National Instruments NI 9502 Specifications

OPERATING INSTRUCTIONS AND

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SPECIFICATIONS

NI 9502

Brushless Servo Motor Drive

This document describes how to use the National Instruments 9502
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

2 | ni.com | NI 9502 Operating Instructions and Specifications

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.

NI 9502 Operating Instructions and Specifications | © National Instruments | 3

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 transien t o vervoltage
condition.

Special Conditions for Hazardous Locations Use in
Europe and Internationally

This equipment has been evaluated as Ex nA IIC T4 Gc 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.

4 | ni.com | NI 9502 Operating Instructions and Specifications

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 electrom agnetic compatibility (EMC)
as stated in the product specifications. These requirements and
limits are designed to provide reasonable protection agai nst
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

NI 9502 Operating Instructions and Specifications | © National Instruments | 5

the potential for the product to cause interference to radio and
television reception or to experience una cceptable 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 compli ance 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.

6 | ni.com | NI 9502 Operating Instructions and Specifications

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 Lloy d’ 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 wh en
designing, selecting, and installing measurement probes
and cables to ensure that the desired EMC performance is
attained.

NI 9502 Operating Instructions and Specifications | © National Instruments | 7

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
T rapezoidal 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.

8 | ni.com | NI 9502 Operating Instructions and Specifications

Figure 1 shows the NI 9502 working with the LabVIEW FPGA

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

module in Trapezoidal commutation mode.

Figure 1. NI 9502 Trapezoidal Commutation Mode Block Diagram

NI 9502 Operating Instructions and Specifications | © National Instruments | 9

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

LabVIEW FPGA Module

Position

Setpoint

Velocity
Command

Position

Loop

Position

Feedback

Feedback

Estimator

Current
Command*

Velocity

Loop

Velocity

Velocity

FOC

Algorithm**

Phase U &
W Current

Position

Decoder

Fault

Monitor

SVPWM

Generators

(3 To t al)

Hall

Inputs

NI 9502

Fault

Detection

Bridge

Controller

C Series I/O Module

Encoder Feedback

3-Phase

Bridge

Current

Sense

Motor

Encoder

Feedback

* Proportional to Torque
** Available with the LabVIEW NI SoftMotion Module Premium

10 | ni.com | NI 9502 Operating Instructions and Specifications

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

considerations are required for all cable 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.

NI 9502 Operating Instructions and Specifications | © National Instruments | 11

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

12 | ni.com | NI 9502 Operating Instructions and Specifications

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

NI 9502 Operating Instructions and Specifications | © National Instruments | 13

Motor Power Signals

The Phase U, Phase V, and Phase W connections provide PWM
outputs to 3-phase ungrounded W ye or delta connected permanent
magnet brushless motors. Refer to the motor documentation for
motor phase wiring information.

Caution The motor terminals on thi s drive are ener gized

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 co nnect 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
Effect Sensors for Trapezoidal Commutation topic in the LabVIEW

14 | ni.com | NI 9502 Operating Instructions and Specifications

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 2 3 4

1 Enabled (green)
2 Vsup (Motor Power) (green)

NI 9502 Operating Instructions and Specifications | © National Instruments | 15

3 User (yellow)
4 Fault (red)

Enabled

The Enabled LED (green) illumina tes when the drive is ena b le d
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 If the Fault LED is lit, determine the cause of the

fault and correct it before enabling the drive.

16 | ni.com | NI 9502 Operating Instructions and Specifications

The Fault LED (red) illuminates when a fault occurs. A fault
disables the drive. Cause s 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 re sult 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

NI 9502 Operating Instructions and Specifications | © National Instruments | 17

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

18 | ni.com | NI 9502 Operating Instructions and Specifications

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
ferrites as shown in Figures and . Select the ferrite with the
smallest aperture that will fit the actual wires us ed.

NI 9502 Operating Instructions and Specifications | © National Instruments | 19

– Install a snap-on ferrite bead from Table 1 on the power

supply cable (marked as Ferrite 2 in Figure ) an d the motor
cable (marked as Ferrite 3 in Figure ) as close to the
NI 9502 as practical. If a single, shielded cable is used,
install only one ferrite bead (marked as Ferrite 2 in Figure )
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 wit h the smallest aper ture that will fit the
actual cable(s) used.

– Ferrite beads can be ordered from the National 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)

20 | ni.com | NI 9502 Operating Instructions and Specifications

Table 2. Ferrite Sizing Chart for Module Side Motor Phase Cables

NI Part Number Aperture Size mm (inches)

781233-02 10.2 (0.402)
781950-01 5.10 (0.201)

Figure 5. NI 9502 Cable Connection (One Cable Option)

Ferrite 1

Ferrite 2

(3 To t al)

Shield

NI 9502

Phase U

Motor

Phase V
Phase W

Hall 1
Hall 2
Hall 3

Motor DC

Power

COM
Vsup

Supply

Ferrites. Refer to Tables 1 and 2 for
sizing information.

NI 9502 Operating Instructions and Specifications | © National Instruments | 21

Figure 6. NI 9502 Cable Connection (Two Cable Option)

Ferrite 1

Ferrite 3

Shield

(3 To t al)

NI 9502

Phase U

Motor

Phase V
Phase W

Hall 1
Hall 2
Hall 3

Motor DC

Power

COM
Vsup

Supply

Ferrite 2

Ferrites. Refer to Tables 1 and 2 for
sizing information.

22 | ni.com | NI 9502 Operating Instructions and Specifications

Specifications

The following specific ations are typi cal for t he tem perature ran ge

-40 to 70 °C and a PWM rate of 20 kHz for Trapezoidal

commutation mode and 10 kHz for FOC commutation mode unless
otherwise noted. All voltages are relative to COM unless otherwise
noted.

Input/Output Characteristics

Motor outputs

Current........................................4 A (2.8 Arms) continuous/

8 A (5.6 Arms) peak

Maximum peak time...................1 second

Minimum dwell time

between peaks ............................15 seconds

Peak output power..... .................0.2 kW

Continuous output power...........0.1 kW

Commutation..............................Field Oriented Control or

Trapezoidal

NI 9502 Operating Instructions and Specifications | © National Instruments | 23

Modulation

Field oriented control...........Center-aligned PWM with

space vector modulation

Trapezoidal...................... .. ...Left-aligned PWM

Minimum inductance..................250 µH

PWM ripple frequency...............20 kHz

Current loop

ADC resolution ..........................12 bits

Current range............. .................±8 A

Sampling rate..............................10 kHz (100 µs)

Bandwidth ..................................2.5 kHz with sp ecified

Hall inputs

Digital logic levels

Voltage .................................-0.25 to 5.25 V

High, VIH ............................2.4 V min

1

1

minimum inductance,

varies with tuning and load

Low, VIL.................. ............0.8 V max

1

Specifications based on the installed examples.

24 | ni.com | NI 9502 Operating Instructions and Specifications

Input current

(0 V  Vin  4.5 V) ...... .. ............±2 mA max

Motor DC power supply (Vsup).......+9 to +30 VDC

Vsup capacitance..............................750 µF

MTBF ...... ............... ................ .. ........Contact NI for Bellcore

MTBF specifications.

Drive Protection

Undervoltage.....................................<6 V

Caution Vsup greater than 40 V will result in damage to

the module.

Overvoltage...................... ... ..............>32 V

Power Requirements

Power consumption from chassis

Active mode ...............................700 mW max

Sleep mode.................................2.5 mW max

Thermal dissipation (at 70 °C)

Active mode ........ .. ................ .....1.5 W max

Sleep mode.................................2.5 mW max

NI 9502 Operating Instructions and Specifications | © National Instruments | 25

Physical Characteristics

If you need to clean the module, wipe it with a dry towel.

Note For two-dimensional drawings and

three-dimensional models of the C Series module and
connectors, visit
module number.

Screw terminal wiring

Gauge .. ................ .......................0.2 mm2 to 2.5 mm2

Temperature rating .....................90 °C

Torque for screw terminals.........0.5 to 0.6 N · m

Wires per screw terminal.. ..........One wire per screw terminal,

ni.com/dimensions and search by

(26 to 14 AWG copper)

conductor wire with 10 mm

(0.39 in.) of insulation

stripped from the end

(4.4 to 5.3 lb · in.)

two when using 2-wire

Ferrules.......................................0.25 mm

26 | ni.com | NI 9502 Operating Instructions and Specifications

ferrule

2

to 2.5 mm

2

Connector securem ent

Securement type.........................Screw flanges provided

Torque for screw flanges............0.2N · m (1.80 lb · in.)

Weight...............................................144 g (5.1 oz)

Safety Voltages

Connect only voltages that are within the following lim its.

Channel-to-COM..............................0 to +30 VDC max,

Measurement Category I

Isolation

Channel-to-channel ....................None

Channel-to-earth ground

Continuous...........................60 VDC,

Measurement Category I

Withstand .............................1000 Vrms, verified by a 5 s

dielectric withstand test

Measurement Category I is for measurements performed on
circuits not directly connected to the electrical distribution system
referred to as MAINS voltage. MAINS is a hazardous live electrical
supply system that powers equipment. This category is for

NI 9502 Operating Instructions and Specifications | © National Instruments | 27

measurements of voltages from specially protected secondary
circuits. Such voltage measurements inc lude signa l levels, speci al
equipment, limited-energy parts of equipment, circuits powered by
regulated low-voltage sources, and electronics.

Caution Do not connect the NI 9502 to signals or use for

measurements within Measurement Categories II, III,
or IV.

Hazardous Locations

U.S. (UL) ..................... ................ .....Class I, Division 2,

Groups A, B, C, D, T4;

Class I, Zone 2,

AEx nA IIC T4

Canada (C-UL) ............ .. ...................Class I, Division 2,

Groups A, B, C, D, T4;

Class I, Zone 2,

Ex nA IIC T4

Europe (DEMKO) ............................Ex nA IIC T4

28 | ni.com | NI 9502 Operating Instructions and Specifications

Power Supply Requirements

Caution You must use a UL Listed ITE power supply

marked LPS with the NI 9502.

Safety and Hazardous Location Standards

This product is designed to meet 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

• EN 60079-0:2012, EN 60079-15:2010

• IEC 60079-0: Ed 6, IEC 60079-15; Ed 4

• UL 60079-0; Ed 5, UL 60079-15; Ed 3

• CSA 60079-0:2011, CSA 60079-15:2012

Note For UL and other safety certifications, refer to the

product label or the Online Product Ce rtification section.

NI 9502 Operating Instructions and Specifications | © National Instruments | 29

Electromagnetic Compatibility

This product meets the requirements of the following EMC
standards for electrical equipment for measurement, con trol,
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

• FCC 47 CFR Part 15B: Class A emissions

• ICES-001: Class A emissions

Note For the standards applied to assess the EMC of this

product, refer to the Online Product Certification section.

Note For EMC compliance, operate this device with

shielded cabling.

30 | ni.com | NI 9502 Operating Instructions and Specifications

CE Compliance

This product meets the essential requirements of applicable
European directives as follows:

• 2014/35/EU; Low-Voltage Directive (safety)

• 2014/30/EU; Electromagnetic Compatibility Directive (EMC)

• 94/9/EC; Potentially Explosive Atmospheres (ATEX)

Online Product Certification

Refer to the product Declaration of Conformity (DoC) for
additional regulatory compliance information. To obtain product
certifications and the DoC for this product, visit ni.com/

certification

, search by module number or product line, and

click the appropriate link in the Certific at ion column.

NI 9502 Operating Instructions and Specifications | © National Instruments | 31

Shock and Vibration

T o meet these specifications, you must panel mount the system and
affix ferrules to the end of the screw terminal wires.

Operating vibration

Random (IEC 60068-2-64).........5 grms, 10 to 500 Hz

Sinusoidal (IEC 60068-2-6).......5 g, 10 to 500 Hz

Operating shock

(IEC 60068-2-27)..............................30 g, 11 ms half sine,

50 g, 3 ms half sine,
18 shocks at 6 orientations

Environmental

Refer to the manual for the chassis you are using for more
information about meeting these specifications.

Operating temperature

(IEC 60068-2-1, IEC 60068-2-2) .....-40 to 70 °C

Storage temperature

(IEC 60068-2-1, IEC 60068-2-2) .....-40 to 85 °C

Ingress protection..............................IP 40

32 | ni.com | NI 9502 Operating Instructions and Specifications

Operating humidity

(IEC 60068-2-56)..............................10 to 90% RH,

noncondensing

Storage humidity

(IEC 60068-2-56)..............................5 to 95% RH,

noncondensing

Pollution Degree (IEC 60664)..........2

Maximum altitude.............................2,000 m

Indoor use only.

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.

NI 9502 Operating Instructions and Specifications | © National Instruments | 33

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Electronic Equipment, visit

weee

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34 | ni.com | NI 9502 Operating Instructions and Specifications

Worldwide Support and Services

The National Instruments website is your complete resource for
technical support. At

ni.com/support you have access to

everything from troubleshooting and application development
self-help resources to email and phone assistance from NI
Application Engineers.

A Declaration of Conformity (DoC) is our claim of compliance
with the Council of the European Communities using the
manufacturer’s declar ation of con formi ty. This system affords the
user protection for electromagnetic compatibility (EMC) and
product safety . Y ou can obtain the DoC for your product by visiting

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you can obtain the calibration certificate for your product at

ni.com/calibration.

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