.7 Seconds  
© National Instruments Corporation  
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MID-7654/7652 Servo Power Motor Drive User Guide  
 
   
The amplifier peak and continuous current limits have been factory set for  
5 A continuous current output and 10 A peak current output. Verify that  
these settings are appropriate for your application before powering your  
motors.  
Use DIP switches 1 through 4 on each of the 9-position DIP switch banks  
to set the continuous current limit for each axis. Use DIP switches  
5 through 8 on each of the 9-position DIP switch banks to set the peak  
current limit for each axis. Refer to Figures 1 and 3 for the location of the  
continuous current limit and peak current limit switches. Table 5 shows the  
DIP switch settings for all possible current limit settings.  
Note The switches shown in Table 5 show the settings for switches 1 through 4, which are  
the continuous current DIP switches. Configure the settings for switches 5 through 8 in the  
same manner to set the peak current values.  
Table 5. Continuous and Peak Output Current DIP Switch Settings  
Continuous Peak Current  
Continuous Peak Current  
Switch  
Current (A)  
(A)  
Switch  
Current (A)  
(A)  
O
N
O
N
5.00  
10.00  
1.25  
2.50  
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
4.50  
3.80  
3.00  
2.45  
2.10  
1.95  
1.70  
9.00  
7.55  
6.00  
4.90  
4.20  
3.85  
3.45  
1.15  
1.10  
1.05  
1.00  
0.95  
0.90  
2.30  
2.20  
2.10  
1.95  
1.85  
1.80  
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
0.85  
1.70  
(default)  
(default)  
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If you are connecting multiple motors to your MID-7654/7652, 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.  
Your MID-7654/7652 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  
400 W at 25% duty cycle for a sustained period of time.  
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 400 W at 25% duty cycle, you will not exceed  
the capabilities of the MID-7654/7652.  
If the value is greater than 400 W at 25% duty cycle, you may still be within  
the operating capabilities of the MID-7654/7652, 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 400 W at 25% duty  
cycle.  
Setting Motor Inductance Levels  
Depending on the construction of your motor, you may need to configure  
one or more axes to the low inductance setting rather than the default  
standard inductance setting. Table 6 shows the motor inductance level  
ranges for the two different settings.  
Table 6. Motor Inductance Levels  
Motor Inductance  
Greater than 440 µH  
MID-7654/7652 Setting  
Standard  
Low  
Between 110 and 440 µH  
© National Instruments Corporation  
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MID-7654/7652 Servo Power Motor Drive User Guide  
 
   
Use the last DIP switch on each of the 9-position DIP switch banks to set  
the motor inductance level for each axis. Refer to Figures 1 and 3 for the  
location of the of the motor inductance level switch. Table 7 shows the DIP  
switch settings for low and standard motor inductance.  
Table 7. Motor Inductance Level DIP Switch Settings  
Switch Setting  
Operation  
O
N
Low motor inductance  
9
O
N
Standard motor inductance  
(factory default)  
9
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Back Panel Connector Wiring  
Figure 6 shows the MID-7654/7652 back panel connectors without their  
rear guards.  
MID-7654  
MID-7652  
1
2
3
4
5
6
7
Motion Controller Connector  
Encoder  
Connectors  
Limit  
Motor  
Analog Input Connector  
Analog Output Connector  
Trigger Connector  
Breakpoint Connector  
Step/Direction Connector  
AC Power  
Connectors  
12 Axis 1  
13 Axis 2  
14 Axis 3*  
15 Axis 4*  
Connectors  
16 Axis 1  
17 Axis 2  
18 Axis 3*  
19 Axis 4*  
8
9
Axis 1  
Axis 2  
10 Axis 3*  
11 Axis 4*  
* This connector is available only on the MID-7654.  
Figure 6. MID-7654/7652 Back Panel Connectors  
© National Instruments Corporation  
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MID-7654/7652 Servo Power Motor Drive User Guide  
 
   
Caution Be sure to turn off the ENABLE and AC POWER switches for your  
MID-7654/7652 and host computer and disconnect the unit from the power outlet before  
making connections to your motion controller.  
Warning The servo motor connectors on this drive are energized when the unit is powered  
on. The rear guard must be in place at all times while the unit is connected to a power  
outlet. Disconnect the MID-7654/7652 unit from power outlet before connecting wires  
to or disconnecting wires from the servo motor connectors. Strip back the insulation of  
the servo motor wires to the servo motor connectors no more than 7 mm. Reattach the rear  
guard before you reconnect the unit to a power outlet. Failure to do so could result in  
electric shock leading to serious bodily injury or death. Refer to the Rear Guard section of  
this guide for information on using the rear guard.  
Take the following steps to wire your motion system to your  
MID-7654/7652:  
1. Connect the motion controller to the MID-7654/7652 using the  
interface cable. Wire the motor power, limit switch, encoder, and I/O  
terminal blocks to your motion control system.  
2. For proper operation, configure the power entry module to match the  
voltage of your power source. Refer to the Modifying the Power Entry  
Module section for more information.  
Caution You must change the MID-7654/7652 main input fuse on the rear panel if you  
change the line voltage from the factory setting. Refer to the Replacing a Fuse section in  
the Modifying the Power Entry Module section of this guide for information on changing  
a fuse.  
3. Install the power cord into the back panel AC connector and plug it into  
a correctly rated power source.  
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Terminal Block Wiring  
This section describes how to wire the terminal blocks on your  
MID-7654/7652.  
Servo Motor Power Terminal Blocks  
For motor power wiring, each MID-7654/7652 axis has a separate  
5-position removable screw terminal block. Figure 7 shows a typical servo  
motor configuration pin assignment. The dotted loop indicates a shielded  
cable.  
Motor +  
Motor –  
Motor Case Ground  
1
+
2
3
4
5
Shield  
Servo Motor  
Figure 7. Typical Servo Motor (DC Brush Type) Terminal Block Pin Assignment  
Warning The servo motor connectors on this drive are energized when the unit is powered  
on. The rear guard must be in place at all times while the unit is connected to a power  
outlet. Disconnect the MID-7654/7652 unit from power outlet before connecting wires  
to or disconnecting wires from the servo motor connectors. Strip back the insulation of  
the servo motor wires to the servo motor connectors no more than 7 mm. Reattach the rear  
guard before you reconnect the unit to a power outlet. Failure to do so could result in  
electric shock leading to serious bodily injury or death. Refer to the Rear Guard section of  
this guide for information on using the rear guard.  
You should use shielded 20 AWG wire or larger for the motor power  
cable. If available, connect a motor case ground wire to pin 3  
(Ground/Shield) on the MID-7654/7652 as shown in Figure 7; this wire  
helps avoid ground loops and signal noise problems. (Case ground connects  
to the motor housing, not to any of the motor power terminals.)  
Caution Never connect unused center taps or winding terminals to pin 3.  
© National Instruments Corporation  
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Depending on your motor, you may need to reverse the connections shown  
in Figure 7, as there is no industry standard for direction of movement  
relative to the positive and negative motor inputs. Table 8 shows the  
National Instruments motion control standard directional polarity.  
Table 8. National Instruments Standard Directional Polarity  
Commanded  
Direction  
Motor Signal  
Relationship  
Command  
Signal  
Description  
Forward  
Clockwise (CW) facing  
motor shaft  
Motor is greater than  
Motor +  
Positive voltage  
Reverse  
Counter-clockwise (CCW)  
facing motor shaft  
Motor + is greater than  
Motor –  
Negative voltage  
Figure 8 shows clockwise and counter-clockwise motor rotation.  
CW  
CCW  
Figure 8. Clockwise and Counter-Clockwise Motor Rotation  
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Rear Guard  
The rear guard consists of the protection cover, protection plates, and  
bottom mounting plate as shown in Figure 9.  
1
2
Bottom Mounting Plate  
Protection Cover  
3
Protection Plate  
Figure 9. Rear Guard Consisting of the Protection Cover,  
Protection Plates, and Bottom Mounting Plate  
© National Instruments Corporation  
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The rear guard installed on the MID-7654/7652 is shown in Figure 10.  
S
N T  
L
M E  
R U  
T
I O N A  
S
T
A
I N  
N
Figure 10. Rear Guard Installed on the MID-7654/7652  
Warning The servo motor connectors on this drive are energized when the unit is powered  
on. The rear guard must be in place at all times while the unit is connected to a power  
outlet. Disconnect the MID-7654/7652 unit from power outlet before connecting wires  
to or disconnecting wires from the servo motor connectors. Strip back the insulation of  
the servo motor wires to the servo motor connectors no more than 7 mm. Reattach the rear  
guard before you reconnect the unit to a power outlet. Failure to do so could result in  
electric shock leading to serious bodily injury or death.  
Follow these steps carefully to ensure safe operation of your  
MID-7654/7652:  
1. Ensure that the MID-7654/7652 is powered off and disconnected from  
the power outlet before wiring any cables to the unit. The +5V green  
LED should not be illuminated after the MID-7654/7652 is powered  
off and disconnected from the power outlet.  
2. Ensure that the bottom mounting plate of the rear guard is securely  
fastened to both sides of the MID-7654/7652, as shown in Figure 10.  
3. Remove the protection plates for the axes to be used, rotate, and  
re-install the protection plates in the open position, as shown in  
Figure 11.  
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1
Protection Cover  
2
Protection Plate  
Figure 11. Protection Cover and Protection Plates:  
Used Axes 1 & 2, Unused Axes 3 & 4.  
Note The protection plates for any unused axes should remain installed in the closed  
position at all times, as shown on axes 3 and 4 in Figure 11. For axes you are using, the  
protection plates must be removed, rotated, and re-installed in the open position, as shown  
on axes 1 and 2 in Figure 11.  
Contact your National Instruments sales representative to replace lost protection plates  
(part number 188063A-01).  
4. Remove the protection cover using the following procedure:  
a. Remove the two screws that attach the protection cover to the side  
of the bottom mounting plate, as shown in Figure 10.  
b. Lift the protection cover from the slot on the bottom mounting  
plate, as shown in Figure 9.  
5. Plug the servo motor cables into the servo motor terminals of the  
MID-7654/7652. The cables must be placed over the bottom mounting  
plate of the rear guard.  
6. Re-attach the protection cover  
a. Insert the tab of the protection cover, shown in Figure 9, into the  
slot on the bottom mounting plate.  
b. Lower the protection cover over the servo motor cables and secure  
it to the side of the bottom mounting plate using the two screws  
you removed in step 4.  
© National Instruments Corporation  
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7. Ensure that the rear guard is held securely in place before reconnecting  
your MID-7654/7652 to a power outlet.  
Encoder Terminal Blocks  
For quadrature incremental encoder signals, each MID-7654/7652 axis has  
a separate 8-position removable screw terminal block. Where applicable,  
the MID-7654/7652 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 12 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 12. Typical Single-Ended Encoder Wiring Pin Assignment  
Figure 13 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 13. Typical Differential Line Driver Encoder Wiring Pin Assignment  
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-7654/7652is available on pin 7.  
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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-7654/7652 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 required by your application. The Index signal must  
occur when both Phase A and Phase B signals are low, as shown in  
Figure 14. 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 14 shows the proper encoder phasing for CW (forward) motor  
rotation.  
Phase A  
Phase B  
Index  
Figure 14. Encoder Signal Phasing, CW Rotation  
Closed-loop servo 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  
Refer to Figure 8 for a depiction of clockwise and counter-clockwise  
rotation.  
When connecting the encoder wiring to your MID-7654/7652, use shielded  
wire of at least 24 AWG. You must use cables with twisted pairs and an  
overall shield for improved noise immunity and enhanced encoder signal  
integrity. Figure 15 shows twisted pairs in a shielded cable.  
© National Instruments Corporation  
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Drain  
Shield  
Encoder A  
Encoder A  
Encoder B  
Encoder B  
Encoder Index  
Encoder Index  
+5 V  
Digital  
Ground  
Figure 15. Shielded Twisted Pairs  
Note Using an unshielded cable may produce noise, which can corrupt the encoder signals  
and cause lost counts, reduced accuracy, or other erroneous encoder and controller  
operation.  
Limit Switch Terminal Blocks  
For end-of-travel limit, home, inhibit input, and inhibit output connections,  
MID-7654/7652 axes have a separate, 6-position removable screw terminal  
connector block. Figure 16 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 16. Limit Switch Terminal Block Pin Assignment  
(Passive Limit Switch Connection Example)  
You can configure the inhibit output signal to be asserted low or asserted  
high from the MID-7654/7652 when an axis is inhibited. This signal can be  
useful for actuating mechanical brakes or for monitoring an axis status.  
Refer to the Amplifier Inhibit LEDs section of this guide for a description  
of the conditions that will cause an axis to be inhibited.  
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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, the +5 V supplied by the  
MID-7654/7652, and the digital ground. Figures 17 and 18 show the  
breakpoint and trigger 6-position terminal block assignments.  
Trigger Input 1  
Trigger Input 2  
Trigger Input 3  
Trigger Input 4  
Shutdown Input  
Digital Ground  
1
2
3
4
5
6
Figure 17. 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 18. Breakpoint Terminal Block Pin Assignment  
Analog I/O Terminal Blocks  
The MID-7654/7652 features two analog I/O connectors.  
The analog input connector uses a 6-pin removable terminal block, which  
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 connector uses a 5-pin removable terminal block, which  
provides access to four digital-to-analog converter channels and analog  
output ground. Refer to Figures 19 and 20 for terminal block pin  
assignments.  
© National Instruments Corporation  
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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 19. 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 20. Analog Output Terminal Block Pin Assignment  
Step and Direction Terminal Block  
The MID-7654/7652 passes step and direction signals from the controller  
directly through the drive, allowing you to access them through the 8-pin  
removable terminal block. This feature is useful if your system includes  
both stepper and servo motors, as it reduces the amount of custom cabling  
required to connect your motors and drives to the controller.  
To use the step and direction connector, select an unused axis on the  
MID-7654/7652 and connect the step and direction outputs for that axis  
to your stepper drive. Refer to Figure 21 for the terminal block pin  
assignments. Connect additional signals for the axis, such as inhibit  
outputs, limit switches, breakpoints and triggers, and encoder feedback,  
as described earlier in this guide.  
Step 1  
Direction 1  
Step 2  
Direction 2  
Step 3  
Direction 3  
Step 4  
Direction 4  
1
2
3
4
5
6
7
8
Figure 21. Step and Direction Terminal Block Pin Assignment  
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Take the following additional steps to ensure CE Compliance:  
1. Enclose the terminal block wires in a 360-degree shielded cable. This  
requires a braided shield.  
2. Install the strain-relief bar on the MID-7654/7652 as described in the  
Accessories Included for Optional Use section of this guide.  
3. Place all cables connecting to the back panel through the strain-relief  
bar, as follows:  
a. All servo motor cables must pass through the far right clamp on  
the strain-relief bar, which is directly aligned with the servo motor  
terminals and protection cover.  
b. All remaining cables should pass through the three clamps to the  
left of the servo motor terminals.  
c. Cables passing through the same clamp must be of the same cable  
diameter.  
d. Cables passing through the same clamp must be parallel and must  
not overlap each other, as shown in Figure 22.  
4. All cables must be properly grounded to the strain-relief bar, which  
grounds them to the MID-7654/7652 chassis ground. Follow these  
steps to ground the cables to the strain-relief bar:  
a. Remove the outer jacket from the section of the cable to be  
inserted between the strain-relief bar clamp and foam, as shown in  
Figure 22. This will expose the braided shield of the cable.  
Note Do not cut the braided shield of the cable.  
3
2
1
1
2
Braided Shield of the Cable  
Strain Relief Bar  
3
Terminal Block Connector  
Figure 22. Required Cabling for CE Compliance  
© National Instruments Corporation  
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MID-7654/7652 Servo Power Motor Drive User Guide  
 
   
b. Lay the cables so that the braided shield makes full contact with  
the foam of the strain-relief bar. The braided shield must only  
make contact with the strain-relief bar, and no other part of the  
device.  
c. Lower the clamp and tighten the thumb nuts to remove all gaps  
between the foam and the cable shields. The foam should press  
around the shield of the cable to provide 360-degree grounding to  
the cable shield.  
5. Ground the braided shield at the opposite end of the cables to your  
destination enclosure ground.  
Accessories Included for Optional Use  
Strain-Relief Bar Installation  
The strain-relief bar provides strain relief for wiring to the back panel  
terminals of the MID-7654/7652. It must be used to provide necessary  
grounding for CE compliance. Refer to the Cable Installation for CE  
Compliance section of this guide for more information.  
The arms of the strain-relief bar attach between the sides of the  
MID-7654/7652 and the bottom mounting plate of the rear guard with the  
thumb nuts facing upwards, as shown in Figure 23. Refer to the Rear Guard  
section of this guide for more information on removing and replacing the  
protection cover from the rear guard. Refer to Figure 23 while following  
these strain-relief bar installation steps:  
1. Remove the protection cover of the rear guard.  
2. Place the strain-relief bar so it fits within the sides of the bottom  
mounting plate.  
3. Attach the strain-relief bar to the side panels of the MID-7654/7652  
using the provided screws.  
4. Replace the protection cover.  
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2
1
1
Rear Guard Assembly  
2
Strain Relief Bar  
Figure 23. MID-7654/7652 with the Strain-Relief Bar Installed  
Panel Mount Kit Installation  
The panel mount kit allows you to mount the MID-7654/7652 inside a  
cabinet or enclosure. Attach the panel mount kit to the rear and front set  
of screw holes on the side panels of the MID-7654/7652, as shown in  
Figure 24, using the provided screws.  
© National Instruments Corporation  
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S
N T  
L
M E  
R U  
T
I O N A  
S
T
A
I N  
N
1
2
1
Rear Guard Assembly  
2
Panel Mount  
Figure 24. MID-7654/7652 with the Panel Mount Kit Installed  
Note The strain-relief bar and panel mount kit cannot be installed at the same time,  
because they will not simultaneously fit under the sides of the bottom mounting plate.  
Modifying the Power Entry Module  
This section covers replacing fuses and switching the line voltage for  
your drive.  
Replacing a Fuse  
Follow these steps to replace a fuse on your MID-7654/7652:  
1. Pry open the hinged cover on the power entry module (number 7 in  
Figure 6).  
2. Remove the fuse holder. Notice how the fuse holder is oriented so you  
can replace it properly.  
3. Replace the blown fuse in the fuse holder. Be sure the new fuse is  
oriented in the same way as the original fuse, and that it is rated at the  
proper voltage.  
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4. Push the fuse holder back into the power entry module with the same  
orientation you observed in step 2.  
5. Close the hinged cover.  
Changing the Line Voltage  
Follow these steps to change the line voltage on your MID-7654/7652:  
1. Pry open the hinged cover on the power entry module (number 7 in  
Figure 6).  
2. Remove the fuse holder.  
3. Replace the two fuses with the appropriate fuses for the desired line  
voltage as listed in the Specifications section.  
4. Rotate the fuse holder 180 degrees so the desired line voltage number  
shows through the window when the power module cover is closed.  
5. Push the fuse holder back into the power entry module with the new  
orientation.  
6. Close the hinged cover.  
Amplifier/Driver Command Signals  
The PWM amplifiers used in the MID-7654/7652 accept an  
industry-standard 10 V analog torque (current) command signal. Servo  
motion controllers used with the MID-7654/7652 provide this standard  
output and are programmed to close both the velocity loop and position  
loop using an enhanced PID algorithm.  
Specifications  
The following specifications apply only to the MID-7654/7652. You must  
account for your motion controller to obtain a system specification. Refer  
to your controller specifications to determine overall system specifications.  
Some signals define compatibility as signal pass-through, which means the  
MID-7654/7652 may use passive filtering on these signals. This 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.  
Servo Amplifiers  
Type ....................................................... Elmo Motion Control VIO 10/100  
Peak current limit (2.7 s)........................ 1.710 A (default 1.7 A)  
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Continuous current limit.........................0.855 A (default 0.85 A)  
DC-bus motor voltage ............................48 VDC  
PWM frequency......................................32 kHz  
Continuous power output rating  
(all axes combined).................................400 W at 25% duty cycle  
Encoders  
Inputs ......................................................Quadrature, incremental  
Differential input threshold .................... 0.3 V (typical)  
Single ended input threshold ..................TTL/CMOS  
Voltage range..........................................05 VDC  
Maximum quadrature frequency.............20 MHz  
Limit and Home Switch Inputs  
Compatibility..........................................Signal pass-through  
Inhibit Inputs  
Voltage range..........................................012 VDC  
Input low voltage....................................0.8 V  
Input high voltage...................................2 V  
Inhibit Outputs  
Voltage range..........................................05 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..........................................Signal pass-through  
Breakpoint Outputs  
Compatibility..........................................Signal pass-through  
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Analog Inputs  
Noise filter (RC time constant) .............. 10 µs  
Compatibility ......................................... Signal pass-through  
Analog Outputs  
Compatibility ......................................... Signal pass-through  
Step/Direction Outputs  
Compatibility ......................................... Signal pass-through  
Shutdown Input  
User 5 V Supply  
Compatibility ......................................... Signal pass-through  
Voltage range @ 0.5 A........................... 4.75.2 V  
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)  
Servo Motors.......................................... 5-position combicon  
5.08 mm plug (1 per axis)  
Breakpoints ............................................ 6-position mini-combicon  
3.81 mm plug (1 total)  
Triggers .................................................. 6-position mini-combicon  
3.81 mm plug (1 total)  
Step/Direction ........................................ 8-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)  
© National Instruments Corporation  
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MID-7654/7652 Servo Power Motor Drive User Guide  
 
AC power................................................Detachable AC power cord  
(IEC standard type)  
Motion I/O ..............................................68-pin female high density  
VHDCI type  
Environment  
Operating temperature ............................0 to 50 °C (32 to 122 °F)  
Storage temperature................................20 to 70 °C (4 to 158 °F)  
Humidity.................................................10% 90% (noncondensing)  
Maximum Altitude .................................2,000 meters  
Pollution Degree.....................................2  
Indoor Use Only  
Power Supply  
Input voltage...........................................90132 VAC / 198264 VAC,  
4763 Hz  
Input fuse  
115 VAC (factory default)...............8 A (Littelfuse #312008)  
230 VAC..........................................6 A (Littelfuse #312006)  
Input fuse dimensions.............................0.25 in. by 1.25 in.  
Input Power Peak Current (at max load)  
115 VAC..........................................10 A  
230 VAC..........................................5 A  
Installation category ...............................II  
Host Bus Voltage Interlock  
Undervoltage threshold...........................4 VDC  
Physical  
Length.....................................................30.6 by 25.4 by 8.8 cm  
(12.0 by 10 by 3.5 in.)  
Weight ....................................................10.2 kg (22.5 lb.)  
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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  
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.  
© National Instruments Corporation  
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MID-7654/7652 Servo Power Motor Drive User Guide  
 
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, manuals, 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  
 
     

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