National Instruments NI 9502 User manual

OPERATING INSTRUCTIONS AND
SPECIFICATIONS
NI 9502
Brushless Servo Motor Drive
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2|ni.com |NI 9502 Operating Instructions and Specifications
Thisdocumentdescribeshowto usethe National Instruments9502
module and includes specifications and pin assignments for the
NI 9502.
Note The safety guidelines and specifications in this
document are specific to the NI 9502. The other
components in the system may not meet the same safety
ratings and specifications. Refer to the documentation for
each component in the system to determine the safety
ratings and specifications for the entire system.
Related Information

NI 9502 Operating Instructions and Specifications |© National Instruments |3
Safety Guidelines
Operate the NI 9502 only as described in these operating
instructions.
Safety Guidelines for Hazardous Locations
The NI 9502 is suitable for use in Class I, Division 2, Groups A, B,
C, D, T4 hazardous locations; Class I, Zone 2, AEx nA IIC T4 and
Ex nA IIC T4 hazardous locations; and nonhazardous locations
only. Follow these guidelines if you are installing the NI 9502 in a
potentially explosive environment. Not following these guidelines
may result in serious injury or death.
Caution Do not disconnect I/O-side wires or connectors
unless power has been switched off or the area is known to
be nonhazardous.
Caution Do not remove modules unless power has been
switched off or the area is known to be nonhazardous.
Caution Substitution of components may impair
suitability for Class I, Division 2.

4|ni.com |NI 9502 Operating Instructions and Specifications
Caution For Division 2 and Zone 2 applications, install
the system in an enclosure rated to at least IP 54 as defined
by IEC/EN 60079-15.
Caution For Division 2 and Zone 2 applications, install a
protection device between the input signal and the Vsup
pin. The device must prevent the Vsup-to-channel voltage
from exceeding 42 V if there is a transient overvoltage
condition.
Special Conditions for Hazardous Locations Use in
Europe and Internationally
Thisequipment has been evaluatedasEx nA IIC T4Gc equipment
under DEMKO Certificate No. 07 ATEX 0626664X and is IECEx
UL 14.0089X certified. Each module is marked II 3G and is
suitable for use in Zone 2 hazardous locations, in ambient
temperatures of -40 °C Ta 70 °C. If you are using the NI 9502
in Gas Group IIC hazardous locations, you must use the device in
an NI chassis that has been evaluated as Ex nC IIC T4, Ex IIC T4,
Ex nA IIC T4, or Ex nL IIC T4 equipment.
Caution You must make sure that transient disturbances
do not exceed 140% of the rated voltage.

NI 9502 Operating Instructions and Specifications |© National Instruments |5
Caution The system shall only be used in an area of not
more than Pollution Degree 2, as defined in IEC 60664-1.
Caution The system shall be mounted in an
ATEX/IECEx-certified enclosure with a minimum ingress
protection rating of at least IP54 as defined in
IEC/EN 60079-15.
Caution The enclosure must have a door or cover
accessible only by the use of a tool.
Electromagnetic Compatibility Guidelines
This product was tested and complies with the regulatory
requirements and limits for electromagnetic compatibility (EMC)
as stated in the product specifications. These requirements and
limits are designed to provide reasonable protection against
harmful interference when the product is operated in its intended
operational electromagnetic environment.
This product is intended for use in industrial locations. As such,
there is no guarantee that harmful interference will not occur in a
particular installation, when the product is connected to a test
object, or if the product is used in residential areas. To minimize

6|ni.com |NI 9502 Operating Instructions and Specifications
the potential for the product to cause interference to radio and
television reception or to experience unacceptable performance
degradation, install and use this product in strict accordance with
the instructions in the product documentation.
Furthermore, any changes or modifications to the product not
expressly approved by National Instruments could void your
authority to operate it under your local regulatory rules.
Caution The inputs/outputs of this product can be
damaged if subjected to Electrostatic Discharge (ESD).
To prevent damage, industry-standard ESD prevention
measures must be employed during installation,
maintenance, and operation.
Caution To ensure compliance with the applicable
regulatory requirements, product installation requires
special considerations and user-installed, add-on devices.
Refer to the Connecting the NI 9502 and Cable
Requirements for EMC Compliance sections for details.

NI 9502 Operating Instructions and Specifications |© National Instruments |7
Special Guidelines for Marine Applications
Some products are Lloyd’s Register (LR) Type Approved for
marine (shipboard) applications. To verify Lloyd’s Register
certification for a product, visit ni.com/certification and
search for the LR certificate, or look for the Lloyd’s Register mark
on the product label.
Caution In order to meet the EMC requirements for
marine applications, install the product in a shielded
enclosure with shielded and/or filtered power and
input/output ports. In addition, take precautions when
designing, selecting, and installing measurement probes
and cables to ensure that the desired EMC performance is
attained.

8|ni.com |NI 9502 Operating Instructions and Specifications
NI 9502 Hardware Overview
The NI 9502 is a brushless servo motor drive. It contains motor
outputs for a brushless servo motor, Hall effect sensor inputs, and
power connections.
The NI 9502 returns the motor current to the LabVIEW FPGA
module for use in a current loop or for monitoring. NI 9502 status
information such as drive status and drive faults are also returned
to the LabVIEW FPGA module. Refer to the NI 9502 topic in the
LabVIEW Help, available by selecting Help»LabVIEW Help, for
more information about the available status information.
Depending on software settings, the NI 9502 can operate in either
Trapezoidal or Field Oriented Control (FOC) commutation mode.
Refer to the NI 9502 topic in the LabVIEW Help, available by
selecting Help»LabVIEW Help, for more information about the
available modes.
The LabVIEW SoftMotion Module provides VIs and example
programs that make it easier to use the NI 9502 in FOC
commutation mode. Refer to ni.com/info and enter nismpkg
for more information about the SoftMotion Module.

NI 9502 Operating Instructions and Specifications |© National Instruments |9
Figure 1 shows the NI 9502 working with the LabVIEW FPGA
module in Trapezoidal commutation mode.
Figure 1. NI 9502 Trapezoidal Commutation Mode Block Diagram
Velocity
Loop
Current
Loop
Fault
Monitor
Bridge
Controller
Fault
Detection
Current
Sense
Motor
Velocity
Command
Current
Command*
LabVIEW FPGA Module NI 9502
Motor
Current
Velocity
Feedback
Velocity
Estimator
* Proportional to Torque
PWM
Generator
Hall Sensor Inputs
3-Phase
Bridge

10 |ni.com |NI 9502 Operating Instructions and Specifications
Figure 2 shows the NI 9502 working with the LabVIEW FPGA
module in FOC commutation mode.
Figure 2. NI 9502 FOC Commutation Mode Block Diagram
Position
Loop
Velocity
Loop
FOC
Algorithm**
Fault
Monitor
Bridge
Controller
Fault
Detection
Current
Sense
Encoder
Feedback
Motor
Velocity
Command
Current
Command*
Position
Setpoint
LabVIEW FPGA Module
NI 9502
Encoder Feedback
Position
Decoder
Phase U &
W Current
Velocity
Feedback
Position
Feedback
Velocity
Estimator
* Proportional to Torque
** Available with the LabVIEW NI SoftMotion Module Premium
SVPWM
Generators
(3To t al)
Hall
Inputs
C SeriesI/O Module
3-Phase
Bridge

NI 9502 Operating Instructions and Specifications |© National Instruments |11
Connecting the NI 9502
The NI 9502 has a 10-terminal detachable screw-terminal
connector that provides connections for the brushless servo motor
signals, Hall effect sensors, a 9 to 30 VDC power supply, COM,
and chassis ground. Refer to Figure 3 for the pin assignments.
Caution To ensure EMC compliance, special
considerationsarerequiredforallcable connections.Refer
to the Cable Requirements for EMC Compliance section.
Note You must use 2-wire ferrules to create a secure
connection when connecting more than one wire to a
single terminal on the NI 9502 screw terminal. Refer to
Figure 4 for an illustration of using ferrules.
Caution Do not turn on or plug in the motor DC power
supply until the screw-terminal connector is fully inserted
and the two connector flange screws are tightened.

12 |ni.com |NI 9502 Operating Instructions and Specifications
Figure 3. NI 9502 Connections
Phase U
Phase V
Phase W
Reserved
Hall 1
Hall 2
Hall 3
COM
Vsup
(Chassis Ground)
0
1
2
3
4
5
6
7
8
9

NI 9502 Operating Instructions and Specifications |© National Instruments |13
Wiring for High Vibration Applications
If an application is subject to high vibration, National Instruments
recommends that you use ferrules to terminate wires to the
detachable screw-terminal connector.
Refer to Figure 4 for an illustration of using ferrules.
Figure 4. 10-Terminal Detachable Screw-Terminal Connector
with Ferrule
Ferrule

14 |ni.com |NI 9502 Operating Instructions and Specifications
Motor Power Signals
The Phase U, Phase V, and Phase W connections provide PWM
outputs to 3-phase ungrounded Wye or delta connected permanent
magnet brushless motors. Refer to the motor documentation for
motor phase wiring information.
Caution The motor terminals on this drive are energized
when the module is enabled. Do not connect wires to or
disconnect wires from the NI 9502 when it is enabled.
Use a multiconductor cable with an overall shield and conductors
of 12 to 20 AWG for the motor cable. Figure in the Cable
Requirements for EMC Compliance section shows a simplified
connection diagram.
Hall Effect Sensor Connections
Use the Hall 1, Hall 2, and Hall 3 inputs to connect the motor Hall
effect sensors. For proper phase switching to occur, the Hall
sensors from the motor must be connected to the correct Hall
inputs on the NI 9502 module. The Hall sensor phase sequence is
motor-dependent, so selecting the correct inputs may require
manually testing the motor wiring. Refer to the Connecting Hall
EffectSensors for TrapezoidalCommutationtopicin theLabVIEW

NI 9502 Operating Instructions and Specifications |© National Instruments |15
Help, available by selecting Help»LabVIEW Help, for
information about determining the proper Hall input connections
to the NI 9502 module when using the NI 9502 module in
trapezoidal commutation mode.
Note The LabVIEW SoftMotion Module provides an
example that allows you to automatically determine the
phasing for FOC commutation mode.
LED Indicators
The NI 9502 has four LEDs to display status information.
1 Enabled (green)
2 Vsup (Motor Power) (green)
3 User (yellow)
4 Fault (red)
1 2 34

16 |ni.com |NI 9502 Operating Instructions and Specifications
Enabled
The Enabled LED (green) illuminates when the drive is enabled
and the output power stage is active, and is flashing when the drive
is disabled and the output power stage is inactive. Refer to the
NI 9502 topic in the LabVIEW Help, available by selecting
Help»LabVIEW Help, for information about enabling the drive.
Vsup
The Vsup LED (green) illuminates when the motor DC power
supply is properly connected.
User
You can define the User LED (yellow) to meet the needs of your
application. Use the User LED I/O node to turn this LED on and
off. Refer to the NI 9502 topic in the LabVIEW Help, available
by selecting Help»LabVIEW Help, for information about the
NI 9502 User LED I/O node.
Fault
Caution IftheFaultLEDislit,determinethecauseofthe
fault and correct it before enabling the drive.

NI 9502 Operating Instructions and Specifications |© National Instruments |17
The Fault LED (red) illuminates when a fault occurs. A fault
disables the drive. Causes for a fault are the following:
• Vsup undervoltage. Refer to the NI 9502 Module Faults
topic in the LabVIEW Help, available by selecting Help»
LabVIEW Help, for more information about this fault.
Caution Vsup greater than 40 V will result in damage to
the NI 9502.
• Vsup overvoltage
Caution Current greater than ±8 A will result in damage
to the NI 9502.
• Overcurrent
• Module current sampling fault. Refer to the NI 9502 Module
Faults topic in the LabVIEW Help, available by selecting
Help»LabVIEW Help, for more information about this fault

18 |ni.com |NI 9502 Operating Instructions and Specifications
Hot-Swap Behavior
The NI 9502 is always disabled when it is first inserted in the
chassis, regardless of whether Vsup is present or not. You can
enable the drive using the Enable Drive method in software. Refer
to the NI 9502 topic in the LabVIEW Help, available by selecting
Help»LabVIEW Help, for more information about enabling the
drive.
When the NI 9502 is removed from the chassis while it is enabled,
the power to the motor is removed and the motor decelerates to a
stop based on its own friction.
Sleep Mode
This module supports a low-power sleep mode. Support for sleep
mode at the system level depends on the chassis that the module is
plugged into. Refer to the chassis manual for information about
support for sleep mode. If the chassis supports sleep mode, refer
to the software help for information about enabling sleep mode.
Visit ni.com/info and enter cseriesdoc for information about
C Series documentation.
Typically, when a system is in sleep mode, you cannot
communicate with the modules and the drive is disabled. In sleep

NI 9502 Operating Instructions and Specifications |© National Instruments |19
mode, the system consumes minimal power and may dissipate less
heat than it does in normal mode. Refer to the Specifications
section for more information about power consumption and
thermal dissipation.
Cable Requirements for EMC Compliance
Select and install cables for the NI 9502 in accordance with the
following requirements:
• Use only shielded cables to connect the NI 9502 to a motor and
a power supply.
• Terminate the motor and power supply cable shields to the
COM terminal of the NI 9502. In addition, terminate the cable
shields at the other end to either earth ground or the chassis of
the connected motor and/or power supply.
• Install snap-on, ferrite beads to the cables as follows:
– Install a snap-on ferrite bead from Table 2 on each phase
wire of the motor cable within one (1) centimeter of the
NI 9502 (marked as Ferrite 1 in Figures and ). All other
wires, including the cable shields, should bypass these
ferritesasshown inFigures and .Selecttheferritewiththe
smallest aperture that will fit the actual wires used.

20 |ni.com |NI 9502 Operating Instructions and Specifications
– Install a snap-on ferrite bead from Table 1 on the power
supply cable (markedas Ferrite 2 in Figure ) and the motor
cable (marked as Ferrite 3 in Figure ) as close to the
NI 9502 as practical. If a single, shielded cable is used,
installonlyone ferritebead(marked asFerrite2 inFigure )
as shown. If two cables are used, install two ferrites from
Table 1 as shown in Figure . The ferrite beads should
encompass the entire cable, including the cable shield.
Select the ferrite with the smallest aperture that will fit the
actual cable(s) used.
– Ferritebeads canbe orderedfromtheNational Instruments
Web site at ni.com by selecting Order by Part Number.
Power to the module must be off when adding ferrites.
Table 1. Ferrite Sizing Chart for Power Supply and Motor Side Cables
NI Part Number Aperture Size mm (inches)
781233-01 7.0 (0.275)
781233-02 10.2 (0.402)
777297-01 13.4 (0.528)