NI 9757 User Manual - National Instruments
Contents
1. lal aa OR s aaeh Ooo og Oo a oOo Oo on The NI O2 Sensor Kit part number 782083 01 includes the following components e Bosch USA LSU 4 9 17025 Sensor e 10 ft 6 conductor cable with a Bosch USA LSU 4 9 mating connector on one end and unterminated wires on the opposite end e Sensor bung NI 9757 User Manual National Instruments 5 Note Custom cables must be 6 conductor and 0 65 mm in diameter 22 AWG with stranded tinned copper wires and proper shielding Adding the Sensor Cable to the Module Connector The color coding of the Bosch USA LSU 4 x wide band sensor wires differs from the available color coding in the 10 ft 6 conductor cable included in the NI O2 Sensor Kit Tables 2 and 3 show the proper connection between the LSU 4 2 and LSU 4 9 sensor connectors respectively to the intermediate cable and to the NI 9757 The NI 9757 module housing label provides wire color information next to the DB 37 pin names according to the standard Bosch USA LSU 4 x sensor wire coloring not according to the intermediate wiring Note Sensor connector pin 2 does not actually have a green wire from the sensor to the sensor connector A calibration resistor feeds this connector pin within the sensor connector hous2. 2015 National Instruments All rights reserved 375007A 01 Jan15
3. elsewhere on the cable noticeably impairs its effectiveness Determine the clamp on ferrite beads to install based on your application Use the following ferrites or other similar ferrites e Power cable Laird 28A0592 0A2 2 total e Signal cable Wurth Electronics 7427154 2 total Refer to the NI Trademarks and Logo Guidelines at ni com trademarks for more information on National Instruments trademarks Other product and company names mentioned herein are trademarks or trade names of their respective companies For patents covering National Instruments products technology refer to the appropriate location Help Patents in your software the patents txt file on your media or the National Instruments Patents Notice at ni com patents You can find information about end user license agreements EULAs and third party legal notices in the readme file for your NI product Refer to the Export Compliance Information at ni com legal export compliance for the National Instruments global trade compliance policy and how to obtain relevant HTS codes ECCNs and other import export data NI MAKES NO EXPRESS OR IMPLIED WARRANTIES AS TO THE ACCURACY OF THE INFORMATION CONTAINED HEREIN AND SHALL NOT BE LIABLE FOR ANY ERRORS U S Government Customers The data contained in this manual was developed at private expense and is subject to the applicable limited rights and restricted data rights as set forth in FAR 52 227 14 DFAR 252 227 7014 and DFAR 252 227 7015
4. to 18 V Without sensors connected and enabled the NI 9757 requires up to 100 mA from the external supply The external power source must be capable of powering the sensor heaters which may require up to 12 A if all channels are in use Each sensor heater requires approximately 2 A during the first 30 seconds of operation and approximately 1 A thereafter The UEGO sensor heaters are powered and controlled directly from the NI 9757 The EGO sensor heaters are powered externally and do not require heater control by the NI 9757 The NI 9757 external power ground and CompactRIO backplane power ground are isolated and have no internal connection A Caution The external battery supply input terminals are reverse voltage polarity protected to 18 V Connecting power to the NI 9757 in reverse polarity at voltages greater than 18 V will result in damage This event is not covered by the warranty Platform Compatibility NI Powertrain Control modules require a hardware support system to function You cannot use the modules independently or interfaced with third party devices at the backplane HD15 connector NI Powertrain Control modules are compatible with the following National Instruments platforms e CompactRIO which consists of a CompactRIO controller chassis or integrated controller chassis e NI PXI which consists of any NI PXI chassis NI PXI RT controller and NI PXI 78xxR R Series FPGA card The NI Powertrain Control modules inse
5. O Sensor Connection Module NI 9757 User Manual National Instruments 7 Physical Specifications and Characteristics We 1ghitisss caisduscs soostedaecasdenstesbssdeed niiina 170 g Maximum Altitude eeseseeseeeecneeneeneenee 2000 m Maximum Ambient Temperature e 60 C Operating Humidity 0 0 ceeeeceeceecseeneeneeeee 10 to 90 RH noncondensing Pollution Degr e us 24 cecscssteeseee cbsbieeees 2 Ingress Protection ccccccecceceseeseeeeeeeeesesenee IP40 For indoor use only If you need to clean the module wipe it with a dry towel Electrical Specifications and Characteristics External Power Input Rang eserine 6to32 V Input Range for Functional VEGO Sensors oieee an a eoa 8to 16 5 V Reverse Polarity Protection c6 18 V Input Capacitance sssesseeeeseesese reeset 300 uF Inrush Current esssessesesseseseseeseseersesesse 3 A for 1 msec at 13 8 V Consumption No UEGO Sensors Enabled 1 3 W at 13 8 V 1 UEGO Sensor Enabled 15 W at 13 8 V 2 UEGO Sensors Enabled 30 W at 13 8 V Maximum Module Power Dissipation 2 UEGO Sensors Enabled eee eeeeeeeeees 1 4 W at 13 8 V Internal Analog to Digital Conversion Range 0 to 4 096 V Internal Analog to Digital Conversion RESOLUMION ear asire a ENEAS S 12 bit Internal Analog to Digital Conversion Rate 1000 samples s UEGO Sensor Analog Measurement Hardware Fil
6. USER MANUAL NI 9757 NI Powertrain Controls O2 Sensor Module Kit Rev E Contents TnthOGU Ct ON pesanta a abe eaisvd teas tasaear als RI aac ae 2 AOU EEEE AEE A ETEA EE EA EE AEE EAA EEEE AET TS 2 Phar bA E 1 E S E EEI EAA EAT S EIEE N E E E E E E 2 Powering the Module Platform Compatibility Bosch USA LSU 4 x Wide Band Oxygen Sensor Controllers Narrow Band Oxygen Sensor Inputs ccccecsessecescesesseeseeseceeceeceeceaeeaessenaecsecaecaeeseeaeeneeaeeas Physical Specifications and Characteristics ccccceccssessessessecseeseeseeseeeeeeeeeeeecesceseeaeeaseasensenes 8 Electrical Specifications and Characteristics Compliance and Certifications ccceccecceseeseesessecsecsecsecseeseesceseeseesececeececaeeseeaeeaecaecnecneenaente Qy NATIONAL p INSTRUMENTS Introduction The National Instruments 9757 offers an interface for multiple wide band and narrow band exhaust oxygen sensors Features e 2 Ch Bosch USA LSU 4 2 or LSU 4 9 wide band sensor controller Fuse protected heater control circuits serviceable e 4Ch Narrow band sensor input differential e All channel readings updated at 1 kHz e LabVIEW FPGA and LabVIEW Real Time VIs for quick integration with application Pinout Figure 1 NI 9757 Pin Assignments Hardware The NI 9757 Sensor Module Kit part number 782079 01 includes controllers for Bosch USA LSU 4 2 or LSU 4 9 wide band oxygen sensors and inputs for zirconi
7. eets the requirements of the following standards of safety for electrical equipment for measurement control and laboratory use e TEC 61010 1 EN 61010 1 e UL 61010 1 CSA 61010 1 Electromagnetic Compatibility This product meets the requirements of the following EMC standards for electrical equipment for measurement control and laboratory use e EN 61326 1 IEC 61326 1 Class A emissions Industrial immunity e EN 55011 CISPR 11 Group 1 Class A emissions e AS NZS CISPR 11 Group 1 Class A emissions NI 9757 User Manual National Instruments 9 FCC 47 CFR Part 15B Class A emissions e ICES 001 Class A emissions A Caution When operating this product use shielded cables and accessories CE Compliance C This product meets the essential requirements of applicable European Directives as follows e 2006 95 EC Low Voltage Directive safety e 2004 108 EC Electromagnetic Compatibility Directive EMC Environmental Management NI is committed to designing and manufacturing products in an environmentally responsible manner NI recognizes that eliminating certain hazardous substances from our products is beneficial to the environment and to NI customers For additional environmental information refer to the Minimize Our Environmental Impact web page at ni com environment This page contains the environmental regulations and directives with which NI complies as well as other environmental information not included i
8. ing The color code of green is the standard color for the NI 9757 module IA pin location Note The LSU 4 2 and LSU 4 9 sensors have identical signal definitions but different connector housings and pin number assignments The sensors are not interchangeable with the intermediate cable assembly Table 2 Bosch USA LSU 4 2 Sensor Connection Intermediate LSU 4 2 LSU 4 2 Module Pin Label Cable Wire Color Pin Number Wire Color UNx B Black 1 Black IAx GN Green 2 HTRx GY Brown 3 Grey HTRx W White 4 White VMx Y Blue 5 Yellow IPx R Red 6 Red Table 3 Bosch USA LSU 4 9 Sensor Connection Intermediate LSU 4 9 LSU 4 9 Module Pin Label Cable Wire Color Pin Number Wire Color UNx B Black 6 Black IAx GN Green 5 HTRx GY Brown 4 Grey HTRx W White 3 White 6 nicom NI 9757 User Manual Intermediate LSU 4 9 LSU 4 9 Module Pin Label Cable Wire Color Pin Number Wire Color VMx Y Blue 2 Yellow IPx R Red 1 Red Narrow Band Oxygen Sensor Inputs The NI 9757 provides four identical zirconium dioxide element narrow band switching Exhaust Gas Oxygen EGO sensor inputs and supports several different types of standard zirconium oxide element oxygen sensors also known as lambda sensors NI recommends that you use a 4 wire heated universal EGO sensor such as the Bosch USA 15717 EN Note This document discusses EGO sensor
9. intain a fixed voltage reference across the element The exhaust oxygen content and the air fuel mass ratio are proportional to the controlled sensor pump current The temperature of the sensor element is also critical to obtain a good exhaust oxygen measurement The NI 9757 controls the sensor element temperature at 750 C for LSU 4 2 sensors and at 780 C for LSU 4 9 sensors Use only the widely available production Bosch USA LSU 4 2 or LSU 4 9 sensors with the NI 9757 wide band sensor controllers The NTK wide band sensor is not compatible with the NI 9757 4 nicom NI9757 User Manual L Table 1 Example Bosch USA Model Numbers for LSU 4 x Sensors Sensor Bosch USA Model Number LSU 4 2 sensor 17014 LSU 4 9 sensor 17025 The NI 9757 does not support mixed UEGO sensor types If dual UEGO sensors are used they must be identical If mixed UEGO sensor types are required you must use multiple NI 9757 modules pairing one to each sensor type By default the NI 9757 is configured to use the LSU 4 9 sensor Figure 2 illustrates the top of the circuit card assembly inside the module housing The switch position for the associated sensor type is labeled next to the switch Caution Do not attempt to open the module housing or change the switch selection while the module is inserted in a chassis or externally connected to sensors or power Figure 2 ia tt O AAA
10. n this document Waste Electrical and Electronic Equipment WEEE K EU Customers At the end of the product life cycle all products must be sent to dr a WEEE recycling center For more information about WEEE recycling centers National Instruments WEFE initiatives and compliance with WEEE Directive 2002 96 EC on Waste and Electronic Equipment visit ni com environment weee BT Re mis Riehl EHE A ChE ROHS OO RAZA National Instruments 46t H EFIE A m P REEN SE ROHS XF National Instruments FE ROHS ARIE WK ni com environment rohs_china For information about China RoHS compliance go to ni com environment rohs_china Battery Replacement and Disposal Battery Directive This device contains a long life coin cell battery If you need to replace it use the Return Material Authorization RMA process or contact an authorized National Instruments service representative For more information about compliance with the EU Battery Directives 2006 66 EC about Batteries and Accumulators and Waste Batteries and Accumulators visit ni com environment batterydirective Ca he Pb Ferrite Requirement for EMC Compliance Install a clamp on ferrite bead onto the power supply cable and the signal cable Power to the module must be off when adding ferrites Ferrites must be connected to the power cable and to 10 nicom NI9757 User Manual the signal cable as close to the module as possible Placing the ferrite
11. rt into an NI R Series NI 9757 User Manual National Instruments 3 expansion chassis Connect an NI R Series expansion chassis to the NI PXI FPGA card using a SHC68 68 RDIO cable Note NI Powertrain Control modules are not compatible with the National Instruments CompactDAQ chassis You can use NI Powertrain Control modules with NI cRIO 91 1x NI cRIO 907x and NIR Series Expansion systems under the following conditions e Leave one empty chassis slot between NI Powertrain Control modules and other NI modules e Maintain an ambient system operating temperature of 0 C to 45 C Note Typical specifications of National Instruments modules might not apply when used in a system with NI Powertrain Control modules Note National Instruments guarantees warranted specifications for all National Instruments modules except thermocouple modules when used in a system with NI Powertrain Control modules m m Note National Instruments recommends the NI 9214 for thermocouple measurements in CompactRIO systems using NI Powertrain Control modules m Note NI Powertrain Control modules do not support Scan Interface mode auto detection or ID mode Bosch USA LSU 4 x Wide Band Oxygen Sensor Controllers The NI 9757 Sensor Module Kit part number 782079 01 includes two Bosch USA LSU 4 2 and LSU 4 9 Universal Exhaust Gas Oxygen UEGO sensor controllers The NI 9757 controls the pump current referred to as Ip to the sensor element to ma
12. ter lst order RC lowpass 16 Hz cutoff Pump Current Ip Measurement Range 2 0 to 2 4 mA Pump Current Ip Measurement Resolution eeeceeceeeeseeeceeeeeeeeeeeeeeeeeeeeees 1 pA Pump Current Ip Measurement ACUTA CY een eana irea 0 1 Lambda Measurement Range 0 0 65 to 15 99 8 ni com NI 9757 User Manual Temperature Measurement Range TSW E EE 610 to 1060 C DES WA O n aea anced 533 to 1200 C Resistance Measurement Resolution 0 5 Q Resistance Measurement Accuracy 0 1 Temperature Control Target LSU 4 2 ieee eich 750 C LSU 4 9 perainen ni 780 C Temperature Control Effective Heater Voltage Range cecesesecsecsecseeseereeneeeees 5 0 to 13 0 V Temperature Control PWM Frequency 100 Hz Heater Fuse vis ccsssssveteaciterecensveeutauieree Littelfuse part number 0451007 MRL 7 A 125 V EGO Sensor Measurement Range s es 0 0 to 1 36 V Measurement Resolution cceeeeee 1 mV Measurement Accuracy s s s 0 1 Input Over Voltage Protection 15 to 44 V Safety Guidelines A Caution Do not operate the NI 9757 n a manner not specified in these operating instructions Product misuse can result in a hazard You can compromise the safety protection built into the product if the product is damaged in any way If the product is damaged return it to National Instruments for repair Compliance and Certifications Safety This product m
13. um dioxide element narrow band oxygen sensors Wide band oxygen sensors may also be referred to as Universal 2 nicom NI 9757 User Manual Exhaust Gas Oxygen UEGO sensors Narrow band sensors may also be referred to as Exhaust Gas Oxygen EGO sensors NI recommends using the NI 9923 Connector Kit for connecting to the NI 9757 The NI 9923 provides proper strain relief for NI 9757 connections Visit ni com info and enter Info Code O2MODULE for more information on parts and accessories for the NI 9757 Powering the Module The NI 9757 requires power from each of the following sources e The CompactRIO backplane male high density DSUB 15 pin HD15 connector which mates with the female HD15 connector on the module This power source provides a regulated 5 V and ground to various digital logic functions The CompactRIO 5 V source is active whenever the CompactRIO or R Series Expansion Chassis is properly powered You can power the NI 9757 only at the HD15 connector by plugging it into a CompactRIO or R Series Expansion Chassis Do not connect the HD15 connector to any other device The external DB 37 connector the terminals of which are labeled BATT 10 and GND 29 A typical power source is an automotive 12 V battery system but the NI 9757 can accept power from a range of 6 V to 32 V The LSU 4 x wide band sensors will only operate when the power supply is in the range of 8 V to 16 5 V The module is reverse battery protected
14. wires in terms of standard EGO sensors which use a standardized wire color code OEM specific EGO sensors might use different wire color code 4 Wire Heated EGO Sensors 4 Wire heated EGO sensors have a black and gray wire and two white wires The black and gray wires provide a differential lambda signal Connect the black wire to the EGO pin of the NI 9757 DB 37 connector Connect the gray wire to one of the EGO pins for the associated channel of the NI 9757 DB 37 connector The two white wires connect to a resistive heater element inside the EGO sensor The NI 9757 does not provide connections for these wires Connect these to an external 12 V power source as shown in Figure 3 You can power the wires through a relay that is energized with the main ignition switch and optionally insert a user supplied 3 A fuse per sensor Ifyou are using a non standard EGO sensor with different wire colorings you must first identify the two wires that are connected to the heater element by testing for approximately 5 Q across two of the wires Any other wire combinations will have a much higher impedance measurement The remaining two wires are the differential lambda signal wires You might need to use trial and error to correct the lambda signal wiring polarity The sensor will not be damaged if the wire polarity is reversed but the sensor will not provide a correct reading and will likely appear as a cold sensor in the software Figure 3 4 Wire Heated EG
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