National Instruments NI PCI-7342 User Manual

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Motion Control

NI PCI-7342 Hardware User Manual

October 2002 Edition

Part Number 373454A-01

Support

Worldwide Technical Support and Product Information

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For further support information, refer to the Technical Support and Professional Services appendix. To comment on the documentation, send email to techpubs@ni.com.

Important Information

Warranty

The NI PCI-7342 controller 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.

National Instruments believes that the information in this document is accurate. The document has been carefully reviewed for technical accuracy. In the event that technical or typographical errors exist, National Instruments reserves the right to make changes to subsequent editions of this document without prior notice to holders of this edition. The reader should consult National Instruments if errors are suspected. In no event shall National Instruments be liable for any damages arising out of or related to this document or the information contained in it.

XCEPT AS SPECIFIED HEREIN, NATIONAL INSTRUMENTS MAKES NO WARRANTIES, EXPRESS OR IMPLIED, AND SPECIFICALLY DISCLAIMS ANY WARRANTY OF

MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE . CUSTOMER’S RIGHT TO RECOVER DAMAGES CAUSED BY FAULT OR NEGLIGENCE ON THE PART OF

ATIONAL INSTRUMENTS SHALL BE LIMITED TO THE AMOUNT THERETOFORE PAID BY THE CUSTOMER. NATIONAL INSTRUMENTS WILL NOT BE LIABLE FOR DAMAGES RESULTING FROM LOSS OF DATA, PROFITS, USE OF PRODUCTS, OR INCIDENTAL OR CONSEQUENTIAL DAMAGES, EVEN IF ADVISED OF THE PO SSIBILITY THEREOF. This limitation of the liability of National Instruments will apply regardless of the form of action, whether in contract or tort, including

negligence. Any action against National Instruments must be brought within one year after the cause of action accrues. National Instruments shall not be liable for any delay in performance due to causes beyond its reasonable control. The warranty provided herein does not cover damages, defects, malfunctions, or service failures caused by owner’s failure to follow the National Instruments installation, operation, or maintenance instructions; owner’s modification of the product; owner’s abuse, misuse, or negligent acts; and power failure or surges, fire, flood, accident, actions of third parties, or other events outside reasonable control.

Copyright

Under the copyright laws, this publication may not be reproduced or transmitted in any form, electronic or mechanical, including photocopying, recording, storing in an information retrieval system, or translating, in whole or in part, without the prior written consent of National Instruments Corporation.

Trademarks

CVI™, LabVIEW™, National Instruments™, NI™, ni.com™, NI-Motion™, and RTSI™ are trademarks of National Instruments Corporation.

Product and company names mentioned herein are trademarks or trade names of their respective companies.

WARNING REGARDING USE OF NATIONAL INSTRUMENTS PRODUCTS

(1) NATIONAL INSTRUMENTS PRODUCTS ARE NOT DESIGNED WITH COMPONENTS AND TESTING FOR A LEVEL OF RELIABILITY SUITABLE FOR USE IN OR IN CONNECTION WITH SURGICAL IMPLANTS OR AS CRITICAL COMPONENTS IN ANY LIFE SUPPORT SYSTEMS WHOSE FAILURE TO PERFORM CAN REASONABLY BE EXPECTED TO CAUSE SIGNIFICANT INJURY TO A HUMAN.

(2) IN ANY APPLICATION, INCLUDING THE ABOVE, RELIABILITY OF OPERATION OF THE SOFTWARE PRODUCTS CAN BE IMPAIRED BY ADVERSE FACTORS, INCLUDING BUT NOT LIMITED TO FLUCTUATIONS IN ELECTRICAL POWER SUPPLY, COMPUTER HARDWARE MALFUNCTIONS, COMPUTER OPERATING SYSTEM SOFTWARE FITNESS, FITNESS OF COMPILERS AND DEVELOPMENT SOFTWARE USED TO DEVELOP AN APPLICATION, INSTALLATION ERRORS, SOFTWARE AND HARDWARE COMPATIBILITY PROBLEMS, MALFUNCTIONS OR FAILURES OF ELECTRONIC MONITORING OR CONTROL DEVICES, TRANSIENT FAILURES OF ELECTRONIC SYSTEMS (HARDWARE AND/OR SOFTWARE), UNANTICIPATED USES OR MISUSES, OR ERRORS ON THE PART OF THE USER OR APPLICATIONS DESIGNER (ADVERSE FACTORS SUCH AS THESE ARE HEREAFTER COLLECTIVELY TERMED “SYSTEM FAILURES”). ANY APPLICATION WHERE A SYSTEM FAILURE WOULD CREATE A RISK OF HARM TO PROPERTY OR PERSONS (INCLUDING THE RISK OF BODILY INJURY AND DEATH) SHOULD NOT BE RELIANT SOLELY UPON ONE FORM OF ELECTRONIC SYSTEM DUE TO THE RISK OF SYSTEM FAILURE. TO AVOID DAMAGE, INJURY, OR DEATH, THE USER OR APPLICATION DESIGNER MUST TAKE REASONABLY PRUDENT STEPS TO PROTECT AGAINST SYSTEM FAILURES, INCLUDING BUT NOT LIMITED TO BACK-UP OR SHUT DOWN MECHANISMS. BECAUSE EACH END-USER SYSTEM IS CUSTOMIZED AND DIFFERS FROM NATIONAL INSTRUMENTS' TESTING PLATFORMS AND BECAUSE A USER OR APPLICATION DESIGNER MAY USE NATIONAL INSTRUMENTS PRODUCTS IN COMBINATION WITH OTHER PRODUCTS IN A MANNER NOT EVALUATED OR CONTEMPLATED BY NATIONAL INSTRUMENTS, THE USER OR APPLICATION DESIGNER IS ULTIMATELY RESPONSIBLE FOR VERIFYING AND VALIDATING THE SUITABILITY OF NATIONAL INSTRUMENTS PRODUCTS WHENEVER NATIONAL INSTRUMENTS PRODUCTS ARE INCORPORATED IN A SYSTEM OR APPLICATION, INCLUDING, WITHOUT LIMITATION, THE APPROPRIATE DESIGN, PROCESS AND SAFETY LEVEL OF SUCH SYSTEM OR APPLICATION.

Compliance

FCC/Canada Radio Frequency Interference Compliance

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). Depending on where it is operated, this 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. By examining the product you purchased, you can determine the FCC Class and therefore which of the two FCC/DOC Warnings apply in the following sections. (Some products may not be labeled at all for FCC; if so, the reader should then assume these are Class A devices.)

FCC Class A products only display a simple warning statement of one paragraph in length regarding interference and undesired operation. Most of our products are FCC Class A. The FCC rules have restrictions regarding the locations where FCC Class A products can be operated.

FCC Class B products display either a FCC ID code, starting with the letters EXN, or the FCC Class B compliance mark that appears as shown here on the right.

Consult the FCC Web site at

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 National Instruments could void the user’s authority to operate the equipment under the FCC Rules.

http://www.fcc.gov for more information.

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 will be required to correct the interference at his 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.

Class B

Federal Communications Commission

This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures:

• Reorient or relocate the receiving antenna.

• Increase the separation between the equipment and receiver.

• Connect the equipment into an outlet on a circuit different from that to which the receiver is connected.

• Consult the dealer or an experienced radio/TV technician for help.

Canadian Department of Communications

This Class B digital apparatus meets all requirements of the Canadian Interference-Causing Equipment Regulations. Cet appareil numérique de la classe B respecte toutes les exigences du Règlement sur le matériel brouilleur du Canada.

Compliance to EU Directives

Readers in the European Union (EU) must refer to the Manufacturer’s Declaration of Conformity (DoC) for information* pertaining to the CE Marking compliance scheme. The Manufacturer includes a DoC for most every hardware product except for those bought for OEMs, if also available from an original manufacturer that also markets in the EU, or where compliance is not required as for electrically benign apparatus or cables.

To obtain the DoC for this product, click Declaration of Conformity at by product family. Select the appropriate product family, followed by your product, and a link to the DoC appears in Adobe Acrobat format. Click the Acrobat icon to download or read the DoC.

* The CE Marking Declaration of Conformity will contain important supplementary information and instructions for the user

or installer.

ni.com/hardref.nsf/. This Web site lists the DoCs

About This Manual

Conventions ................................................................................................................... ix

Related Documentation..................................................................................................x

Chapter 1 Introduction

About the NI PCI-7342.................................................................................................. 1-1

Hardware .........................................................................................................1-1

RTSI ................................................................................................................1-1

PCI-7342 Features ........................................................................................... 1-2

Servo and Stepper Fundamentals .................................................................... 1-2

Getting Started ...............................................................................................................1-3

Software Programming Choices ....................................................................................1-3

National Instruments Application Software ..................................................................1-3

Optional Equipment.......................................................................................................1-4

Motion I/O Connections ................................................................................................1-4

Chapter 2 Configuration and Installation

Software Installation ......................................................................................................2-1

Controller Configuration................................................................................................2-1

Unpacking......................................................................................................................2-1

Safety Information .........................................................................................................2-2

Hardware Installation.....................................................................................................2-4

Chapter 3 Hardware Overview

User Connectors.............................................................................................................3-2

Chapter 4 Functional Overview

Dual Processor Architecture ..........................................................................................4-1

Embedded Real-Time Operating System (RTOS) .......................................... 4-2

Trajectory Generators......................................................................................4-2

Analog Feedback.............................................................................................4-2

Flash Memory..................................................................................................4-3

Contents

Axes and Motion Resources.......................................................................................... 4-3

Axes ................................................................................................................ 4-3

Motion Resources ........................................................................................... 4-4

Host Communications ................................................................................................... 4-5

Chapter 5 Signal Connections

Motion I/O Connector ................................................................................................... 5-2

Motion Axis Signals........................................................................................ 5-5

Limit and Home Inputs ................................................................................... 5-6

Encoder Signals............................................................................................... 5-8

Analog Inputs.................................................................................................. 5-13

Other Motion I/O Connection ......................................................................... 5-15

Digital I/O Connector .................................................................................................... 5-16

PWM Features.................................................................................................5-17

RTSI Connector............................................................................................................. 5-17

RTSI Signal Considerations............................................................................ 5-17

Wiring Concerns............................................................................... 5-7

Limit and Home Input Circuit .......................................................... 5-7

Encoder <1..2> Phase A/Phase B ..................................................... 5-8

Encoder <1..2> Index ....................................................................... 5-9

Wiring Concerns............................................................................... 5-10

Encoder Input Circuit ....................................................................... 5-11

Trigger Inputs, Shutdown Input, and Breakpoint Outputs ............... 5-11

Wiring Concerns............................................................................... 5-12

Trigger Input, Shutdown Input, and Breakpoint Output Circuits..... 5-12

Wiring Concerns............................................................................... 5-15

Appendix A Specifications

Appendix B Cable Connector Descriptions

Appendix C Technical Support and Professional Services

Glossary

Index

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About This Manual

This manual provides guidelines for programming and operating the National Instruments PCI-7342 motion controller and includes controller specifications and descriptions of electrical and mechanical features.

Refer to the Glossary for definitions of selected related terms.

Conventions

The manual uses the following conventions:

<> Angle brackets that contain numbers separated by an ellipsis represent a

range of values associated with a bit or signal name—for example, DBIO<3..0>.

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.

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. This font also denotes text that is a placeholder for a word or value that you must supply.

monospace Text in this font denotes text or characters that you should enter from the

keyboard, sections of code, programming examples, and syntax examples. This font is also used for the proper names of disk drives, paths, directories, programs, subprograms, subroutines, device names, functions, operations, variables, filenames and extensions, and code excerpts.

About This Manual

About the NI PCI-7342

The NI PCI-7342 motion controller features advanced motion control with easy-to-use software tools and add-on motion VI libraries for use with LabVIEW. The PCI-7342 controller provides dedicated motion I/O for limit and home switches and additional I/O for general-purpose functions.

The following sections describe the features of the PCI-7342.

Hardware

The PCI-7342 controller has high-performance capabilities because of the advanced dual-processor architecture that uses a Motorola MC68331 real-time 32-bit CPU, combined with an Analog Devices ADSP-2185 digital signal processor (DSP) and custom field programmable gate arrays (FPGAs). The first-in-first-out (FIFO) bus interface and powerful function set provide high-speed communications while offloading complex motion functions from the host PC for optimum command throughput and system performance.

Each axis has motion I/O for end-of-travel limit and home switch inputs, breakpoint output, trigger input, and encoder feedback rates up to 20 MHz. The PCI-7342 controller also has nondedicated user I/O, including 32 bits of digital I/O and two analog inputs for ±10 V signals, joystick inputs, or monitoring of analog sensors. Additionally, the analog inputs can provide feedback for loop closure.

RTSI

The PCI-7342 controller supports the National Instruments Real-Time System Integration (RTSI) bus. RTSI is a dedicated, high-speed digital bus that facilitates low-level, high-speed, real-time communication between

Chapter 1 Introduction

Note Seven of the 34 pins on the RTSI connector are available for user signals. You can

use the software-configurable RTSI switch to accommodate more than seven signal options for each device. With this many-to-few selector switch, any available signal can be routed to any RTSI pin. You can also route more than one signal to a single RTSI pin or connect two RTSI pins to the same signal.

National Instruments devices. The RTSI bus provides high-speed connectivity between National Instruments products, including image acquisition (IMAQ) and data acquisition (DAQ) devices. With RTSI, you can easily synchronize several functions to a common trigger or timing event across multiple motion, IMAQ, and DAQ devices.

RTSI requires no external cabling and does not consume host bus bandwidth. Additionally, the RTSI bus features built-in switching that you can control with software to route signals to and from the bus on the fly.

The bus interface on PCI devices is an internal 34-pin connector. Signals are shared through a ribbon cable inside the PC enclosure. RTSI cables are available for chaining two, three, four, or five devices together.

Refer to the National Instruments Developer Zone at more information about RTSI, including tutorials, examples, and configuration guidelines.

PCI-7342 Features

The PCI-7342 controller combines servo and stepper functionality for PCI bus computers. It provides motion control for up to two independent or coordinated axes of motion.

You can use the PCI-7342 motion controller for point-to-point and straight-line vector moves for stepper and servo motor applications.

Servo and Stepper Fundamentals

Servo axes can control servo motors, servo hydraulics, servo valves, and other servo devices. Servo axes always operate in closed-loop mode. These axes use quadrature encoders or analog inputs for position and velocity feedback and provide analog command outputs with an industry-standard range of ±10 V.

Stepper axes control stepper motors and operate in open- or closed-loop mode. They use quadrature encoders or analog inputs for position and velocity feedback (closed-loop only), and provide step/direction or

ni.com/zone for

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Getting Started

Chapter 1 Introduction

clockwise (CW) /counter-clockwise (CCW) digital command outputs. All stepper axes support full, half, and microstepping applications.

The following items are necessary for setting up and getting started with your motion controller:

❑ PCI-7342 motion controller

❑ A computer with an available PCI slot

❑ One of the following software packages and documentation:

– LabVIEW

™

– LabWindows

– NI-Motion

/CVI

™

❑ NI PCI-7342 Hardware User Manual

❑ NI-Motion Software Reference Manual

Software Programming Choices

The simple but powerful high-level function set application programming interface (API) makes programming your controller easy. All setup and motion control functions are easily executed by calling into either a static or dynamic link library (DLL). These libraries are callable from C, Visual Basic, and other high-level languages. Full function set implementations are available for LabVIEW, LabWindows/CVI, and other industry-standard software programs.

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, a series of virtual instruments (VIs) for using LabVIEW with the National Instruments motion control hardware. The NI-Motion VI library implements the full function set API and a powerful set of demo functions, example programs, and fully operational, high-level application routines.

Chapter 1 Introduction

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 all measurement and automation solutions.

NI-Motion is the motion control software and virtual instruments (VIs) for interfacing with all National Instruments motion controllers.

Optional Equipment

The following optional products are available for use with the National Instruments motion controllers:

• Cables and cable assemblies for motion and digital I/O

• RTSI bus cables

• UMI wiring connectivity blocks with integrated motion signal

conditioning and motion inhibit functionality

• Stepper and servo motor compatible driver amplifier units with integrated power supply and wiring connectivity

• Connector blocks, shielded and unshielded 68-pin screw terminal wiring aids

For specific information about these products, refer to the National Instruments catalog, the National Instruments Web site at your National Instruments sales representative.

ni.com, or call

Motion I/O Connections

The external motion I/O and digital I/O connectors are high-density, 68-pin female VHDCI connectors. Refer to the User Connectors section of Chapter 3, Hardware Overview, for more information about these connectors.

For custom cables, use the AMP mating connector (part number 787801-01).

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Configuration and Installation

This chapter describes how to configure, unpack, and install the National Instruments PCI-7342 motion controller.

Software Installation

Before installing your controller, install the NI-Motion driver software and, if appropriate, the Motion VI libraries.

Note You must install the NI-Motion driver software before installing your motion

controller.

Refer to the Release Notes included with the controller for specific instructions on the software installation sequence for your host PC.

Controller Configuration

Because motion I/O-related configuration is performed entirely with software, it is not necessary to set jumpers for motion I/O configuration.

The PCI-7342 controller is fully compatible with the PCI Local Bus Specification, Revision 2.1. It is not necessary to configure jumpers for

bus-related configuration.

Unpacking

The PCI-7342 motion controller ships in an antistatic package to prevent electrostatic discharge from damaging board components. To avoid such damage in handling the controller, take the following precautions:

1. Ground yourself via a grounding strap or by holding a grounded object, such as your computer chassis.

2. Touch the antistatic package to a metal part of your computer chassis before removing the controller from the package.

3. Remove the controller from the package and inspect it for loose components or any other signs of damage. Notify National Instruments

Chapter 2 Configuration and Installation

if the controller appears damaged in any way. Do not install a damaged controller in your computer.

Caution Never touch the exposed connector pins.

Safety Information

Caution The following paragraphs contain important safety information you must follow

when installing and operating the device.

Do not operate the device in a manner not specified in the documentation. Misuse of the device may result in a hazard and may compromise the safety protection built into the device. If the device is damaged, turn it off and do not use it until service-trained personnel can check its safety. If necessary, return the device to National Instruments for repair.

Keep away from live circuits. Do not remove equipment covers or shields unless you are trained to do so. If signal wires are connected to the device, hazardous voltages can exist even when the equipment is turned off. To avoid a shock hazard, do not perform procedures involving cover or shield removal unless you are qualified to do so. Disconnect all field power prior to removing covers or shields.

If the device is rated for use with hazardous voltages (>30 V or 60 V

), it may require a safety earth-ground connection wire. See the

, 42.4 Vpk,

rms

device specifications for maximum voltage ratings.

Because of the danger of introducing additional hazards, do not install unauthorized parts or modify the device. Use the device only with the chassis, modules, accessories, and cables specified in the installation instructions. All covers and filler panels must be installed while operating the device.

Do not operate the device in an explosive atmosphere or where flammable gases or fumes may be present. Operate the device only at or below the pollution degree stated in the specifications. Pollution consists of any foreign matter—solid, liquid, or gas—that may reduce dielectric strength or surface resistivity. Pollution degrees are listed below:

• Pollution Degree 1—No pollution or only dry, nonconductive pollution occurs. The pollution has no effect.

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Chapter 2 Configuration and Installation

• Pollution Degree 2—Normally only nonconductive pollution occurs. Occasionally, nonconductive pollution becomes conductive because of condensation.

• Pollution Degree 3—Conductive pollution or dry, nonconductive pollution occurs. Nonconductive pollution becomes conductive because of condensation.

Clean the device and accessories by brushing off light dust with a soft, nonmetallic brush. Remove other contaminants with a stiff, nonmetallic brush. The unit must be completely dry and free from contaminants before returning it to service.

Yo u must insulate signal connections for the maximum voltage for which the device is rated. Do not exceed the maximum ratings for the device. Remove power from signal lines before connection to or disconnection from the device.

Operate this device only at or below the installation category stated in the specifications. Installation categories are listed below:

• Installation CAT IV—for measurements performed at the source of the low-voltage (<1000 V) installation. Examples include electricity meters, measurements on primary overcurrent protection devices, and ripple-control units.

• Installation CAT III—for measurements performed in the building installation. Examples include measurements on distribution boards, circuit-breakers, wiring (including cables), bus bars, junction boxes, switches, socket outlets in the fixed installation, equipment for industrial use, and some other types of equipment, such as stationary motors permanently connected to the fixed installation.

• Installation CAT II—for measurements performed on circuits directly connected to the low-voltage installation. Examples include measurements on household appliances, portable tools, and other similar equipment.

• Installation CAT I—for measurements performed on circuits not directly connected to mains

. Examples include measurements on circuits not derived from mains, and specially-protected (internal) mains-derived circuits.

Mains is defined as the electricity supply system to which the equipment concerned is designed to be connected for either powering the equipment or for measurement purposes.

Chapter 2 Configuration and Installation

Figure 2-1 illustrates a sample installation.

Hardware Installation

Install your PCI-7342 controller in any open compatible expansion slot in your computer. Appendix A, Specifications, lists the power requirements for the PCI-7342 controller.

Figure 2-1. Sample Installation

The following instructions are for general installation. Consult your computer user manual or technical reference manual for specific instructions and warnings.

Caution Observe precautions for handling electrostatic-sensitive devices. Refer to the

Unpacking section of this chapter for information about handling the controller.

1. Verify that the NI-Motion software is installed on your computer.

2. Power off and unplug your computer.

Caution To protect yourself and the computer from electrical hazards, the computer

should remain off until you finish installing the controller.

3. Remove the top cover or access port to the PCI expansion slots in your computer.

4. Wait for any motherboard LEDs to turn off to ensure system power has dissipated.

5. Remove the expansion slot connector port cover on the back panel of your computer.

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Chapter 2 Configuration and Installation

6. Insert the controller into a +3.3 V or +5 V PCI slot. Gently rock the device to ease it into place. It may be a tight fit, but do not force the device into place.

7. If available, screw the controller mounting bracket to the back panel rail of the computer.

8. Replace the cover.

9. Plug in the 68-pin cable for motion I/O to the controller.

10. Plug in and turn on your computer.

Your PCI controller is installed.

Hardware Overview

This chapter provides an overview of the PCI-7342 motion controller hardware functionality.

Figure 3-1 shows the PCI-7342 parts locator diagram.

6 7

2001

PCI-7342

1 RTSI Connector 2 Assembly Number Label 3 Serial Number Label

4 68-Pin Digital I/O Connector 5 68-Pin Motion I/O Connector

Figure 3-1. PCI-7342 Parts Locator Diagram

6 MC68331 CPU 7 ADSP 2185 DSP

Chapter 3 Hardware Overview

User Connectors

The 68-pin motion I/O connector provides all the signals for two axes of closed-loop motion control, including encoder feedback, limit and home inputs, breakpoint outputs, trigger inputs, and analog-to-digital (A/D) converter signals. Refer to Chapter 5, Signal Connections, for details about motion I/O connector signals.

The 68-pin digital I/O connector provides 32 bits of user-configurable digital I/O. Refer to Chapter 5, Signal Connections, for details about the digital I/O connector signals.

The RTSI connector provides up to seven triggers and one high-speed clock signal 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.

The RTSI bus can also be used for general-purpose I/O. Refer to Chapter 5,

Signal Connections, for details about RTSI connector signals.

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Functional Overview

This chapter provides an overview of the motion control algorithms and controller capabilities.

Dual Processor Architecture

With the PCI-7342 controller, you can perform one or two axes of simultaneous, coordinated motion control in a preemptive, multitasking, real-time environment.

An advanced dual-processor architecture that uses a Motorola MC68331 real-time 32-bit CPU combined with an Analog Devices ADSP 2185 DSP and custom FPGAs give the PCI-7342 controller high-performance capabilities. The FIFO bus interface and powerful function set provide high-speed communications while offloading complex motion functions from the host PC for optimized system performance.

The PCI-7342 controller uses the digital signal processor for all closed-loop control, including position tracking, PID control closed-loop computation, and motion trajectory generation. The DSP chip is supported by custom FPGAs that perform the high-speed encoder interfacing, position capture and breakpoint functions, motion I/O processing, and stepper pulse generation for hard real-time functionality.

The embedded, multitasking real-time CPU handles host communications, command processing, multi-axis interpolation, onboard program execution, error handling, general-purpose digital I/O, and overall motion system integration functions.

Chapter 4 Functional Overview

Embedded Real-Time Operating System (RTOS)

The embedded firmware is based upon an embedded RTOS kernel and provides optimum system performance in varying motion applications. Motion tasks are prioritized, and task execution order depends on the priority of each task, the state of the entire motion system, I/O or other system events, and the real-time clock.

The DSP chip is a separate processor that operates independently from the CPU but is closely synchronized by an internal packet-based command, data, and messaging event structure. The PCI-7342 controller is a true multiprocessing and multitasking embedded controller.

The advanced architecture of the PCI-7342 controller enables advanced motion features, such as enhanced PID functions. Refer to the NI-Motion Software Reference Manual for more information about the features available on the PCI-7342 controller.

Trajectory Generators

The trajectory generators on the PCI-7342 controller calculate the instantaneous position command that controls acceleration and velocity while moving the axis to its target position. Depending on how you configure the axis, this command is sent to the PID servo loop or stepper pulse generator.

To implement infinite trajectory control, the PCI-7342 controller has four trajectory generators (two per axis) implemented in the DSP chip. Each generator calculates an instantaneous position each PID update period. While simple point-to-point moves require only one trajectory generator, blended moves and infinite trajectory control processing require two simultaneous generators.

Analog Feedback

The PCI-7342 controller has two multiplexed, 12-bit ADC channels available for analog feedback. The converted analog values transmit to both the DSP and CPU through a dedicated internal high-speed serial bus. The multiplexer scan rate is approximately 50 µs per enabled ADC channel, which provides the high sampling rates required for feedback loop closure, joystick inputs, and monitoring analog sensors.

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Flash Memory

Flash ROM implements the nonvolatile memory on the PCI-7342 controller, which enables the controllers to electrically erase and reprogram its ROM. Flash memory stores all the embedded firmware, including the RTOS and DSP code, enabling you to upgrade the onboard firmware contents in the field for support and new feature enhancement.

Flash memory also allows objects such as programs and data arrays to be stored in nonvolatile memory. It is possible to save the entire parameter state of the controller to the flash memory. On the next power cycle, the controller automatically loads and returns the configuration to these new saved default values.

Flash ROM also stores the FPGA configuration programs. At power-up, the FPGAs are booted with these programs, which means that updates to the FPGA programs can be performed in the field.

Note A flash memory download utility is included with the NI-Motion software that ships

with the controller.

Axes and Motion Resources

Chapter 4 Functional Overview

The PCI-7342 controller can control one or two axes of motion. The axes can be completely independent, simultaneously coordinated, or mapped in multidimensional groups called vector spaces. You can also synchronize vector spaces for multi-vector space coordinated motion control.

Axes

An axis consists of a trajectory generator, a PID (for servo axes) or stepper control block, and at least one output resource—either a DAC output (for servo axes) or a stepper pulse generator output. Servo axes must have either an encoder or ADC channel feedback resource. Closed-loop stepper axes also require a feedback resource, while open-loop stepper axes do not. Figures 4-1 and 4-2 show these axis configurations.

You can map one or two feedback resources and one or two output resources to the axis. An axis with its primary output resource mapped to a stepper output is by definition a stepper axis. An axis with its primary output resource mapped to a DAC is by definition a servo axis.

Chapter 4 Functional Overview

øA

øB

Index

øA

øB

Index

32-Bit Encoder Interface

0101011101101 11101101100

101100111

PID

Servo

Loop

101100111

16-Bit

D/A

Converter

±10 V

Figure 4-1. Servo Axis Resources

32-Bit Encoder Interface

01011010 010010110

101100111

Stepper

Control

Loop

101100111

Stepper

Pulse

Generator

Figure 4-2. Stepper Axis Resources

The PCI-7342 controller supports axes with secondary output resources (DACs for servo axes or stepper outputs). Defining two output resources is useful when controlling axes with multiple motors, such as gantry systems in which two DAC outputs can be configured with different torque limits and/or offsets.

The PCI-7342 controller supports secondary feedback resources (encoders) for axes defined as servo. Two feedback resources are necessary when implementing dual-loop control, such as in backlash compensation, which reduces the number of encoders available for other axes.

Note Refer to the Axis and Resource Configuration section of the NI-Motion Software

Reference Manual for more information about configuring axes.

Motion Resources

Encoder, DAC, ADC, and motion I/O resources that are not used by an axis are available for nonaxis- or nonmotion-specific applications. You can directly control an unmapped DAC as a general-purpose analog output (±10 V). Similarly, you can use any ADC channel to measure potentiometers or other analog sensors.

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If an encoder resource is not needed for axis control, you can use it for any number of other functions, including position or velocity monitoring, as a digital potentiometer encoder input, or as a master encoder input for master/slave (electronic gearing) applications.

Each axis also has an associated forward and reverse limit input, a home input, a high-speed capture trigger input, a breakpoint output, and an inhibit output. These signals can be used for general-purpose digital I/O when not being used for their motion-specific purpose.

Note Once mapped to an axis, all features and functions of a resource are available as part

of the axis. It is not necessary to remember or use the resource number directly when accessing these features. Resources are referenced by axis number once assigned to that axis.

Host Communications

The host computer communicates with the controller through a number of memory port addresses on the host bus.

The primary bi-directional data transfer port is at the base address of the controller. This port supports FIFO data passing in both send and readback directions. The PCI-7342 controller has both a command buffer for incoming commands and a return data buffer (RDB) for readback data.

Chapter 4 Functional Overview

Two read-only status registers are at offsets from the base address. The communications status register (CSR) provides bits for communications handshaking as well as real-time error reporting and general status feedback to the host PC. The move complete status (MCS) register provides instantaneous motion status of all axes.

Signal Connections

This chapter describes how to send input and output signal connections directly to the controller and briefly describes the associated I/O circuitry.

The PCI-7342 controller has three connectors that handle all signals to and from the external motion system:

• 68-pin motion I/O connector

• 68-pin digital I/O connector

• RTSI connector

You can connect to your motion system with cables and accessories, varying from simple screw terminal blocks to enhanced UMI units and drives.

Caution Power off all devices when connecting or disconnecting the motion I/O and

auxiliary digital I/O cables. Failure to do so may damage the controller.

Figure 5-1 shows the connectors on the PCI-7342 controller. Refer to Figure 3-1, PCI-7342 Parts Locator Diagram, to locate the RTSI connector.

DIGITAL I/O MOTION I/O

Figure 5-1. PCI-7342 Motion Controller Connectors

Chapter 5 Signal Connections

Motion I/O Connector

The motion I/O connector contains all signals necessary for controlling axes of servo and stepper motion, including the following features:

• Encoder feedback inputs

• Forward, home, and reverse limit inputs

• Trigger inputs

• Motor command analog and stepper outputs

• Breakpoint outputs

• Inhibit outputs

The motion I/O connector also contains two channels of 12-bit A/D inputs for analog feedback or general-purpose analog input.

Figure 5-2 shows the pin assignments for the 68-pin motion I/O connector on the PCI-7342 controller. Refer to Table 5-1 for a description of each motion I/O signal.

Note Lines above signal names indicate that the signal is active-low.

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Axis 1 Dir (CCW)

Digital Ground Digital Ground

Axis 1 Home Switch

Trigger 1

Axis 1 Inhibit

Axis 2 Dir (CCW)

Digital Ground Digital Ground

Axis 2 Home Switch

Trigger 2

Axis 2 Inhibit

NC Digital Ground Digital Ground

NC Digital Ground

Breakpoint 1

NC Digital Ground

Analog Output 1

Analog Output Ground

Analog Input 1

Analog Reference (Output)

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

Chapter 5 Signal Connections

1 2 3 4 5 6 7 8 9

Axis 1 Step (CW)

Axis 1 Encoder Phase A

Axis 1 Encoder Phase B

Axis 1 Encoder Index

Axis 1 Forward Limit Switch

Axis 1 Reverse Limit Switch

Axis 2 Step (CW)

Axis 2 Encoder Phase A

Axis 2 Encoder Phase B

Axis 2 Encoder Index

Axis 2 Forward Limit Switch

Axis 2 Reverse Limit Switch

Host +5 V

Breakpoint 2

Shutdown

Analog Output 2

Analog Input 2

Analog Input Ground

Figure 5-2. 68-Pin Motion I/O Connector Pin Assignment

Caution

Do not connect NC (not connected) signals. Connecting these signals could cause

permanent damage to your motion controller.

Chapter 5 Signal Connections

Table 5-1 describes the signals on the motion I/O connector.

Table 5-1. Motion I/O Signal Connections

Signal Name Reference Direction Description

Axis <1..2> Dir (CCW) Digital Ground Output Motor direction or

counter-clockwise control

Axis <1..2> Step (CW) Digital Ground Output Motor step or clockwise control

Axis <1..2> Encoder Phase A Digital Ground Input Closed-loop only—phase A encoder

input

Axis <1..2> Encoder Phase B Digital Ground Input Closed-loop only—phase B encoder

input

Axis<1..2> Encoder Index Digital Ground Input Closed-loop only—index encoder

input

Axis <1..2> Home Switch Digital Ground Input Home switch

Axis <1..2> Forward Limit Switch Digital Ground Input Forward/clockwise limit switch

Axis <1..2> Reverse Limit Switch Digital Ground Input Reverse/counter-clockwise limit

switch

Axis <1..2> Inhibit Digital Ground Output Drive inhibit

Trigger <1..2> Digital Ground Input High-speed position capture trigger

Breakpoint <1..2> Digital Ground Output Breakpoint output <1..2>

Host +5 V Digital Ground Output +5 V—host computer +5 V supply

Analog Input Ground — — Reference for analog inputs

Analog Input <1..2> Analog Input Ground Input 12-bit analog input

Analog Output <1..2> Analog Output Ground Output 16-bit analog output

Analog Output Ground — — Reference for analog outputs

Shutdown Digital Ground Input Controlled device shutdown

Analog Reference (Output) Analog Input Ground Output +7.5 V—analog reference level

Digital Ground — — Reference for digital I/O

input <1..2>

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Motion Axis Signals

Chapter 5 Signal Connections

The following signals control the servo amplifier or stepper driver:

• Analog Output <1..2>—These 16-bit DAC outputs are typically

the servo command outputs for each axis. They can drive the industry-standard ±10 V output, and you can limit them to any positive or negative voltage range desired. They also feature a software-programmable voltage offset.

Although typically used as the command output of an axis control loop, unused DACs can also function as independent analog outputs for general-purpose control.

• Analog Output Ground—This separate return connection is

available to help keep digital noise separate from the analog DAC outputs. Use this analog ground connection and not Digital Ground (digital I/O reference) as the reference for the DAC outputs when connecting to servo amplifiers.

• Axis <1..2> Step (CW) and Dir (CCW)—These open-collector

signals are the stepper command outputs for each axis. The PCI-7342 controller supports both major industry standards for stepper command signals: step and direction, or independent CW and CCW pulse outputs.

The output configuration and signal polarity is software programmable for compatibility with various third-party drives, as follows:

– When step and direction mode is configured, each commanded

step (or microstep) produces a pulse on the step output. The direction output signal level indicates the command direction of motion, either forward or reverse.

– CW and CCW mode produces pulses (steps) on the CW output for

forward-commanded motion and pulses on the CCW output for reverse-commanded motion.

In either case, you can set the active polarity of both outputs to active-low (inverting) or active-high (non-inverting). For example, with step and direction, you can make a logic high correspond to either forward or reverse direction.

The Step (CW) and Dir (CCW) outputs are driven by high-speed open-collector transistor-to-transistor (TTL) buffers that feature 64 mA sink current capability and built-in 3.3 kΩ pull-up resistors to +5 V.

Caution Do not connect these outputs to anything other than a +5 V circuit. The output

buffers will fail if subjected to voltages in excess of +5.5 V.

Chapter 5 Signal Connections

• Axis <1..2> Inhibit—Use the inhibit output signals to control the

enable/inhibit function of a servo amplifier or stepper driver. When properly connected and configured, the inhibit function de-energizes the connected motor its shaft turns freely. These open-collector inhibit signals feature 64 mA current sink capability with built-in 3.3 kΩ pull-up resistors to +5 V, and can directly drive most driver/amplifier inhibit input circuits.

While the industry standard for inhibits is active-low (inverting), these outputs have programmable polarity and can be set to active-high (non-inverting) for increased flexibility and unique drive compatibility.

Inhibit output signals can automatically activate upon a Kill Motion command or any motion error that causes a kill motion condition—a following error trip, for example. You can also directly control the inhibit output signals to enable or disable a driver or amplifier. Figure 5-3 shows a simplified schematic diagram of the step, direction, and inhibit output.

Vcc

3.3 kΩ

To the External

Connector Step,

Direction, or Inhibit Pins

74AS760

From the

Step, Direction,

or Inhibit Circuits

Figure 5-3. Step, Direction, and Inhibit Output

Limit and Home Inputs

The following signals control limit and home inputs:

• Axis <1..2> Forward Limit Input

• Axis <1..2> Home Input

• Axis <1..2> Reverse Limit Input

These inputs are typically connected to limit switches located at physical ends of travel and/or at a specific home position. You can use software to enable or disable limit and home inputs at any time. Enabling an active transition on a limit or home input causes a full torque halt stop of the associated motor axis. In addition, an active forward or reverse limit input impedes future commanded motion in that direction for as long as the signal is active.

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Chapter 5 Signal Connections

Note Limit and home inputs are digitally filtered and must remain active for at least 1 ms

to be recognized. Active signals should remain active to prevent motion from proceeding further into the limit. Pulsed limit signals stop motion but do not prevent further motion in that direction if another move is started.

The input polarity of these signals is software programmable for active-low (inverting) or active-high (non-inverting).

You can use software disabled limit and home inputs as general-purpose inputs. You can read the status of these inputs at any time and set and change their polarity as required.

Limit and home inputs are a per-axis enhancement and are not required for basic motion control. These inputs are part of a system solution for complete motion control.

Wiring Concerns

For the end of travel limits to function correctly, the forward limit must be at the forward or positive end of travel, and the reverse limit at the negative end of travel.

Caution Failure to follow these guidelines may result in motion that stops at a limit but

then travels through the limit, which could damage the motion system. Miswired limits could prevent motion from occurring at all.

Keep limit and home switch signals and their ground connections wired separately from the motor driver/amplifier signal and encoder signal connections.

Caution Wiring these signals near each other can cause faulty motion system operation

due to signal noise and crosstalk.

Limit and Home Input Circuit

All limit and home inputs are digitally filtered and must be active for at least 1 ms. Figure 5-4 shows a simplified schematic diagram of the circuit the limit and home switch inputs use for input signal buffering and detection.

Chapter 5 Signal Connections

From the External

Connector Limit

and Home Switch Pins

3.3 kΩ

Vcc

1 kΩ

1/8 W

74HC244

DGND

Figure 5-4. Limit and Home Input Circuit

To the Limit and

Home Switch

Circuits

Caution

Excessive input voltages can cause erroneous operation and/or component

failure. Verify that your input voltage is within the specification range.

Encoder Signals

The PCI-7342 controller offers two channels of single-ended quadrature encoder inputs. All National Instruments power drives and UMI accessories provide built-in circuitry that converts differential encoder signals to single-ended encoder signals. Each channel consists of a Phase A, Phase B, and Index input, as described in the following sections.

Encoder <1..2> Phase A/Phase B

The encoder inputs provide position and velocity feedback for absolute and relative positioning of axes in any motion system configuration.

If you do not need an encoder resource for axis control, you can use it for other functions, including position or velocity monitoring, digital potentiometer encoder inputs, or as a master encoder input for master/slave (electronic gearing) applications.

A field-programmable gate array (FPGA) implements the encoder channels (Encoder <1..2>). The encoders are high-performance with extended input frequency response and advanced features, such as high-speed position capture inputs and breakpoint outputs. Their maximum count frequency is 20 MHz.

An encoder input channel converts quadrature signals on Phase A and Phase B into 32-bit up/down counter values. Quadrature signals are generated by optical, magnetic, laser, or electronic devices that provide two signals, Phase A and Phase B, that are 90° out of phase. The leading phase, A or B, determines the direction of motion. The four transition states of the relative signal phases provide distinct pulse edges that cause count up or count down pulses in the direction determined by the leading phase.

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Chapter 5 Signal Connections

A typical encoder with a specification of N (N = number) lines per unit of measure (revolutions or linear distance) produces 4 × N quadrature counts per unit of measure. The count is the basic increment of position in National Instruments motion systems.

Note Determine quadrature counts by multiplying the encoder resolution in encoder lines

by 4. The encoder resolution is the number of encoder lines between consecutive encoder indexes (marker or Z-bit). If the encoder does not have an index output, the resolution is referred to as lines per revolution, or lines per unit of measure—inch, centimeter, millimeter, and so on.

Encoder <1..2> Index

The Index input works primarily with the Find Index function. This function uses the number of counts per revolution, or linear distance, to initiate a search move that locates the index position. When a valid Index signal transition occurs during a Find Index sequence, the position of the Index signal is captured very accurately. Use this captured position to establish a reference zero position for absolute position control or any other motion system position reference required. Figure 5-5 shows the quadrature encoder phasing diagram when using a UMI or drive accessory.

Phase A

Phase B

Index

Figure 5-5. Quadrature Encoder Phasing with a UMI or Drive Accessory

Chapter 5 Signal Connections

Figure 5-6 shows the quadrature encoder phasing diagram when interfacing directly to the PCI-7342 without using a UMI or drive accessory.

Phase A

Phase B

Index

Figure 5-6. Quadrature Encoder Phasing without a UMI or Drive Accessory

Wiring Concerns

The encoder inputs are connected to quadrature decoder/counter circuits. It is very important to minimize noise at this interface. Excessive noise on these encoder input signals may result in loss of counts or extra counts and erroneous closed-loop motion operation. Verify the encoder connections before powering up the system.

Caution Wire encoder signals and their ground connections separately from all other

connections. Wiring these signals near the motor drive/amplifier or other signals can cause positioning errors and faulty operation.

National Instruments recommends using encoders with differential line driver outputs for all applications. If the encoder cable length is longer than

3.05 m (10 ft), you must use encoders with differential line driver outputs. Shielded 24 AWG wire is the minimum recommended size for the encoder cable. For optimized noise immunity, use cables with twisted pairs and an overall shield.

All National Instruments power drives and UMI accessories provide built-in circuitry that converts differential encoder signals to single-ended encoder signals.

Caution Unshielded cable can cause noise to corrupt the encoder signals, resulting in lost

counts and reduced motion system accuracy.

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3.3 kΩ

From the External

Connector Encoder

Input Pins

Chapter 5 Signal Connections

Encoder Input Circuit

Figure 5-7 shows a simplified schematic diagram of the circuit used for the Phase A, Phase B, and Index encoder inputs. Both Phases A and B are required for proper encoder counter operation, and the signals must support the 90° phase difference within system tolerance. The encoder and Index signals are conditioned by a software-programmable digital filter inside the FPGA. The Index signal is optional but highly recommended and required for initialization functionality with the Find Index function.

Vcc

1 kΩ

74HC244

1/8 W

DGND

Figure 5-7. Encoder Input Circuit

To the Quadrature

Decoder Circuit

Trigger Inputs, Shutdown Input, and Breakpoint Outputs

The PCI-7342 controller offers additional high-performance features in the encoder FPGA. The encoder channels have high-speed position capture trigger inputs and breakpoint outputs. These signals are useful for high-speed synchronization of motion with actuators, sensors, and other parts of the complete motion system:

• Trigger Input <1..2>—When enabled, an active transition on a

high-speed position capture input causes instantaneous position capture (<100 ns latency) of the corresponding encoder count value. You can use this high-speed position capture functionality for applications ranging from simple position tagging of sensor data to complex camming systems with advance/retard positioning and registration.

The polarity of the trigger input is programmable in software as active-low (inverting) or active-high (non-inverting), rising or falling edge. You can also use a trigger input as a latching general-purpose digital input by simply ignoring the captured position.

• Shutdown Input—When enabled in software, the shutdown input

signal can be used to kill all motion by asserting the controller inhibits, setting the analog outputs to 0 V, and stopping any stepper pulse

Chapter 5 Signal Connections

generation. To activate shutdown, the signal must transition from a low to high state (rising edge). Shutdown occurs when a rising edge is detected on the shutdown line.

• Breakpoint Output <1..2>—You can program a breakpoint output to

transition when the associated encoder value equals the breakpoint position. You can use a breakpoint output to directly control actuators or as a trigger to synchronize data acquisition or other functions in the motion control system.

You can program breakpoints as either absolute, modulo, or relative position. You can preset breakpoint outputs to a known state so that when the breakpoint occurs the transition is low to high, high to low, or toggled.

Open-collector TTL buffers drive the breakpoint outputs. These buffers feature 64 mA sink current capability and built-in 3.3 kΩ pull-up resistors to +5 V.

You can directly set and reset breakpoint outputs to use as general-purpose digital outputs.

Wiring Concerns

Caution Keep trigger input, shutdown input, and breakpoint output signals and their

ground connections wired separately from the motor driver/amplifier signal and encoder signal connections. Wiring these signals near each other can cause faulty operation. Excessive input voltages can cause erroneous operation and/or component failure.

Trigger Input, Shutdown Input, and Breakpoint Output Circuits

Figures 5-8, 5-9, and 5-10 show a simplified schematic diagram of the circuits trigger inputs, shutdown inputs, and breakpoint outputs use for signal buffering.

Vcc

3.3 kΩ

From the External

Connector

Trigger Pins

1 kΩ

1/8 W

DGND

Figure 5-8. Trigger Input Circuit

74HC244

To the Trigger

Circuits

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3.3 kΩ

From the External

Connector

Shutdown Pin

To the External

Connector Step,

Direction, or Inhibit Pins

Figure 5-10. Breakpoint Output Circuit

Chapter 5 Signal Connections

Vcc

74HC244

1 kΩ

1/8 W

DGND

Figure 5-9. Shutdown Input Circuit

Vcc

3.3 kΩ

74AS760

To the

Shutdown

Circuits

From the

Step, Direction,

or Inhibit Circuits

Analog Inputs

The PCI-7342 controller has the following ADC input signals:

• Analog Input <1..2>—The PCI-7342 controller includes an

8-channel multiplexed, 12-bit ADC capable of measuring ±10 V, ±5 V, 0–10 V, and 0–5 V inputs. ADC channels 1 and 2 are brought out externally on the 68-pin motion I/O connector. ADC channels 5 through 8 connect internally, as shown in Table 5-2. You can use these signals for ADC testing.

Table 5-2. Internal ADC Channels

ADC Input Signal

3 Unavailable

4 Unavailable

5 Filtered +5 V

6 Floating (NC)

7 Analog Reference (7.5 V)

8 Analog Input Ground

Chapter 5 Signal Connections

You can configure each ADC channel for motion feedback, simple A/D conversion, or both.

You can use the Read ADC function to read the digital value of analog voltage on any of the eight ADC channels on the controller. Table 5-3 shows the range of values read back and the voltage resolution for each setting. The voltage resolution is in volts per least significant bit (V/LSB).

Table 5-3. Analog Input Voltage Ranges

Input Range Binary Values Resolution

±10 V –2,048 to 2,047 0.0049 V/LSB

±5 V –2,048 to 2,047 0.0024 V/LSB

0–10 V 0 to 4,095 0.0024 V/LSB

0–5V 0 to 4,095 0.0012 V/LSB

As indicated in Figure 5-3, when configured as analog feedback, an analog sensor acts like a limited range absolute position device with a full-scale position range. You can map any ADC channel as feedback to any axis.

You can enable and disable individual ADC channels in software. Disable unused ADC channels for the highest multiplexer scan rate performance. Properly enabled, the scan rate is high enough to support analog feedback at the highest PID sample rate.

• Analog Reference—For convenience, 7.5 V (nominal) analog

reference voltage is available. You can use this output as a low-current supply to sensors that require a stable reference.

• Analog Input Ground—This separate return connection is available

to help keep digital noise out of the analog input. Use this reference ground connection and not Digital Ground (digital I/O reference) or Analog Output Ground as the reference for the analog inputs.

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Wiring Concerns

For proper use of each ADC input channel, connect the analog signal to be measured to the channel input, and connect its ground reference to the Analog Input Ground.

Note The analog reference output is an output signal only and must not connect to an

external reference voltage. Connect the common of the external reference to the Analog Input Ground pin for proper A/D reference and improved voltage measurement.

Other Motion I/O Connection

The PCI-7342 controller provides the following other motion I/O connection:

• Host +5 V—This signal is the internal +5 V supply of the host

computer. The typical uses of this signal are to detect when the host computer is powered on and to shut down external motion system components when the host computer is turned off or disconnected from the motion accessory.

Caution The host +5 V signal is limited to <100 mA. Do not use this signal to power any

external devices, except those intended in the host bus monitor circuits on the UMI and drive products.

Chapter 5 Signal Connections

Digital I/O Connector

All the general-purpose digital I/O lines are available on a separate 68-pin digital I/O connector. Figure 5-11 shows the pin assignments for this connector.

+5 V

PCLK Reserved Reserved

PWM1 Reserved Reserved Reserved

PWM2

Port 1:bit 0

Digital Ground

Port 1:bit 3 Port 1:bit 4

Digital Ground

Port 1:bit 7 Port 2:bit 0

Port 2:bit 1 Digital Ground Digital Ground Digital Ground

Port 2:bit 6

Port 2:bit 7

Port 3:bit 0 Digital Ground

Port 3:bit 3

Port 3:bit 4 Digital Ground

Port 3:bit 7

Port 4:bit 0 Digital Ground

Port 4:bit 3

Port 4:bit 4 Digital Ground

Port 4:bit 7

10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

1 2 3 4 5 6 7 8 9

Digital Ground

DPull

Digital Ground

Reserved

Digital Ground

Port 1:bit 1

Port 1:bit 2

Digital Ground

Port 1:bit 5

Port 1:bit 6

Digital Ground

Port 2:bit 2

Port 2:bit 3

Port 2:bit 4

Port 2:bit 5

Digital Ground

Port 3:bit 1

Port 3:bit 2

Digital Ground

Port 3:bit 5

Port 3:bit 6

Digital Ground

Port 4:bit 1

Port 4:bit 2

Digital Ground

Port 4:bit 5

Port 4:bit 6

Digital Ground

Figure 5-11. 68-Pin Digital I/O Connector Pin Assignments

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PWM Features

Chapter 5 Signal Connections

The 32-bit digital I/O port is configured in hardware as four 8-bit digital I/O ports. The bits in a port are typically controlled and read with byte-wide bitmapped commands.

All digital I/O lines have programmable direction and polarity. Each output circuit can sink and source 24 mA.

The DPull pin controls the state of the input pins at power-up. Connecting DPull to +5 V or leaving it unconnected configures all pins in all ports for 100 kΩ pull-ups. Connecting DPull to ground configures the ports for 100 kΩ pull-downs.

The PCI-7342 controller provides two pulse-width modulation (PWM) outputs on the digital I/O connector. The PWM outputs generate periodic waveforms whose period and duty cycles can be independently controlled through software commands. PWM is a digital representation of an analog value, because the duty cycle is directly proportional to the desired output value. The typical use of PWM outputs is to transmit an analog value through an optocoupler. A simple lowpass filter turns a PWM signal back into its corresponding analog value. If desired, you can use the PCLK input instead of the internal source as the clock for the PWM generators.

Note These signals are configured in software and are in no way associated with the

PID servo control loop. Refer to your NI-Motion Software Reference Manual for more information about PWM signals.

RTSI Connector

The RTSI bus on PCI-7342 is connected with a ribbon cable to National Instruments DAQ and IMAQ PCI devices that have RTSI capability.

RTSI Signal Considerations

The PCI-7342 motion controller allows you to use the RTSI signals as sources for trigger inputs, or as destinations for breakpoint outputs and encoder signals. The RTSI bus can also serve as a generic digital I/O port. Breakpoint outputs are output-only signals that generate an active-high pulse of 90 to 120 ns duration, as shown in Figure 5-12.

Chapter 5 Signal Connections

tw = 90 to 120 ns

Figure 5-12. Breakpoint Across RTSI

Encoder and Index signals are output-only signals across RTSI that are the digitally-filtered versions of the raw signals coming into the controller. If you are using the RTSI bus for trigger inputs or generic digital I/O, all signals are passed through unaltered.

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Specifications

This appendix lists the hardware and software performance specifications for the PCI-7342 controller. Hardware specifications are typical at 25 °C, unless otherwise stated.

Servo Performance

PID update rate range............................. 62.5 to 500 µs/sample

Maximum PID update rate.............. 62.5 µs/axis

2-axis PID update rate..................... 125 µs total

Trajectory update rate ............................ Same as PID update rate

Multi-axis synchronization .................... < 1 update sample

Position accuracy

Encoder feedback............................ ±1 quadrature count

Analog feedback ............................. ±1 LSB

Double-buffered trajectory parameters

Absolute position range .................. ±2

Maximum relative move size.......... ±2

Velocity range.................................1 to ±20,000,000 counts/s

RPM range ...................................... 10

Acceleration/deceleration ............... 4,000 to 128,000,000 counts/s

RPS/s range..................................... 10–1 to 108 revolutions/s

S-Curve time range ......................... 1 to 32,767 samples

Following error range ..................... 0 to 32,767 counts

Gear ratio ........................................ ±32,767:1 to 1:32,767

Servo control loop modes ......................PID, PIVff, S-Curve, Dual Loop

PID (Kp, Ki, and Kd) gains ............ 0 to 32,767

Integration limit (Ilim) .................... 0 to 32,767

counts

–5

to 106 revolutions/minute

Appendix A Specifications

Servo command analog outputs

Stepper Performance

Trajectory update rate range ...................62.5 to 500 µs/sample

Multi-axis synchronization .....................< 1 update sample

Derivative sample period (Td).........1 to 63 samples

Feedforward (Aff and Vff) gains.....0 to 32,767

Velocity feedback (Kv) gain ...........0 to 32,767

Voltage range...................................±10 V

Resolution........................................16 bits (0.000305 V/LSB)

Programmable torque (velocity) limits

Positive limit ............................±10 V (–32,768 to +32,767)

Negative limit...........................±10 V (–32,768 to +32,767)

Programmable offset .......................±10 V (–32,768 to +32,767)

Maximum update rate......................62.5 µs/axis

2-axis update rate.............................125 µs total

Position accuracy

Open-loop stepper ...........................1 full, half, or microstep

Encoder feedback ............................±1 quadrature count

Analog feedback..............................±1 LSB

Double-buffered trajectory parameters

Position range ..................................±2

Maximum relative move size ..........±2

steps

Velocity range .................................1 to 4,000,000 steps/s

RPM range.......................................10

–5

to 106 revolutions/minute

Acceleration/deceleration ................4,000 to 128,000,000 steps/s

RPS/s range .....................................10–1 to 108 revolutions/s

S-curve time range...........................1 to 32,767 samples

Following error range......................0 to 32,767 counts

Gear ratio .........................................±32,767:1 to 1:32,767

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System Safety

Appendix A Specifications

Stepper outputs

Maximum pulse rate ....................... 4 MHz (full, half, and microstep)

Minimum pulse width..................... 120 ns at 4 MHz

Step output mode ............................ Step and direction or CW/CCW

Voltage range.................................. 0 to 5 V

Output low voltage .................. < 0.6 V at 64 mA sink

Output high voltage ................. Open collector with built-in

3.3 kΩ pull-up to +5 V

Polarity............................................ Programmable, active-high

or active-low

Watchdog timer function ....................... Resets board to startup state

Watchdog timeout........................... 63 ms

Shutdown input

Voltage range.................................. 0 to 12 V

Input low voltage .....................0.8 V

Input high voltage .................... 2 V

Polarity..................................... Rising edge

Control ............................................Disable all axes and

command outputs

Motion I/O

Encoder inputs........................................Quadrature, incremental,

single-ended

Maximum count rate ....................... 20 MHz

Minimum pulse width..................... Programmable; depends

on digital filter settings

Voltage range.................................. 0 to 12 V

Input low voltage .....................0.8 V

Input high voltage .................... 2 V

Minimum index pulse width ........... 60 ns

Appendix A Specifications

Forward, reverse, and home inputs

Number of inputs.............................6 (3 per axis)

Voltage range...................................0 to 12 V

Input low voltage......................0.8 V

Input high voltage.....................2 V

Polarity ............................................Programmable, active-high

or active-low

Minimum pulse width......................1 ms

Control.............................................Individual enable/disable, stop on

input, prevent motion, Find Home

Trigger inputs

Number of inputs.............................2

Voltage range...................................0 to 12 V

Input low voltage......................0.8 V

Input high voltage.....................2 V

Polarity ............................................Programmable, active-high

or active-low

Minimum pulse width......................83 ns

Capture latency................................<100 ns

Capture accuracy .............................1 count

Breakpoint outputs

Number of outputs...........................2

Voltage range...................................0 to 5 V

Output low voltage ...................< 0.6 V at 64 mA sink

Output high voltage..................Open collector with built-in

3.3 kΩ pull-up to +5 V

Polarity ............................................Programmable, active-high

or active-low

Inhibit/enable output

Number of outputs...........................2 (1 per axis)

Voltage range...................................0 to 5 V

Output low voltage ...................<0.6 V at 64 mA sink

Output high voltage..................Open collector with built-in

3.3 kΩ pull-up to +5 V

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Appendix A Specifications

Polarity............................................ Programmable, active-high

or active-low

Control ............................................MustOn/MustOff or automatic

when axis off

Analog inputs

Number of inputs ............................ 2, multiplexed

Voltage range (programmable)....... ±10 V, ±5 V, 0–10 V, 0–5V

Input resistance ............................... 10 kΩ minimum

Resolution ....................................... 12 bits

Analog reference output.................. 7.5 V (nominal)

Reference drift ................................ ±30 ppm/°C typical

INL.................................................. ±1 LSB

DNL ................................................ ±1 LSB

Offset error

Unipolar ................................... ±5 LSB

Bipolar ..................................... ±10 LSB

Gain error

Unipolar ................................... ±10 LSB

Bipolar ..................................... ±10 LSB

Conversion time.............................. 6 µs

Multiplexor scan rate ...................... 50 µs/enabled channel

Analog outputs

Number of outputs .......................... 2

Voltage range.................................. ±10 V

Output current ................................. ±5 mA

Resolution ....................................... 16 bits (0.000305 V/LSB)

Gain accuracy ................................. ±3%

Drift.................................................100 ppm/°C typical

Appendix A Specifications

Digital I/O

Ports ........................................................4, 8-bit ports

Line direction...................................Individual bit programmable

Inputs

Voltage range...................................0 to 5 V

Input low voltage......................0.8 V

Input high voltage.....................2.0 V

Polarity ............................................Programmable, active-high

or active-low

Outputs

Voltage range...................................0 to 5 V

Output low voltage ...................< 0.45 V at 24 mA sink

Output high voltage..................>2.4 V at 24 mA source

Polarity ............................................Programmable, active-high

or active-low

PWM outputs

Number of PWM outputs .........2

Maximum PWM frequency......32 kHz

Resolution.................................8-bit

Duty cycle range.......................0 to (255/256)%

Clock sources ...........................Internal or external

RTSI

Trigger Lines ..........................................7

Maximum Power Requirements

+5 V (±3%).............................................1 A

+12 V (±3%)...........................................30 mA

–12 V (±3%) ...........................................30 mA

Power consumption ................................5.7 W

NI PCI-7342 Hardware User Manual A-6 ni.com

Physical

Dimensions (Not Including Connectors)

PCI-7342 ................................................ 17.5 × 9.9 cm (6.9 × 3.9 in.)

Connectors

Motion I/O connector............................. 68-pin female high-density

32-bit digital I/O connector.................... 68-pin female high-density

Weight

PCI-7342 ................................................ 113 g (4 oz)

Maximum Working Voltage

Channel-to-earth..................................... 12 V, Installation CAT I (signal

Appendix A Specifications

VHDCI type

voltage plus common-mode voltage)

Channel-to-channel ................................22 V, Installation CAT I (signal

voltage plus common-mode voltage)

Caution These values represent the maximum allowable voltage between any accessible

signals on the controller. To determine the acceptable voltage range for a particular signal, please refer to the individual signal specifications.

Environment

Operating temperature............................ 0 to 55 °C

Storage temperature ............................... –20 to 70 °C

Humidity ................................................ 10 to 90% RH, noncondensing

Maximum altitude .................................. 2000 m

Pollution Degree .................................... 2

Appendix A Specifications

Safety

This device meets the following electrical equipment safety standard requirements for measurement, control, and laboratory use:

• EN 61010-1, IEC 61010-1

• UL 3111-1

• CAN/CSA C22.2 no. 1010.1

Electromagnetic Compatibility

EMC/EMI ...............................................CE, C-Tick, and FCC Part 15

Electromagnetic emissions .....................EN 55011 Class A at 10 meters

Electromagnetic immunity .....................Evaluated to EN 61326:1997/

Note For full EMC compliance, you must operate this device with shielded cabling.

In addition, all covers and filler panels must be installed. Refer to the Declaration of Conformity (DoC) for this product for any additional regulatory compliance information. To obtain the DoC for this product, click Declaration of Conformity at

ni.com/hardref.nsf/. This Web site lists the DoCs by product family. Select the

appropriate product family, followed by your product, and a link to the DoC appears in Adobe Acrobat format. Click the Acrobat icon to download or read the DoC.

(Class A) Compliant

FCC Part 15A above 1 GHz

A1:1998, Table 1

NI PCI-7342 Hardware User Manual A-8 ni.com

Cable Connector Descriptions

This appendix describes the connector pinout for the cables that connect to your PCI-7342 controller.

Figures B-1 and B-2 show the pin assignments for the stepper and servo 50-pin motion connectors. These connectors are available when you use the SH68-C68-S shielded cable assembly and the 68M-50F step/servo bulkhead cable adapter.

Axis 1 Dir (CCW)

Digital Ground Digital Ground

Axis 1 Home Switch

Trigger/Breakpoint 1

Axis 1 Inhibit

Axis 2 Dir (CCW)

Digital Ground

Axis 2 Home Switch

Trigger/Breakpoint 2

Axis 2 Inhibit

Digital Ground

NC NC

Digital Ground

910

11 12

13 14

15 16

17 18

19 20

21 22

23 24

25 26

27 28

29 30

31 32

33 34

35 36

37 38

39 40

41 42

43 44

45 46

47 48

49 50

Axis 1 Step (CW) Axis 1 Encoder Phase A

Axis 1 Encoder Phase B

Axis 1 Encoder Index

Axis 1 Forward Limit Switch

Axis 1 Reverse Limit Switch

Axis 2 Step (CW)

Axis 2 Encoder Phase A

Axis 2 Encoder Phase B

Axis 2 Encoder Index Axis 2 Forward Limit Switch

Axis 2 Reverse Limit Switch

NC NC

Host +5 V

Figure B-1. 50-Pin Stepper Connector Pin Assignment

Caution

Do not connect NC (not connected) signals. Connecting these signals could cause

permanent damage to your motion controller.

Appendix B Cable Connector Descriptions

Analog Output Ground

Digital Ground Digital Ground

Axis 1 Home Switch

Trigger/Breakpoint 1

Axis 1 Inhibit

Analog Output Ground

Digital Ground

Axis 2 Home Switch

Trigger/Breakpoint 2

Axis 2 Inhibit

Analog Output Ground

Digital Ground

NC NC

Digital Ground

910

11 12

13 14

15 16

17 18

19 20

21 22

23 24

25 26

27 28

29 30

31 32

33 34

35 36

37 38

39 40

41 42

43 44

45 46

47 48

49 50

Analog Output 1 Axis 1 Encoder Phase A

Axis 1 Encoder Phase B

Axis 1 Encoder Index

Axis 1 Forward Limit Switch

Axis 1 Reverse Limit Switch

Analog Output 2

Axis 2 Encoder Phase A

Axis 2 Encoder Phase B

Axis 2 Encoder Index Axis 2 Forward Limit Switch

Axis 2 Reverse Limit Switch

NC NC

Host +5 V

Figure B-2. 50-Pin Servo Connector Pin Assignment

Caution

Do not connect NC (not connected) signals. Connecting these signals could cause

permanent damage to your motion controller.

NI PCI-7342 Hardware User Manual B-2 ni.com

Technical Support and Professional Services

Visit the following sections of the National Instruments Web site at

ni.com for technical support and professional services:

• Support—Online technical support resources include the following:

– Self-Help Resources—For immediate answers and solutions,

visit our extensive library of technical support resources available in English, Japanese, and Spanish at resources are available for most products at no cost to registered users and include software drivers and updates, a KnowledgeBase, product manuals, step-by-step troubleshooting wizards, hardware schematics and conformity documentation, example code, tutorials and application notes, instrument drivers, discussion forums, a measurement glossary, and so on.

– Assisted Support Options—Contact NI engineers and other

measurement and automation professionals by visiting

ni.com/ask. Our online system helps you define your question

and connects you to the experts by phone, discussion forum, or email.

• Training—Vis i t

interactive CDs. You also can register for instructor-led, hands-on courses at locations around the world.

• System Integration—If you have time constraints, limited in-house

technical resources, or other project challenges, NI Alliance Program members can help. To learn more, call your local NI office or visit

ni.com/alliance.

ni.com/custed for self-paced tutorials, videos, and

ni.com/support. These

If you searched your local office or NI corporate headquarters. Phone numbers for our worldwide offices are listed at the front of this manual. You also can visit the Worldwide Offices section of office Web sites, which provide up-to-date contact information, support phone numbers, email addresses, and current events.

ni.com and could not find the answers you need, contact

ni.com/niglobal to access the branch

Glossary

Prefix Meanings Value

p- pico- 10

n- nano- 10

µ- micro- 10

m- milli- 10

c- centi 10

k- kilo- 10

M- mega- 10

Numbers/Symbols

° degrees

/per

–12

–9

– 6

–3

–

% percent

± plus or minus

+ positive of, or plus

– negative of, or minus

Ω ohm

+5 V +5 VDC source signal

1394 A high-speed external bus that implements the IEEE 1394 serial bus

protocol

Glossary

A amperes

A/D analog-to-digital

absolute mode treat the target position loaded as position relative to zero (0) while making

absolute position position relative to zero

acceleration/ deceleration

active-high a signal is active when its value goes high (1)

active-low a signal is active when its value goes low (0)

ADC analog-to-digital converter

address character code that identifies a specific location (or series of locations)

amplifier the drive that delivers power to operate the motor in response to low level

a move

a measurement of the change in velocity as a function of time. Acceleration and deceleration describes the period when velocity is changing from one value to another.

in memory or on a host PC bus system

control signals. In general, the amplifier is designed to operate with a particular motor type—you cannot use a stepper drive to operate a DC brush motor, for instance.

Analog Input <1..2> 12-bit analog ADC input

Analog Output <1..2> DAC voltage output

API application programming interface

axis unit that controls a motor or any similar motion or control device

Axis <1..2> Inhibit

Axis <1..2> Forward Limit Input

NI PCI-7342 Hardware User Manual G-2 ni.com

axis 1 through 2 inhibit output

axis 1 through 2 forward/clockwise limit switch

Glossary

Axis <1..2> Home Input

Axis <1..2> Reverse Limit Input

axis 1 through 2 home input

axis 1 through 2 reverse/counter-clockwise limit input

bbit—one binary digit, either 0 or 1

base address memory address that serves as the starting address for programmable or

I/O bus registers. All other addresses are located by adding to the base address.

binary a number system with a base of 2

buffer temporary storage for acquired or generated data (software)

bus the group of conductors that interconnect individual circuitry in a computer.

Typically, a bus is the expansion vehicle to which I/O or other devices are connected.

byte eight related bits of data, an eight-bit binary number. Also used to denote

the amount of memory required to store one byte of data.

CCW counter-clockwise—implies direction of rotation of the motor

closed-loop a motion system that uses a feedback device to provide position and

velocity data for status reporting and accurately controlling position and velocity

common reference signal for digital I/O

CPU central processing unit

crosstalk an unwanted signal on one channel due to an input on a different channel

CSR Communications Status Register

CW clockwise—implies direction of motor rotation

Glossary

DAC Digital-to-Analog Converter

DC direct current

dedicated assigned to a particular function

DGND digital ground signal

digital I/O port a group of digital input/output signals

DIP dual inline package

DLL dynamic link library—provides the API for the motion control boards

drivers software that communicates commands to control a specific motion control

board

DSP Digital Signal Processor

encoder device that translates mechanical motion into electrical signals; used for

monitoring position or velocity in a closed-loop system

encoder resolution the number of encoder lines between consecutive encoder indexes (marker

or Z-bit). If the encoder does not have an index output, the encoder resolution can be referred to as lines per revolution.

f farad

FIFO First-In, First-Out

filtering a type of signal conditioning that filters unwanted signals from the signal

being measured

filter parameters indicates the control loop parameter gains (PID gains) for a given axis

flash ROM a type of electrically reprogrammable read-only memory

NI PCI-7342 Hardware User Manual G-4 ni.com

Glossary

following error trip point

FPGA Field Programmable Gate Array

freewheel the condition of a motor when power is de-energized and the motor shaft is

full-step full-step mode of a stepper motor—for a two phase motor this is done by

the difference between the instantaneous commanded trajectory position and the feedback position

free to turn with only frictional forces to impede it

energizing both windings or phases simultaneously

Gnd ground

GND ground

half-step mode of a stepper motor—for a two phase motor this is done by alternately

energizing two windings and then only one. In half step mode, alternate steps are strong and weak but there is significant improvement in low-speed smoothness over the full-step mode.

hex hexadecimal

home switch (input) A physical position determined by the mechanical system or designer as the

reference location for system initialization. Frequently, the home position is also regarded as the zero position in an absolute position frame of reference.

host computer computer into which the motion control board is plugged

I/O input/output—the transfer of data to and from a computer system involving

communications channels, operator interface devices, and/or motion control interfaces

ID identification

in. inches

Glossary

index marker between consecutive encoder revolutions

inverting the polarity of a switch (limit switch, home switch, and so on) in active

state. If these switches are active-low they are said to have inverting polarity.

IRQ interrupt request

kkilo—the standard metric prefix for 1,000, or 103, used with units of

measure such as volts, hertz, and meters

Kkilo—the prefix for 1,024, or 2

computer memory

, used with B in quantifying data or

LIFO Last-In, First-Out

limit switch/ end-of-travel position (input)

sensors that alert the control electronics that physical end of travel is being approached and that the motion should stop

m meters

MCS Move Complete Status

microstep The proportional control of energy in the coils of a Stepper Motor that

allow the motor to move to or stop at locations other than the fixed magnetic/mechanical pole positions determined by the motor specifications. This capability facilitates the subdivision of full mechanical steps on a stepper motor into finer microstep locations that greatly smooth motor running operation and increase the resolution or number of discrete positions that a stepper motor can attain in each revolution.

modulo position treat the position as within the range of total quadrature counts per

revolution for an axis

NI PCI-7342 Hardware User Manual G-6 ni.com

Glossary

noise an undesirable electrical signal—noise comes from external sources such

as the AC power line, motors, generators, transformers, fluorescent lights, soldering irons, CRT displays, computers, electrical storms, welders, radio transmitters, and internal sources such as semiconductors, resistors, and capacitors. Noise corrupts signals you are trying to send or receive.

noninverting the polarity of a switch (limit switch, home switch, etc.) in active state. If

these switches are active-high, they are said to have non-inverting polarity.

open-loop refers to a motion control system where no external sensors (feedback

devices) are used to provide position or velocity correction signals

open collector refers to a transistor current that can only sink current, allowing multiple

devices to communicate bidirectionally on a single line

PCI Peripheral Component Interconnect—a high-performance expansion bus

architecture originally developed by Intel to replace ISA and EISA. It is achieving widespread acceptance as a standard for PCs and workstations; it offers a theoretical maximum transfer rate of 132 MB/s.

PID proportional-integral-derivative control loop

PIVff proportional-integral-velocity feedforward

port (1) a communications connection on a computer or a remote controller

(2) a digital port, consisting eight lines of digital input and/or output

position breakpoint position breakpoint for an encoder can be set in absolute or relative

quadrature counts. When the encoder reaches a position breakpoint, the associated breakpoint output immediately transitions.

power cycling turning the host computer off and then back on, which causes a reset of

the motion control board

Glossary

PWM Pulse Width Modulation—a method of controlling the average current in a

motor phase winding by varying the on-time (duty cycle) of transistor switches

PXI PCI eXtensions for Instrumentation

quadrature counts the encoder line resolution times four

RAM random-access memory

relative breakpoint sets the position breakpoint for an encoder in relative quadrature counts

relative position destination or target position for motion specified with respect to the

current location regardless of its value

relative position mode position relative to current position

ribbon cable a flat cable in which the conductors are side by side

RPM revolutions per minute—units for velocity

RPSPS or RPS/S revolutions per second squared—units for acceleration and deceleration

RTR Ready to Receive

s seconds

servo specifies an axis that controls a servo motor

stepper specifies an axis that controls a stepper motor

stepper <1..2> Dir (CCW)

stepper <1..2> Step (CW)

NI PCI-7342 Hardware User Manual G-8 ni.com

direction output or counter-clockwise direction control

stepper pulse output or clockwise direction control

toggle changing state from high to low, back to high, and so on

torque force tending to produce rotation

trapezoidal profile a typical motion trajectory, where a motor accelerates up to the

programmed velocity using the programmed acceleration, traverses at the programmed velocity, then decelerates at the programmed acceleration to the target position

trigger any event that causes or starts some form of data capture

TTL transistor-transistor logic

Vvolts

Glossary

velocity mode move the axis continuously at the specified velocity

positive voltage supply

watchdog a timer task that shuts down (resets) the motion control board if any serious

error occurs

word the standard number of bits that a processor or memory manipulates at one

time, typically 8-, 16-, or 32-bit

Index

Numbers

+5 V signal. See Host +5 V signal

analog feedback, 4-2 Analog Input <1..2> signal

analog input voltage ranges (table), 5-14 description (table), 5-4 internal ADC channels (table), 5-13 purpose and use, 5-13 to 5-14

Analog Input Ground signal

description (table), 5-4 purpose and use, 5-14

analog inputs

signal descriptions, 5-13 to 5-15 wiring concerns, 5-15

Analog Output <1..2> signal

description (table), 5-4 purpose and use, 5-5

Analog Output Ground signal

description (table), 5-4 purpose and use, 5-5

Analog Reference signal

description (table), 5-4 purpose and use, 5-14

axes, 4-3 to 4-4

National Instruments NI PCI-7342 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

NI PCI-7342 Hardware User Manual

Support

Worldwide Technical Support and Product Information

National Instruments Corporate Headquarters

Worldwide Offices

Important Information

Warranty

Copyright

Trademarks

WARNING REGARDING USE OF NATIONAL INSTRUMENTS PRODUCTS

Compliance

Contents

About This Manual

Conventions

Related Documentation

About the NI PCI-7342

Hardware

RTSI

PCI-7342 Features

Servo and Stepper Fundamentals

Getting Started

Software Programming Choices

National Instruments Application Software

Optional Equipment

Motion I/O Connections

Software Installation

Controller Configuration

Unpacking

Safety Information

Hardware Installation

Figure 2-1. Sample Installation

Figure 3-1. PCI-7342 Parts Locator Diagram

User Connectors

Dual Processor Architecture

Embedded Real-Time Operating System (RTOS)

Trajectory Generators

Analog Feedback

Flash Memory

Axes and Motion Resources

Axes

Figure 4-1. Servo Axis Resources

Figure 4-2. Stepper Axis Resources

Motion Resources

Host Communications

Figure 5-1. PCI-7342 Motion Controller Connectors

Motion I/O Connector

Figure 5-2. 68-Pin Motion I/O Connector Pin Assignment

Table 5-1. Motion I/O Signal Connections

Motion Axis Signals

Figure 5-3. Step, Direction, and Inhibit Output

Limit and Home Inputs

Wiring Concerns

Limit and Home Input Circuit

Figure 5-4. Limit and Home Input Circuit

Encoder Signals

Encoder <1..2> Phase A/Phase B

Encoder <1..2> Index

Figure 5-5. Quadrature Encoder Phasing with a UMI or Drive Accessory

Figure 5-6. Quadrature Encoder Phasing without a UMI or Drive Accessory

Wiring Concerns

Encoder Input Circuit

Figure 5-7. Encoder Input Circuit

Trigger Inputs, Shutdown Input, and Breakpoint Outputs

Wiring Concerns

Trigger Input, Shutdown Input, and Breakpoint Output Circuits

Figure 5-8. Trigger Input Circuit

Figure 5-10. Breakpoint Output Circuit

Figure 5-9. Shutdown Input Circuit

Analog Inputs

Table 5-2. Internal ADC Channels

Table 5-3. Analog Input Voltage Ranges

Wiring Concerns

Other Motion I/O Connection

Digital I/O Connector

Figure 5-11. 68-Pin Digital I/O Connector Pin Assignments

PWM Features