National Instruments nuDrive 4SX-411 User manual

FlexMotion™, National Instruments™, ni.com™, nuDrive™, and ValueMotion™are trademarks of National Instruments Corporation. Product and
company names mentioned herein are trademarks or trade names of their respective companies.
321942B-01 ©Copyright 1998, 2000 National Instruments Corp. All rights reserved. January 2000
USER GUIDE
NUDRIVE ACCESSORY
This user guide describes the electrical and mechanical aspects of the
nuDrive power amplifier accessory and describes how to use the nuDrive
with your motion controller.
Contents
Conventions ............................................................................................2
Introduction.............................................................................................2
What You Need to Get Started ...............................................................5
Safety Information ..................................................................................5
Installation and Connector Wiring..........................................................6
Front Panel Switches and Host Bus Interlock Circuit.............................6
Rear Panel Connector Wiring .................................................................7
Motor Power Terminal Blocks ........................................................7
Encoder Terminal Blocks ................................................................8
Limit Switch Terminal Blocks.........................................................11
CX and SX nuDrive Configuration ..........................................11
CF nuDrive Configuration........................................................12
I/O Terminal Blocks ........................................................................13
CX and SX nuDrive Configuration ..........................................13
CF nuDrive Configuration........................................................15
Amplifier/Driver Command Signals.......................................................16
Servo Amplifier Signals...................................................................16
Stepper Driver Signals.....................................................................16
Optional Configurations..........................................................................16
E-Stop Terminal Block....................................................................16
Servo Amplifier Configurations ......................................................17
Adjusting Current Gain and Current Limits.............................19
Balancing the Amplifier Gain...................................................21
Status LEDs..............................................................................22
Stepper Driver Configurations.........................................................23
Stepper Motor Current..............................................................24
Microstep Selection..................................................................26
Stepper Motor Configurations ................................................................26
Specifications..........................................................................................29

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Conventions
The following conventions are used in this manual:
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 warning, which advises you of precautions to take to
avoid being electrically shocked.
♦The ♦symbol indicates that the following text applies only to a specific
product.
overline Indicates the signal is active-low.
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.
CF nuDrive Refers to the 4CF-001 and 2CF-001 nuDrives.
CX nuDrive Refers to the 4CX-001 and 2CX-001 nuDrives.
SX nuDrive Refers to the 4SX-211, 2SX-211, 4SX-411, and 2SX-411 nuDrives.
stepper nuDrive Refers to the 4SX-211, 2SX-211, 4SX-411, and 2SX-411 nuDrives.
servo nuDrive Refers to the 4CF-001, 2CF-001, 4CX-001, and 2CX-001 nuDrives.
Introduction
Your nuDrive accessory is a complete power amplifier and system
interface for use with up to four axes of simultaneous or independent servo
or stepper motion control. Ideally suited to industrial and laboratory
applications, your nuDrive has everything you need to connect motors,
encoders, limit switches, I/O, and other motion hardware to National
Instruments motion controllers.

©National Instruments Corporation 3 nuDrive Accessory User Guide
Table 1 lists the available nuDrives and describes the properties of each
nuDrive.
The nuDrive can drive a broad range of servo or stepper motors.
Servo nuDrives use pulse-width modulation (PWM) amplifiers with a
user-specified peak output current rating and a DC bus voltage to drive
servo motors. Stepper nuDrives use a rugged microstepping bipolar
chopper driver. Stepper driver configurations are available in a wide range
of user-specified current per phase and voltage settings to drive stepper
motors. In all configurations, power supplies are built in and use standard
115 VAC for operation. Electronics are fan cooled to assure reliable
operation.
nuDrives simplify 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.
Refer to Table 2 for a summary of how to connect various motion
controllers to different nuDrives.
Table 1. nuDrive Properties
nuDrive Type
Number of Axes
Motor Type
Motion Board
Cable Connector
Driver/Amplifier
Nominal Bus Voltage
Driver/Amplifier
Type
AC Input
4SX-411 4Stepper
(2-phase) 50-pin 40 VDC Bus Microstepping Driver IM483 115 V (50/60 Hz)
2SX-411 2Stepper
(2-phase) 50-pin 40 VDC Bus Microstepping Driver IM483 115 V (50/60 Hz)
4SX-211 4Stepper
(2-phase) 50-pin 24 VDC Bus Microstepping Driver IM483 115 V (50/60 Hz)
2SX-211 2Stepper
(2-phase) 50-pin 24 VDC Bus Microstepping Driver IM483 115 V (50/60 Hz)
4CX-001 4DC Brush
Servo 50-pin 48 VDC Bus DC Brush Servo Amplifier SSA 8/100 115 V (50/60 Hz)
2CX-001 2DC Brush
Servo 50-pin 48 VDC Bus DC Brush Servo Amplifier SSA 8/100 115 V (50/60 Hz)
4CF-001 4DC Brush
Servo 100-pin 48 VDC Bus DC Brush Servo Amplifier SSA 8/100 115 V (50/60 Hz)
2CF-001 2DC Brush
Servo 100-pin 48 VDC Bus DC Brush Servo Amplifier S SA 8/100 115 V (50/60 Hz)

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nuDrives havethree levels ofamplifierinhibit/disableprotection for motion
systemshutdown.Thefrontpanelcontains both enableand powerswitches
for direct motor inhibiting and system power-down operations. Each
nuDrive also has a host bus power interlock that activates an amplifier
inhibit signal if the host computer is shut down or the motion controller
interface cable is disconnected. On nuDrives with the emergency stop
(E-Stop) option enabled, you can wire a 115 V emergency stop switch to
the rear panel I/O connector for remote interlock shut down, as described
in the E-Stop Terminal Block section of this document.
Each nuDrive is packaged in arugged aluminum enclosure that can be used
as a benchtop unit or that can be rack-mounted.
Table 2. nuDrive Connectivity
Controller Connection nuDrives
All 7344 controllers SH68-C68-S cable with a
68M-50F step/servo
bulkhead cable adapter
4SX-411
2SX-411
4SX-211
2SX-211
4CX-001
2CX-001
All FlexMotion-6C
controllers SH100-100-Fshieldedcable cable 4CF-001 2CF-001
All 7324/7314
controllers* SH68-C68-S cable with a 68M-50F step/servo
bulkhead cable adapter
4SX-411
2SX-411
4SX-211
2SX-211
Non-73xx ValueMotion
stepper controllers SH50-50 shielded cable or NB1 ribbon cable 4SX-411 2SX-411
4SX-211
2SX-211
All ValueMotion servo
controllers SH50-50 shielded cable or NB1 ribbon cable 4CX-001 2CX-001
*For PXI-7324/7314 controllers prior to Rev. C, make the connection using a SH68-68-S
cable with a 68M-50F step/servo bulkhead cable adapter.

©National Instruments Corporation 5 nuDrive Accessory User Guide
What You Need to Get Started
To set up and use your nuDrive accessory, you will need the following
items:
❑The nuDrive accessory and nuDrive Accessory User Guide
❑Power cord (IEC type)
❑One or more of the following National Instruments cables and
adapters:
– SH68-68-S shielded cable, part number 185262-02
– NB1 ribbon cable, part number 180524-20
– SH50-50 shielded cable, part number 185319-02
– SH100-100-F shielded cable, part number 185095-02
– SH68-C68-S shielded cable, part number 186381-02
– 68M-50F step/servo bulkhead cable adapter, part number
185630-01
❑(Optional) ISO power supply (for FlexMotion-6C boards)
Detailed specifications for the nuDrive accessory are in the Specifications
section later in this guide.
Safety Information
Warnings Keepawayfromlivecircuits.Do notremoveequipment coversor 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 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 until service-trained personnel can check its safety. If
necessary, return the device to National Instruments for serviceand repair to ensure that its
safety is not compromised.
Do not operate this equipment in a manner that contradicts the information specified in this
document. 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

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device to National Instruments for service and repair to ensure that its safety features are
not compromised.
When connecting or disconnecting signal lines to the nuDrive terminal block screw
terminals, make sure the lines are powered off. Potential differences between the lines and
the nuDrive ground create a shock hazard while you connect the lines.
Connections, including power signals to ground and vice versa, that exceed any of the
maximum signal ratings on the nuDrive device can create a shock or fire hazard or can
damage any or all of the boards connected to the nuDrive chassis, the host computer, and
the nuDrive device. National Instruments is not liable for any damages or injuries resulting
from incorrect signal connections.
Installation and Connector Wiring
Caution Be sure to turn off the enable switches and the main AC power to your nuDrive
and host computer before connecting to your motion controller.
Connect the motion controller to the nuDrive interface cable. Wire the
motor power, limit switch, encoder, I/O, and E-Stop terminal blocks as per
the instructions and diagrams in this manual and/or your specific system
requirements. Finally, install the power cord into the rear panel AC
connector and plug it into a correctly rated power source.
Note For 50-pin ribbon cable interconnection, be certain that the colored indicator strip
(pin 1) on the cable between the motion controller and the 50-pin connector on the rear of
the nuDrive is properly aligned and inserted on both ends. 68- and 100-pin cables are keyed
metal-shell style.
Front Panel Switches and Host Bus Interlock Circuit
There are two lighted rocker switches on the nuDrive front panel, POWER
and ENABLE.
The POWER switch energizes the DC bus and the logic power supplies
(+5 V, +12 V), and illuminates to indicate that the main AC power is
present. If the POWER switch fails to illuminate, check the power cord and
main input fuse in the power connector.
The ENABLE switch enables or inhibits the servo amplifiers or stepper
drivers. It illuminates to indicate that it is switched on and that the logic
power supply +12 V output is functioning.

©National Instruments Corporation 7 nuDrive Accessory User Guide
Either switch can turn off the motors. However, as long as the nuDrive
POWER switch is still on, independent power and enable circuits cause the
incremental encoders to continue to track motor position while the
amplifiers (drivers) are disabled by the ENABLE switch being off.
Note The ENABLE switchilluminates wheneveritisswitchedon.It doesnotindicatethat
the amplifiers/drivers are disabled under the following conditions: E-Stop active (see
E-Stop Terminal Block), host bus interlock fault, or amplifier/driver protection fault (over
current, over temperature, and so on). Conversely, it does not light if the remote enable
function is used because the ENABLE switch is off (see I/O Terminal Blocks).
The nuDrive has a host bus interlock circuit that monitors the presence of
+5 V from the host computer and disables the nuDrive when the voltage
disappears or falls out of tolerance. This circuit shuts down the motors by
activating the Inhibit, or disable circuit for all axes, when the host computer
is disconnected from the nuDrive or inadvertently or unexpectedly shut
down.
Rear Panel Connector Wiring
Motor Power Terminal Blocks
For motor power wiring on the nuDrive, each axis has a separate 5-position
terminal block with removable screw terminals. There are two types of
wiring from the same connector for typical operation. Which of these two
configurations you use depends upon whether you are using the servo or
stepper version of the nuDrive. Figure 1 shows a typical servo motor
configuration pin assignment. Figure 2 shows a typical stepper motor
configuration pin assignment.
Note The dotted loop indicates a shielded cable.
Figure 1. Typical Servo Motor (DC Brush Type) Terminal Block Pin Assignment
1
2
3
4
5
Motor +
Motor –
Motor Case Ground
+–
Shield
Servo Motor

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Figure 2. Typical Full-Coil Stepper Motor (2-Phase Type)
Terminal Block Pin Assignment
It is recommended you 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); this helps to avoid ground loops and signal noise
problems. (Case ground connects to the motor housing, and not to any of
the motor power terminals.)
The stepper nuDrives contain bipolar chopper drivers. The stepper motors
must be wired in a four-wire configuration as shown in Figure2. Unused
lead wires must be isolated and not connected. SeeStepper Motor
Configurations for additional information on connecting
6- and 8-wire motors and on the alternate half-coil configuration.
Caution Never connect unused center taps or winding terminals to pin 3.
Encoder Terminal Blocks
For quadrature incremental encoder signals, each nuDrive axis has a
separate 8-position terminal block with removable screw terminals.
Whereapplicable, the nuDrive 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 kΩpullup
resistors to +5VDC.
Figure3 shows the typical encoder wiring pin assignment for single-ended
signal input. Figure4 shows the typical encoder wiring pin assignment for
differential line driver signal inputs.
1
2
3
4
5
Winding AStart
Winding B Start
Winding B End
Winding AEnd
Motor Case Ground
Shield
Stepper Motor

©National Instruments Corporation 9 nuDrive Accessory User Guide
Figure 3. Typical Single-Ended Encoder Wiring Pin Assignment
Figure 4. Typical Differential Line Driver Encoder Wiring Pin Assignment
If the encoder cable length is greater than 15 ft, you should use encoders
with line driver outputs for your applications. Power for a +5 V encoder is
available on pin 7, generated by a power supply inside the nuDrive.
Note If you require other encoder power values, reference an external power supply to the
Common (ground) signal on the 8-pin encoder terminal block.
nuDrives have 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 pulse must occur when both
Phase A and Phase B signals are logic low, as shown in Figure 5. If the
Index pulse is inverted, try reversing the Index and Index signals on
differential encoders or wiring to the Index input with single-ended wiring.
1
2
3
4
5
6
7
8
Phase A
Phase B
Index
+5 V
Common
1
2
3
4
5
6
7
8
Phase A
Phase A
Phase B
Phase B
Index
Index
+5 V
Common

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Figure 5 shows the proper encoder phasing for CW (forward) motor
rotation.
Figure 5. Encoder Signal Phasing, CW Rotation
Servo and closed-loop stepper applications require consistent directional
polarity between the motor and encoder for stable 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
Figure 6 shows the clockwise and counter-clockwise motor rotation.
Figure 6. Clockwise and Counter-Clockwise Motor Rotation
When connecting the encoder wiring to your nuDrive accessory, you
should use shielded wire of at least 24 AWG. Both analog and digital noise
filters filter the encoder inputs in the nuDrive and on the motion controller
itself. You must use cables with twisted pairs and an overall shield for
improved noise immunity and enhanced encoder signal integrity. Figure 7
shows twisted pairs in a shielded cable.
Phase A
Phase B
Index
CCW CW