National Instruments Network Card NI 9478 User Manual

OPERATING INSTRUCTIONS AND SPECIFICATIONS  
NI 9478  
16-Channel, 0–50 V, Sinking Digital Output Module  
with Programmable Current Limits  
Français Deutsch  
ni.com/manuals  
 
Safety Guidelines  
Operate the NI 9478 only as described in these operating  
instructions.  
Hot Surface This icon denotes that the component may be  
hot. Touching this component may result in bodily injury.  
Safety Guidelines for Hazardous Locations  
The NI 9478 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 9478 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.  
© National Instruments Corp.  
3
NI 9478 Operating Instructions and Specifications  
 
Caution Substitution of components may impair  
suitability for Class I, Division 2.  
Caution For Zone 2 applications, install the system  
in an enclosure rated to at least IP 54 as defined by  
IEC 60529 and EN 60529.  
Caution For Zone 2 applications, install a protection  
device across the external power supply and the COM  
pin. The device must prevent the external power supply  
voltage from exceeding 70 V if there is a transient  
overvoltage condition.  
Special Conditions for Hazardous Locations Use in Europe  
This equipment has been evaluated as Ex nA IIC T4 equipment  
under DEMKO Certificate No. 07 ATEX 0626664X. Each module  
is marked  
II 3G and is suitable for use in Zone 2 hazardous  
locations. If you are using the NI 9478 in Gas Group IIC hazardous  
locations or in ambient temperatures of –40 °C Ta 70 °C, you  
must use the device in an NI chassis that has been evaluated as  
EEx nC IIC T4, Ex nA IIC T4, or Ex nL IIC T4 equipment.  
NI 9478 Operating Instructions and Specifications  
4
ni.com  
 
Special Conditions for Marine Applications  
Some modules are Lloyd’s Register (LR) Type Approved for  
marine applications. To verify Lloyd’s Register certification,  
visit ni.com/certification and search for the LR certificate,  
or look for the Lloyd’s Register mark on the module.  
Caution To meet radio frequency emission requirements  
for marine applications, use shielded cables and install  
the system in a metal enclosure. Suppression ferrites  
must be installed on power supply inputs near power  
entries to modules and controllers. Power supply and  
module cables must be separated on opposite sides of  
the enclosure and must enter and exit through opposing  
enclosure walls.  
© National Instruments Corp.  
5
NI 9478 Operating Instructions and Specifications  
 
Connecting the NI 9478  
The NI 9478 has a 37-pin DSUB connector that provides  
connections for the 16 digital output channels.  
1
2
3
4
5
6
7
8
9
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
DO0  
DO1  
DO2  
DO3  
DO4  
DO5  
DO6  
DO7  
Vsup  
Vsup  
DO8  
DO9  
DO10  
DO11  
DO12  
DO13  
DO14  
DO15  
NC  
COM  
COM  
COM  
COM  
COM  
COM  
COM  
COM  
Vsup  
Vsup  
COM  
COM  
COM  
COM  
COM  
COM  
COM  
COM  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
35  
36  
37  
Figure 1. NI 9478 Pin Assignments  
NI 9478 Operating Instructions and Specifications  
6
ni.com  
 
Each channel of the NI 9478 has a DO pin to which you can  
connect the load you want to control. Each channel also has a COM  
pin. National Instruments recommends you provide independent  
COM wiring for each channel to minimize current flow in the  
COM wiring. The COM pins are all connected together internally.  
You must connect an external power supply to the NI 9478. This  
power supply provides the current for the devices you connect to  
the module. Connect the positive lead of the power supply to Vsup  
and the negative lead of the power supply to COM.  
Caution Do not remove or insert modules if the external  
power supply connected to the Vsup pin is powered on.  
The NI 9478 has current sinking outputs, meaning the DO pin is  
driven to COM when the channel is turned on.  
You can directly connect the NI 9478 to a variety of industrial  
devices such as solenoids, motors, actuators, relays, and lamps.  
Make sure the devices you connect to the NI 9478 are compatible  
with the output specifications of the module. Refer to the  
Specifications section for more information about the output  
specifications.  
© National Instruments Corp.  
7
NI 9478 Operating Instructions and Specifications  
 
Connect the device to DO and the positive lead of the power  
supply. Refer to Figure 2 for an illustration of how to connect  
a device to the NI 9478.  
Vsup  
Cable  
Clamp  
DO  
Device  
External  
+
Power  
Supply  
COM  
NI 9478  
Figure 2. Connecting a Device to the NI 9478  
You must connect the Vsup pin to the power supply to enable a  
weak cable clamping diode that protects the module from cable  
inductance flyback. This flyback voltage results from small  
amounts of energy stored in the inductance of the cabling. Refer  
to the Using Long Cables section for more information about  
protection from cable inductance flyback. You still must install an  
external flyback diode when switching inductive loads. Refer to the  
Protecting the Module from Flyback Voltages section for more  
information about installing a flyback diode.  
NI 9478 Operating Instructions and Specifications  
8
ni.com  
 
 
Protecting the Module from Flyback Voltages  
If the module is switching an inductive or energy-storing device  
such as a solenoid, motor, or relay, and the device does not have  
flyback protection, install an external flyback diode as shown in  
Figure 3. Refer to the Using Long Cables section for more  
information about protection from cable inductance flyback.  
Vsup  
Cable  
Device  
Clamp  
DO  
External  
Power  
Supply  
+
COM  
NI 9478  
Figure 3. Connecting a Flyback Diode to the NI 9478  
© National Instruments Corp.  
9
NI 9478 Operating Instructions and Specifications  
 
   
Using Long Cables  
The inductance of the cabling that connects the NI 9478, the loads,  
and the external supply stores up energy when a channel is on and  
passing current through the cables. Each time a channel is turned  
off, the energy stored in the cables is released as flyback voltage  
and dissipates as heat in the NI 9478. The total power dissipated in  
the module increases with higher switching frequencies, higher  
currents, and longer cable lengths. The cable length is the total  
distance from the digital output pin of the NI 9478 channel,  
through the load, through the external power supply, and back  
to the COM pin, as shown in Figure 4.  
Vsup  
Load  
Cable  
Clamp  
External  
Power  
Supply  
+
DO  
Cable  
Length  
NI 9478  
COM  
Figure 4. Cable Length of the NI 9478  
NI 9478 Operating Instructions and Specifications  
10  
ni.com  
 
   
You can reduce the effective length of the cable by adding a  
capacitor close to the NI 9478 across the power supply leads and  
adding a diode from the digital output line to the Vsup pin line.  
National Instruments recommends that you use a capacitor with a  
capacitance of at least 20 μF. In this case, the effective length of the  
cable is the distance from the output pin, through the new diode,  
through the capacitor, and back to the COM pin, as shown in  
Figure 5.  
Vsup  
Load  
Cable  
Clamp  
External  
Power  
Supply  
+
DO  
Cable  
Length  
COM  
Figure 5. Cable Length of the NI 9478 with a Capacitor and Diode  
NI 9478  
© National Instruments Corp.  
11 NI 9478 Operating Instructions and Specifications  
 
 
I/O Protection  
The NI 9478 provides protection against overcurrent and  
short-circuit conditions.  
Output Current Limit Thresholds  
The NI 9478 provides two configurable current limit thresholds  
for the module, Limit A and Limit B. The NI 9478 continuously  
monitors the current through each output channel and detects if  
the current exceeds either of the current limit thresholds. You can  
configure the current limit thresholds and check the current limit  
output status in software to determine if the current through each  
channel has exceeded the current limit thresholds. Refer to the  
software help for more information about configuring current  
limits and checking output status. Visit ni.com/info and enter  
cseriesdoc for information about C Series documentation.  
Overcurrent Protection  
You can configure each channel on the NI 9478 to disable the  
output if the current through the output exceeds either current  
limit threshold. This protects the NI 9478 from overcurrent and  
short-circuit conditions and provides a way to limit the current  
through an external device.  
NI 9478 Operating Instructions and Specifications  
12  
ni.com  
 
Some applications require a large inrush current when a channel is  
first turned on. If this inrush current exceeds the maximum current  
limit threshold, you may need to disable overcurrent protection by  
programming the channel to have no current limit. Refer to the  
software help for more information about configuring current  
limits. Visit ni.com/info and enter cseriesdoc for information  
about C Series documentation.  
Caution The NI 9478 is not protected against output  
overcurrent or short-circuit conditions when overcurrent  
protection is disabled. If you disable overcurrent  
protection, ensure that the wiring is correct and that you  
are operating the NI 9478 within the specifications.  
The total amount of current that you can switch with a channel  
depends on the duty cycle of the channel, the ambient temperature,  
the switching frequency, and the amount of current switched by  
other channels within the same module at the same time. Refer to  
the Safe Operating Current section for more information about the  
current specifications.  
© National Instruments Corp.  
13 NI 9478 Operating Instructions and Specifications  
 
Overcurrent Refresh  
The NI 9478 provides an overcurrent refresh setting that enables  
a channel to automatically recover within the specified overcurrent  
refresh period if the channel exceeds its current limit threshold.  
If overcurrent refresh is disabled, the channel remains off after an  
overcurrent condition until software sends a command to turn the  
channel back on. Refer to the software help for more information  
about overcurrent refresh. Visit ni.com/info and enter  
cseriesdoc for information about C Series documentation.  
Safe Operating Current  
The maximum allowable output current depends on the output  
frequency and cable lengths. Higher output currents, higher output  
frequencies, and longer cable lengths can contribute to power  
dissipating and heat increasing in the NI 9478. The Specifications  
section gives allowable current and frequency specifications if you  
use 2 meters of cabling. For other operating conditions, you can  
find the safe operating specifications for the NI 9478 by calculating  
the percentage of the total allowable power each output channel  
dissipates given the output current, frequency, and cable length  
NI 9478 Operating Instructions and Specifications  
14  
ni.com  
 
 
for that channel. Use the following equation to calculate the  
percentage of the total power budget each output channel uses in  
your application.  
2
2
P = 4% I  
out ⎠  
+
0.12%(length 0.2) I  
out ⎠  
+ 0.04%(I  
+ 1) freq  
out  
where P is the percentage of total allowable power the channel uses  
Iout is the output current in amperes while the channel is on  
length is the total cable length in meters, shown in Figure 4  
freq is the frequency rate in kHz at which the output channel goes  
through an on-off cycle  
To verify that your application keeps the NI 9478 within safe  
operating specifications, calculate the average percentage of  
total allowable power each channel uses, then add together the  
percentages for all the channels. For operation in ambient  
temperatures from 55 to 70 °C, the total average power of all  
channels must remain under 100%. For temperatures below 55 °C,  
the total average power of all channels can run up to 150%.  
© National Instruments Corp.  
15 NI 9478 Operating Instructions and Specifications  
 
Example One  
You are driving a load with 2.0 meters of cable through a cycle in  
which the NI 9478 is on and passing 1.25 A of current for 40 μs,  
then off for 10 μs. The output period is 50 μs (40 μs + 10 μs) so the  
output frequency is 20 kHz. The channel uses 14.8% of the total  
power budget, as shown in the following equation.  
2
2
4%(1.25 ) + [0.12%(2.0 0.2)(1.25 ) + 0.04%(1.25 + 1)]20 = 14.8%  
NI 9478 Operating Instructions and Specifications  
16  
ni.com  
 
 
Example Two  
You are driving a load with 2.0 meters of cable through a cycle in  
which the NI 9478 first is constantly on and passing 3 A of current  
for 0.25 seconds, then drives the load at 20 kHz with 1.25 A current  
for 1.25 seconds, then drives the load off for 4 seconds. While the  
NI 9478 is constantly on, the output frequency is 0 kHz and the  
channel uses 36% (4% × 32) of the total power budget. Example  
One shows that while the NI 9478 is driving at 20 kHz, the channel  
uses 14.8% of the total power budget. While the NI 9478 is off, the  
channel uses 0% of the power budget. The average percentage of  
total allowable power over the complete 5.5 second cycle is 5%,  
as shown in the following equation.  
36%(0.25s) + 14.8%(1.25 s) + 0%(4s)  
------------------------------------------------------------------------------------------------- = 5%  
5.5s  
© National Instruments Corp.  
17 NI 9478 Operating Instructions and Specifications  
 
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. In sleep 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.  
NI 9478 Operating Instructions and Specifications  
18  
ni.com  
 
Specifications  
The following specifications are typical for the range –40 to 70 °C  
unless otherwise noted. All voltages are relative to COM unless  
otherwise noted.  
Output Characteristics  
Number of channels..........................16 digital output channels  
Output type .......................................Sinking  
Power-on output state .......................Channels off  
Output voltage (V0)...........................I0R0  
External power supply  
voltage range (Vsup)...........................050 VDC  
Continuous output current (I0)1, per channel  
All channels on...........................1.2 A max  
Four channels on ........................2.5 A max  
One channel on...........................5 A max  
1
Refer to the Safe Operating Current section for more information about safe  
operating current.  
© National Instruments Corp.  
19 NI 9478 Operating Instructions and Specifications  
 
 
Switched output current (10 kHz)1, per channel  
All channels on...........................1 A max  
Four channels on ........................2 A max  
One channel on...........................4 A max  
Switched output current (20 kHz)1, per channel  
All channels on...........................0.75 A max  
Four channels on ........................1.67 A max  
One channel on...........................3.33 A max  
Output impedance (R0) .....................50 mΩ max  
Reversed-voltage protection .............None  
Number of current limit settings.......2 (Limit A and Limit B)  
Current limit range............................05.1 A  
Current limit resolution.....................8-bit, 20 mA per LSB  
Current limit accuracy ......................130 mA + 3% of setting, max  
1
Using up to 2 meters of cabling on each output channel. Refer to the Safe Operating  
Current section for more information.  
NI 9478 Operating Instructions and Specifications  
20  
ni.com  
 
Overcurrent protection threshold  
selection per channel.........................Limit A, Limit B, or  
No Limit  
Overcurrent shutoff response time....1 μs  
Overcurrent refresh configuration ....Enabled or Disabled  
Overcurrent refresh period................20–2550 μs in 10 μs  
increments  
Overcurrent refresh period  
accuracy ............................................ 7% max  
Propagation delay .............................250 ns max  
MTBF ...............................................823,106 hours at 25 °C;  
Bellcore Issue 6, Method 1,  
Case 3, Limited Part Stress  
Method  
Note Contact NI for Bellcore MTBF specifications  
at other temperatures or for MIL-HDBK-217F  
specifications.  
© National Instruments Corp.  
21 NI 9478 Operating Instructions and Specifications  
 
Power Requirements  
Power consumption from chassis  
Active mode ...............................1 W max  
Sleep mode .................................25 μW max  
Thermal dissipation (at 70 °C)  
Active mode ...............................1.5 W max  
Sleep mode .................................25 μW max  
Physical Characteristics  
If you need to clean the module, wipe it with a dry towel.  
Weight...............................................148 g (5.2 oz)  
NI 9478 Operating Instructions and Specifications  
22  
ni.com  
 
Safety  
Maximum Voltage1  
Connect only voltages that are within the following limits.  
Vsup-to-COM.....................................50 VDC,  
Measurement Category I  
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  
measurements of voltages from specially protected secondary  
circuits. Such voltage measurements include signal levels, special  
equipment, limited-energy parts of equipment, circuits powered by  
regulated low-voltage sources, and electronics.  
Caution Do not connect the NI 9478 to signals or use for  
measurements within Measurement Categories II, III,  
or IV.  
1 The maximum voltage that can be applied or output between Vsup and COM without  
creating a safety hazard.  
© National Instruments Corp.  
23 NI 9478 Operating Instructions and Specifications  
 
Isolation Voltages  
Channel-to-channel...........................No isolation between  
channels  
Channel-to-earth ground  
Continuous .................................60 VDC,  
Measurement Category I  
Withstand....................................1,000 V, verified by a 5 s  
dielectric withstand test  
Safety 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  
Note For UL and other safety certifications, refer to the  
product label or visit ni.com/certification, search  
by module number or product line, and click the  
appropriate link in the Certification column.  
NI 9478 Operating Instructions and Specifications  
24  
ni.com  
 
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  
Environmental  
National Instruments C Series modules are intended for indoor use  
only but may be used outdoors if installed in a suitable enclosure.  
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  
© National Instruments Corp.  
25 NI 9478 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  
Maximum altitude.............................2,000 m  
Pollution Degree (IEC 60664)..........2  
Shock and Vibration  
To meet these specifications, you must panel mount the system.  
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  
NI 9478 Operating Instructions and Specifications  
26  
ni.com  
 
Electromagnetic Compatibility  
This product is designed to meet the requirements of the following  
standards of EMC for electrical equipment for measurement,  
control, and laboratory use:  
EN 61326 EMC requirements; Industrial Immunity  
EN 55011 Emissions; Group 1, Class A  
CE, C-Tick, ICES, and FCC Part 15 Emissions; Class A  
Note For EMC compliance, operate this device with  
shielded cabling.  
CE Compliance  
This product meets the essential requirements of applicable  
European directives, as amended for CE markings, as follows:  
2006/95/EC; Low-Voltage Directive (safety)  
2004/108/EC; Electromagnetic Compatibility Directive  
(EMC)  
Note Refer to the Declaration of Conformity (DoC) for  
this product for any additional regulatory compliance  
information. To obtain the DoC for this product, visit  
© National Instruments Corp.  
27 NI 9478 Operating Instructions and Specifications  
 
ni.com/certification, search by module number  
or product line, and click the appropriate link in the  
Certification column.  
Environmental Management  
National Instruments is committed to designing and manufacturing  
products in an environmentally responsible manner. NI recognizes  
that eliminating certain hazardous substances from our products is  
beneficial not only to the environment but also to NI customers.  
For additional environmental information, refer to the NI and the  
Environment 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 their life cycle, all products  
must be sent to a WEEE recycling center. For more  
information about WEEE recycling centers and National  
Instruments WEEE initiatives, visit ni.com/  
environment/weee.htm.  
NI 9478 Operating Instructions and Specifications  
28  
ni.com  
 
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ni.com/environment/rohs_chinaDŽ  
about China RoHS compliance, go to  
environment/rohs_china  
(For information  
ni.com/  
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© National Instruments Corp.  
29 NI 9478 Operating Instructions and Specifications  
 
Where to Go for Support  
The National Instruments Web site 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.  
National Instruments corporate headquarters is located at  
11500 North Mopac Expressway, Austin, Texas, 78759-3504.  
National Instruments also has offices located around the world to  
help address your support needs. For telephone support in the  
United States, create your service request at ni.com/support  
and follow the calling instructions or dial 512 795 8248. For  
telephone support outside the United States, contact your local  
branch office:  
Australia 1800 300 800, Austria 43 662 457990-0,  
Belgium 32 (0) 2 757 0020, Brazil 55 11 3262 3599,  
Canada 800 433 3488, China 86 21 5050 9800,  
Czech Republic 420 224 235 774, Denmark 45 45 76 26 00,  
Finland 358 (0) 9 725 72511, France 01 57 66 24 24,  
Germany 49 89 7413130, India 91 80 41190000,  
Israel 972 3 6393737, Italy 39 02 41309277, Japan 0120-527196,  
NI 9478 Operating Instructions and Specifications  
30  
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Korea 82 02 3451 3400, Lebanon 961 (0) 1 33 28 28,  
Malaysia 1800 887710, Mexico 01 800 010 0793,  
Netherlands 31 (0) 348 433 466, New Zealand 0800 553 322,  
Norway 47 (0) 66 90 76 60, Poland 48 22 3390150,  
Portugal 351 210 311 210, Russia 7 495 783 6851,  
Singapore 1800 226 5886, Slovenia 386 3 425 42 00,  
South Africa 27 0 11 805 8197, Spain 34 91 640 0085,  
Sweden 46 (0) 8 587 895 00, Switzerland 41 56 2005151,  
Taiwan 886 02 2377 2222, Thailand 662 278 6777,  
Turkey 90 212 279 3031, United Kingdom 44 (0) 1635 523545  
© National Instruments Corp.  
31 NI 9478 Operating Instructions and Specifications  
 
National Instruments, NI, ni.com, and LabVIEW are trademarks of National Instruments Corporation. Refer to the  
Terms of Use section on ni.com/legal for more information about 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, refer to the appropriate location: Help»Patents in your software,  
the patents.txt file on your CD, or ni.com/patents.  
© 2007–2008 National Instruments Corp. All rights reserved.  
374612D-01  
Feb08  
 

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