NI PCI-7390 User manual

Motion Control
NI PCI-7390 User Manual
NI PCI-7390 User Manual
November 2005
371520A-01

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Important Information
Warranty
The NI PCI-7390 is warranted against defects in materials and workmanship for a period of one year from the date of shipment, as evidenced
by receipts or other documentation. National Instruments will, at its option, repair or replace equipment that proves to be defective during the
warranty period. This warranty includes parts and labor.
The media on which you receive National Instruments software are warranted not to fail to execute programming instructions, due to defects
in materials and workmanship, for a period of 90 days from date of shipment, as evidenced by receipts or other documentation. National
Instruments will, at its option, repair or replace software media that do not execute programming instructions if National Instruments receives
notice of such defects during the warranty period. National Instruments does not warrant that the operation of the software shall be
uninterrupted or error free.
A Return Material Authorization (RMA) number must be obtained from the factory and clearly marked on the outside of the package before
any equipment will be accepted for warranty work. National Instruments will pay the shipping costs of returning to the owner parts which are
covered by warranty.
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Compliance
Compliance with FCC/Canada Radio Frequency Interference
Regulations
Determining FCC Class
The Federal Communications Commission (FCC) has rules to protect wireless communications from interference. The FCC
places digital electronics into two classes. These classes are known as Class A (for use in industrial-commercial locations only)
or Class B (for use in residential or commercial locations). All National Instruments (NI) products are FCC Class A products.
Depending on where it is operated, this Class A product could be subject to restrictions in the FCC rules. (In Canada, the
Department of Communications (DOC), of Industry Canada, regulates wireless interference in much the same way.) Digital
electronics emit weak signals during normal operation that can affect radio, television, or other wireless products.
All Class A products display a simple warning statement of one paragraph in length regarding interference and undesired
operation. The FCC rules have restrictions regarding the locations where FCC Class A products can be operated.
Consult the FCC Web site at www.fcc.gov for more information.
FCC/DOC Warnings
This equipment generates and uses radio frequency energy and, if not installed and used in strict accordance with the instructions
in this manual and the CE marking Declaration of Conformity*, may cause interference to radio and television reception.
Classification requirements are the same for the Federal Communications Commission (FCC) and the Canadian Department
of Communications (DOC).
Changes or modifications not expressly approved by NI could void the user’s authority to operate the equipment under the
FCC Rules.
Class A
Federal Communications Commission
This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to part 15 of the FCC
Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated
in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and
used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this
equipment in a residential area is likely to cause harmful interference in which case the user is required to correct the interference
at their own expense.
Canadian Department of Communications
This Class A digital apparatus meets all requirements of the Canadian Interference-Causing Equipment Regulations.
Cet appareil numérique de la classe A respecte toutes les exigences du Règlement sur le matériel brouilleur du Canada.
Compliance with EU Directives
Users in the European Union (EU) should refer to the Declaration of Conformity (DoC) for information* pertaining to the
CE marking. Refer to the Declaration of Conformity (DoC) for this product for any additional regulatory compliance
information. To obtain the DoC for this product, visit ni.com/certification, search by model number or product line,
and click the appropriate link in the Certification column.
* The CE marking Declaration of Conformity contains important supplementary information and instructions for the user or
installer.

©National Instruments Corporation v NI PCI-7390 User Manual
Contents
About This Manual
Conventions ...................................................................................................................vii
Related Documentation..................................................................................................viii
Chapter 1
Introduction
About the PCI-7390 Controller......................................................................................1-1
Features............................................................................................................1-1
Hardware .........................................................................................................1-2
RTSI ................................................................................................................1-2
What You Need to Get Started ......................................................................................1-2
Software Programming Choices ....................................................................................1-3
National Instruments Application Software ..................................................................1-3
Optional Equipment.......................................................................................................1-4
Chapter 2
Configuration and Installation
Software Installation ......................................................................................................2-1
Controller Configuration................................................................................................2-1
Safety Information .........................................................................................................2-2
Hardware Installation.....................................................................................................2-4
Chapter 3
Hardware Overview
User Connectors.............................................................................................................3-2
Functional Overview......................................................................................................3-3
Dual Processor Architecture............................................................................3-3
Embedded Real-Time Operating System..........................................3-4
Trajectory Generators .......................................................................3-4
Flash Memory ...................................................................................3-4
Axes and Motion Resources............................................................................3-5
Axes ..................................................................................................3-5
Motion Resources .............................................................................3-6
Host Communications .....................................................................................3-6

Contents
NI PCI-7390 User Manual vi ni.com
Chapter 4
Signal Connections
I/O Connector ................................................................................................................ 4-1
Power Supply Connections ............................................................................. 4-4
Step and Direction Outputs ............................................................................. 4-5
Step and Direction Output Circuit .................................................... 4-6
Limit and Home Inputs ................................................................................... 4-6
Wiring Concerns............................................................................... 4-7
Inhibit-In (Alarm) and In-Position Inputs ....................................................... 4-7
Encoder Inputs ................................................................................................ 4-8
Axis <1..4> Encoder Phase A and Phase B...................................... 4-9
Axis <1..4> Encoder Index (Phase Z) .............................................. 4-9
Encoder Input Circuit ....................................................................... 4-11
Connections for Input Voltages Higher Than 5 V............................ 4-12
Wiring Concerns............................................................................... 4-13
Trigger (Position Capture) Inputs ................................................................... 4-13
Trigger (Position Capture) Input Circuit .......................................... 4-14
Breakpoint (Position Compare) Outputs......................................................... 4-14
Breakpoint (Position Compare) Output Circuit................................ 4-15
General-Purpose Inputs................................................................................... 4-15
General-Purpose Outputs ................................................................................ 4-16
General-Purpose Output Circuit ....................................................... 4-16
Selecting Sinking or Sourcing General-Purpose Outputs................. 4-17
Connecting Inputs to the PCI-7390................................................................. 4-18
RTSI Connector............................................................................................................. 4-21
RTSI Signal Considerations............................................................................ 4-21
Appendix A
Specifications
Appendix B
Motion Connection Accessories
Appendix C
Technical Support and Professional Services
Glossary
Index

©National Instruments Corporation vii NI PCI-7390 User Manual
About This Manual
This manual describes the electrical and mechanical aspects of the National
Instruments PCI-7390 and contains information about how to operate and
program the device.
The NI PCI-7390 is designed for PCI bus computers.
Conventions
The following conventions appear in this manual:
<> Angle brackets that contain numbers separated by an ellipsis represent
a range of values associated with a bit or signal name—for example,
AO <3..0>.
»The »symbol leads you through nested menu items and dialog box options
to a final action. The sequence File»Page Setup»Options directs you to
pull down the File menu, select the Page Setup item, and select Options
from the last dialog box.
This icon denotes a tip, which alerts you to advisory information.
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. When this symbol is marked on a
product, refer to the Safety Information section of Chapter 2, Configuration
and Installation, for information about precautions to take.
bold Bold text denotes items that you must select or click in the software, such
as menu items and dialog box options. Bold text also denotes parameter
names.
italic Italic text denotes variables, emphasis, a cross reference, or an introduction
to a key concept. Italic text 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.

About This Manual
NI PCI-7390 User Manual viii ni.com
Related Documentation
The following documents contain information you might find helpful as
you read this manual:
•NI PCI-7390 Installation Guide—Refer to this document for
installation instructions.
•Getting Started with NI-Motion for NI 73xx Motion Controllers—
Refer to this document for general information about the NI-Motion
product.
•Measurement & Automation Explorer Help for Motion—Refer to this
document for configuration information.
•NI-Motion Function Help—Refer to this document for specific
information about NI-Motion C/C++ functions.
•NI-Motion VI Help—Refer to this document for specific information
about NI-Motion LabVIEW VIs.
•NI-Motion User Manual—Refer to this document for information
about the NI-Motion driver software, including background,
configuration, and programming information.

©National Instruments Corporation 1-1 NI PCI-7390 User Manual
1
Introduction
This chapter includes information about the features of the NI PCI-7390
controller and information about operating the device.
About the PCI-7390 Controller
The PCI-7390 controller features advanced motion control with
easy-to-use software tools and add-on motion VI libraries for use with
LabVIEW.
Features
The PCI-7390 is a position-command (p-command) stepper motion
controller with isolation designed for use with drives that support
p-command mode or step (pulse) command input. The PCI-7390 has
accessories specifically designed for direct connectivity to Yaskawa
Sigma II, Mitsubishi MR-J2S and Panasonic Minas A drives.
The PCI-7390 provides fully programmable motion control for up to
four independent or coordinated axes of motion, with dedicated motion I/O
for limit and home switches and additional I/O for general-purpose
functions.
You can use the PCI-7390 controller for point-to-point and straight-line
vector moves. The PCI-7390 also performs arbitrary and complex motion
trajectories through circular, spherical, or helical interpolation.
Stepper axes can operate in open or closed-loop mode. The PCI-7390 uses
quadrature encoders for position and velocity feedback (closed-loop only),
and provides advanced encoder functions such as trigger (position capture)
and breakpoint (position compare). The PCI-7390 provides step/direction
or clockwise (CW) /counter-clockwise (CCW) digital command outputs.
The controller supports full, half, and microstepping applications on all
four axes.

Chapter 1 Introduction
NI PCI-7390 User Manual 1-2 ni.com
Hardware
The PCI-7390 is a high performance controller that uses an advanced
dual-processor architecture including a 32-bit CPU combined with a digital
signal processor (DSP) and a custom field programmable gate array
(FPGA). The first-in, first-out (FIFO) bus interface and powerful function
set provide high-speed communications while off-loading complex motion
functions from the host PC for optimum command throughput and system
performance.
The PCI-7390 uses a 100-pin SCSI I/O connector. Each axis of the
PCI-7390 has motion I/O for end-of-travel limit and home switch inputs,
breakpoint (position compare) output, trigger (position capture) input,
inhibit (alarm) input, in-position input, drive (servo) ready input, inhibit
(drive enable) output, shutdown input, alarm clear output and encoder
feedback. The PCI-7390 also has eight non-dedicated user inputs and
eight non-dedicated user outputs.
RTSI
The PCI-7390 supports the National Instruments Real-Time System
Integration (RTSI) bus. The RTSI bus provides high-speed connectivity
between National Instruments products, including image acquisition and
data acquisition products. Using the RTSI bus, you can easily synchronize
several functions to a common trigger or timing event across multiple
motion, image or data acquisition devices.
What You Need to Get Started
To set up and use the PCI-7390 controller, you must have the
following items:
❑PCI-7390 motion controller and documentation
❑NI-Motion 7.2 or later driver software and documentation
❑One of the following software packages and documentation:
– LabVIEW 7.0 or later
– LabWindows™/CVI™7.0 or later
–C/C++
– Microsoft Visual Basic 6.0
❑Computer with an available PCI slot
❑+24 V external power supply

Chapter 1 Introduction
©National Instruments Corporation 1-3 NI PCI-7390 User Manual
Software Programming Choices
NI-Motion is a simple but powerful high-level application programming
interface (API) that makes programming the PCI-7390 easy. You can
execute all setup and motion control functions by calling into
a dynamically-linked library (DLL). You can use the full function set
implementations for LabVIEW and LabWindows/CVI, or call the
NI-Motion libraries from C and Visual Basic.
National Instruments Application Software
LabVIEW is based on the graphical programming language, G, and
features interactive graphics and a state-of-the-art user interface. In
LabVIEW, you can create 32-bit compiled programs and stand-alone
executables for custom automation, data acquisition, test, measurement,
and control solutions. National Instruments offers the NI-Motion VI
Library, which is a series of virtual instruments (VIs) for using LabVIEW
with National Instruments motion control hardware. The NI-Motion VI
library implements the full API, along with a useful set of example
programs.
ANSI C-based LabWindows/CVI also features interactive graphics and a
state-of-the-art user interface. Using LabWindows/CVI, you can generate
C code for custom data acquisition, test, and measurement and automation
solutions. The NI-Motion software includes a series of example programs
for using LabWindows/CVI with National Instruments motion control
hardware.
NI Motion Assistant offers a point-and-click interface for creating motion
control sequences quickly and easily. When you have created a motion task,
you can use Motion Assistant to output the task in LabVIEW or C code or
code recipes.

Chapter 1 Introduction
NI PCI-7390 User Manual 1-4 ni.com
Optional Equipment
National Instruments offers a variety of products for use with the
PCI-7390 controller, including the following accessories:
• Cables and cable assemblies for motion and digital I/O
• RTSI cable for connection with other National Instruments devices
• Connector blocks and shielded and unshielded 100-pin screw terminal
wiring aids
• Motion Connection Accessory (MCA) wiring connectivity blocks
for easy and direct connections to Mitsubishi (NI part number
779612-01), Panasonic (NI part number 779613-01), and Yaskawa
(NI part number 779611-01) drives. Refer to Appendix B, Motion
Connection Accessories, for more information.
• +24 V DC power supplies
– PS-4 (NI part number 778586-90)
– PS-5 (NI part number 778805-90)
For more specific information about these products, refer to the
National Instruments catalog, the National Instruments Web site at
ni.com, or call your National Instruments sales representative.

©National Instruments Corporation 2-1 NI PCI-7390 User Manual
2
Configuration and Installation
This chapter describes how to configure and install the NI PCI-7390.
Software Installation
Before installing the PCI-7390, install the NI-Motion driver software and,
if appropriate, the NI-Motion VI libraries. For specific installation
instructions refer to the NI PCI-7390 Installation Guide, which is
included with the controller, or to Getting Started with NI-Motion
for NI 73xx Motion Controllers, which is installed in the
NI-Motion/Documentation folder where you installed NI-Motion.
The default directory is Program Files\National Instruments\
NI-Motion.
Note If you do not install the NI-Motion driver software before attempting to use
the PCI-7390, the system will not recognize the PCI-7390 and you will be unable to
configure or use the device.
Controller Configuration
Because motion I/O-related configuration of the PCI-7390 is performed
entirely with software, it is not necessary to set jumpers for motion I/O
configuration. However, it is necessary to set jumpers to select between
sinking or sourcing output type for the controller’s general-purpose
outputs. Refer to the Selecting Sinking or Sourcing General-Purpose
Outputs section of Chapter 4, Signal Connections, for more information.
The PCI-7390 controller is fully compatible with the industry standard
PCI Local Bus Specification, Revision 2.2. This compatibility allows the
PCI system to automatically perform all bus-related configuration without
user interaction. It is not necessary to configure jumpers for bus-related
configuration, including setting the device base memory and interrupt
channel.
Note When adding or removing a controller from a Windows 2000/XP system, you must
be logged on with administrator-level access. After you have restarted the system, you may
need to refresh Measurement & Automation Explorer (MAX) to view the new controller.

Chapter 2 Configuration and Installation
NI PCI-7390 User Manual 2-2 ni.com
Safety Information
Caution The following section contains important safety information that you must follow
when installing and using the PCI-7390.
Do not operate the device in a manner not specified in this document.
Misuse of the device can result in a hazard. You can compromise the safety
protection built into the device if the device is damaged in any way. If the
device is damaged, return it to National Instruments (NI) for repair.
Do not substitute parts or modify the device except as described in this
document. Use the device only with the chassis, modules, accessories, and
cables specified in the installation instructions. You must have all covers
and filler panels installed during operation of the device.
Do not operate the device in an explosive atmosphere or where there may
be flammable gases or fumes. If you must operate the device in such an
environment, it must be in a suitably rated enclosure.
If you need to clean the device, use a soft, nonmetallic brush. Make sure
that the device is completely dry and free from contaminants before
returning it to service.
Operate the device only at or below Pollution Degree 2. Pollution is foreign
matter in a solid, liquid, or gaseous state that can reduce dielectric strength
or surface resistivity. The following is a description of pollution degrees:
• Pollution Degree 1 means no pollution or only dry, nonconductive
pollution occurs. The pollution has no influence.
• Pollution Degree 2 means that only nonconductive pollution occurs in
most cases. Occasionally, however, a temporary conductivity caused
by condensation must be expected.
• Pollution Degree 3 means that conductive pollution occurs, or dry,
nonconductive pollution occurs that becomes conductive due to
condensation.
Note The PCI-7390 is intended for indoor use only.
You must insulate signal connections for the maximum voltage for which
the device is rated. Do not exceed the maximum ratings for the device.
Do not install wiring while the device is live with electrical signals. Do not
remove or add connector blocks when power is connected to the system.

Chapter 2 Configuration and Installation
©National Instruments Corporation 2-3 NI PCI-7390 User Manual
Remove power from signal lines before connecting them to or
disconnecting them from the device.
Operate the device at or below the measurement category1marked on the
hardware label. Measurement circuits are subjected to working voltages2
and transient stresses (overvoltage) from the circuit to which they are
connected during measurement or test. Installation categories establish
standard impulse withstand voltage levels that commonly occur in
electrical distribution systems. The following is a description of installation
categories:
• Measurement Category I is for measurements performed on circuits
not directly connected to the electrical distribution system referred to
as MAINS3voltage. This category is for measurements of voltages
from specially protected secondary circuits. Such voltage
measurements include signal levels, special equipment, limited-energy
parts of equipment, circuits powered by regulated low-voltage sources,
and electronics.
• Measurement Category II is for measurements performed on circuits
directly connected to the electrical distribution system. This category
refers to local-level electrical distribution, such as that provided
by a standard wall outlet (for example, 115 AC voltage for U.S. or
230 AC voltage for Europe). Examples of Installation Category II are
measurements performed on household appliances, portable tools,
and similar devices/modules.
• Measurement Category III is for measurements performed in the
building installation at the distribution level. This category refers to
measurements on hard-wired equipment such as equipment in fixed
installations, distribution boards, and circuit breakers. Other examples
are wiring, including cables, bus bars, junction boxes, switches, socket
outlets in the fixed installation, and stationary motors with permanent
connections to fixed installations.
• Measurement Category IV is for measurements performed at the
primary electrical supply installation (<1,000 V). Examples include
electricity meters and measurements on primary overcurrent
protection devices and on ripple control units.
1 Measurement categories, also referred to as installation categories, are defined in electrical safety standard IEC 61010-1.
2 Working voltage is the highest rms value of an AC or DC voltage that can occur across any particular insulation.
3 MAINS is defined as a hazardous live electrical supply system that powers equipment. Suitably rated measuring circuits may
be connected to the MAINS for measuring purposes.

Chapter 2 Configuration and Installation
NI PCI-7390 User Manual 2-4 ni.com
Hardware Installation
Install the PCI-7390 in any open PCI slot in the computer. Appendix A,
Specifications, lists typical power requirements for the PCI-7390
controller.
The following instructions are for general installation. Consult the
computer user manual or technical reference manual for specific
instructions and warnings.
Caution The PCI-7390 is a sensitive electronic device shipped in an antistatic bag.
Open only at an approved workstation and observe precautions for handling
electrostatic-sensitive devices.
1. Power off and unplug the computer.
Caution To protect yourself and the computer from electrical hazards, the computer must
remain unplugged until the installation is complete.
2. Open the computer case to expose access to the PCI expansion slots.
3. Choose an unused +3.3 V or +5 V PCI slot, and remove the
corresponding expansion slot cover on the back panel of the computer.
Caution Do not insert or remove any PCI-7390 motion controller from your system
without first disconnecting the +24 V power supplies from all PCI-7390 devices. Failure
to do so may result in damage to your system and/or PCI-7390.
4. Touch a metal part on the computer case to discharge any static
electricity that might be on your clothes or body before handling
the controller. Static electricity can damage the controller.
5. Gently rock the controller into the slot. The connection may be tight,
but do not force the controller into place.
6. If required, screw the mounting bracket of the controller to the back
panel rail of the computer.
7. Replace the cover.
Caution Make sure you have correctly connected all safety devices before you power on
the motion system. Safety devices include inhibits, limit switches, and emergency
shut down circuits.

Chapter 2 Configuration and Installation
©National Instruments Corporation 2-5 NI PCI-7390 User Manual
Caution Always power on the computer containing the PCI-7390, then the +24 V external
power supply, then initialize the controller before you power on the rest of the motion
system. Power off in the reverse order.
8. Plug in and power on the computer, then the +24 V external power
supply.
9. Initialize the controller.
Note When adding or removing a controller from a Windows 2000/XP system, you must
be logged on with administrator-level access. After you have restarted the system, you may
need to refresh MAX to view the new controller.

©National Instruments Corporation 3-1 NI PCI-7390 User Manual
3
Hardware Overview
This chapter presents an overview of the NI PCI-7390 functionality and
capabilities.
Figures 3-1 and 3-2 illustrate the functional components of the PCI-7390.
Figure 3-1. PCI-7390 Parts Locator Diagram (Front)
1 Jumpers for Selecting Output Type: Sinking or Sourcing
2 Non-Volatile Flash Memory
3FPGA
4 RTSI Connector
5DSP
6 32-bit CPU
7 PCI Interface
8 Optical Isolation Area
9 100-pin SCSI I/O connector
1 2 3 4
68
G
P
1
G
P
2
G
P
3
G
P
4
G
P
5
G
P
6
G
P
7
G
P
8
SRC
OUT
SNK
31
24 22
W1
9
7
5

Chapter 3 Hardware Overview
NI PCI-7390 User Manual 3-2 ni.com
Figure 3-2. PCI-7390 Parts Locator Diagram (Back)
User Connectors
The 100-pin SCSI I/O connector provides all the signals for four axes of
closed-loop motion control, including encoder feedback, limit and home
inputs, breakpoint (position compare) outputs, trigger (position capture)
input, inhibit (alarm) inputs, and in-position inputs. The connector also can
provide shutdown (emergency stop) input, drive (servo) ready inputs,
inhibit (drive enable) outputs, alarm clear outputs, and general-purpose
inputs and outputs. All inputs and outputs are optically isolated. Refer to
Chapter 4, Signal Connections, for details about the I/O connector signals.
1 Symbol to Alert User to Read the Manual
2 Symbol Indicating CE Compliance
3 Serial Number Label
4 Identification Number (used in Australia)
5 Assembly Number Label
PCI-7390
ASSY192689A-01
S/N
1
4
5
2 3

Chapter 3 Hardware Overview
©National Instruments Corporation 3-3 NI PCI-7390 User Manual
The PCI-7390 RTSI connector provides up to eight triggers to facilitate
synchronization between multiple National Instruments products. Typical
applications of the RTSI bus include triggering an image acquisition or
DAQ measurement based on motion events, or capturing current motion
positions based on events external to the motion controller. You also can
use the RTSI bus for general hardware-based communication between
RTSI devices.
The RTSI bus also can be used for general-purpose I/O. Refer to Chapter 4,
Signal Connections, for details about RTSI connector signals.
Functional Overview
This section provides an overview of the PCI-7390 capabilities, including
the advanced dual-processor architecture, axes and motion resources, and
communication with the host computer.
Dual Processor Architecture
The PCI-7390 can perform up to four axes of simultaneous motion control
in a preemptive, multitasking, real-time environment.
An advanced dual-processor architecture that uses a real-time 32-bit CPU
combined with a DSP and a custom FPGA give the PCI-7390 controllers
high-performance capabilities. The FIFO bus interface and powerful
function set provide high-speed communications while off-loading
complex motion functions from the host PC for optimized system
performance.
The PCI-7390 uses the DSP for all closed-loop control and motion
trajectory generation. The DSP chip is supported by a custom FPGA that
performs the high-speed encoder interfacing, trigger (position capture) and
breakpoint (position compare) functions, motion I/O processing, and
stepper pulse generation for hard real-time functionality.
The embedded CPU runs a multitasking, real-time operating system and
handles host communications, command processing, multi-axis
interpolation, error handling, general-purpose digital I/O, and overall
motion system integration functions.