National Instruments NI 9757 User manual

USER MANUAL
NI 9757
NI Powertrain Controls O2 Sensor Module Kit - Rev E
Contents
Introduction .............................................................................................................................. 2
Pinout........................................................................................................................................ 2
Hardware .................................................................................................................................. 2
Powering the Module................................................................................................................ 3
Platform Compatibility ............................................................................................................. 3
Bosch USA LSU 4.x Wide-Band Oxygen Sensor Controllers................................................. 4
Narrow-Band Oxygen Sensor Inputs........................................................................................ 7
Physical Specifications and Characteristics ............................................................................. 8
Electrical Specifications and Characteristics............................................................................ 8
Compliance and Certifications ................................................................................................. 9

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Introduction
The National Instruments 9757 offers an interface for multiple wide-band and narrow-band
exhaust oxygen sensors.
Features
• 2 Ch. Bosch USA LSU 4.2 or LSU 4.9 wide-band sensor controller
– Fuse-protected heater control circuits (serviceable)
• 4 Ch. Narrow-band sensor input (differential)
• All channel readings updated at 1 kHz
• 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 zirconium-dioxide-element,
narrow-band oxygen sensors. Wide-band oxygen sensors may also be referred to as Universal

NI 9757 User Manual |© National Instruments |3
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:
• 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 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.
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:
• CompactRIO, which consists of a CompactRIO controller, chassis, or integrated
controller/chassis.
• 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 insert into an NI R Series

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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-911x, NI cRIO-907x, and NI R Series
Expansion systems under the following conditions:
• Leave one empty chassis slot between NI Powertrain Control modules and other
NI modules.
• 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.
Note National Instruments recommends the NI 9214 for thermocouple
measurements in CompactRIO systems using NI Powertrain Control modules.
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 maintain 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.

NI 9757 User Manual |© National Instruments |5
L
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.
The NI O2 Sensor Kit (part number 782083-01) includes the following components:
• Bosch USA LSU 4.9 17025 Sensor
• 10 ft, 6-conductor cable with a Bosch USA LSU 4.9 mating connector on one end and
unterminated wires on the opposite end
• Sensor bung
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
<–LSU4.9 / LSU4.2–>
1
<–LSU4.9 / LSU4.2–>

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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 housing. 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 3. Bosch USA LSU 4.9 Sensor Connection
Table 2. Bosch USA LSU 4.2 Sensor Connection
Module Pin Label
Intermediate
Cable Wire Color
LSU 4.2
Pin Number
LSU 4.2
Wire Color
UNx (B) Black 1Black
IAx (GN) Green 2 —
HTRx+ (GY) Brown 3Grey
HTRx- (W) White 4White
VMx (Y) Blue 5Yello w
IPx (R) Red 6Red
Module Pin Label
Intermediate
Cable Wire Color
LSU 4.9
Pin Number
LSU 4.9
Wire Color
UNx (B) Black 6Black
IAx (GN) Green 5 —
HTRx+ (GY) Brown 4Grey
HTRx- (W) White 3White

NI 9757 User Manual |© National Instruments |7
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.
Note This document discusses EGO sensor 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.
If you 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 Ωacross
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 EGO Sensor Connection
VMx (Y) Blue 2Yello w
IPx (R) Red 1Red
Module Pin Label
Intermediate
Cable Wire Color
LSU 4.9
Pin Number
LSU 4.9
Wire Color

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Physical Specifications and Characteristics
Weight ...............................................................170 g
Maximum Altitude............................................2000 m
Maximum Ambient Temperature......................60 °C
Operating Humidity ..........................................10% to 90% RH, noncondensing
Pollution Degree ...............................................2
Ingress Protection .............................................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 Range...............................................6 to 32 V
Input Range for Functional
UEGO Sensors ..........................................8 to 16.5 V
Reverse Polarity Protection ......................–18 V
Input Capacitance .....................................300 µF
Inrush Current ...........................................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.................................1.4 W at 13.8 V
Internal Analog-to-Digital Conversion Range..0 to 4.096 V
Internal Analog-to-Digital Conversion
Resolution .........................................................12-bit
Internal Analog-to-Digital Conversion Rate.....1000 samples/s
UEGO Sensor
Analog Measurement Hardware Filter .....1st order RC lowpass, 16 Hz cutoff
Pump Current (Ip) Measurement Range...–2.0 to 2.4 mA
Pump Current (Ip) Measurement
Resolution .................................................1 µA
Pump Current (Ip) Measurement
Accuracy ...................................................± 0.1 %
Lambda Measurement Range ...................0.65 to 15.99

NI 9757 User Manual |© National Instruments |9
Temperature Measurement Range
LSU 4.2............................................. 610 to 1060 °C
LSU 4.9............................................. 533 to 1200 °C
Resistance Measurement Resolution ........ 0.5 
Resistance Measurement Accuracy .......... ± 0.1 %
Temperature Control Target
LSU 4.2............................................. 750 °C
LSU 4.9............................................. 780 °C
Temperature Control Effective Heater
Voltage Range ........................................... 5.0 to 13.0 V
Temperature Control PWM Frequency .... 100 Hz
Heater Fuse ............................................... Littelfuse part number 0451007.MRL
(7 A, 125 V)
EGO Sensor
Measurement Range ................................. 0.0 to 1.36 V
Measurement Resolution .......................... 1 mV
Measurement Accuracy ............................ ± 0.1 %
Input Over-Voltage Protection.................. –15 to 44 V
Safety Guidelines
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 meets the requirements of the following standards of safety for electrical equipment
for measurement, control, and laboratory use:
• IEC 61010-1, EN 61010-1
• 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:
• EN 61326-1 (IEC 61326-1): Class A emissions; Industrial immunity
• EN 55011 (CISPR 11): Group 1, Class A emissions
• AS/NZS CISPR 11: Group 1, Class A emissions

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• FCC 47 CFR Part 15B: Class A emissions
• ICES-001: Class A emissions
Caution When operating this product, use shielded cables and accessories.
CE Compliance
This product meets the essential requirements of applicable European Directives as follows:
• 2006/95/EC; Low-Voltage Directive (safety)
• 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 in
this document.
Waste Electrical and Electronic Equipment (WEEE)
EU Customers At the end of the product life cycle, all products must be sent to
a WEEE recycling center. For more information about WEEE recycling centers,
National Instruments WEEE initiatives, and compliance with WEEE Directive
2002/96/EC on Waste and Electronic Equipment, visit ni.com/environment/
weee.
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.
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
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