NI 9502 Series User manual

Getting Started with the NI 9502 Brushless Servo
Drive Module and NI AKM Motors
Note If you are a new user of LabVIEW or are unfamiliar with LabVIEW, refer to the Getting
Started with LabVIEW manual for information about LabVIEW and LabVIEW terminology.
This document explains how to install and configure the NI 9502 C Series brushless servo drive module
for use with the NI AKM motors, and provides a walkthrough for both Trapezoidal and Field Oriented
Control commutation modes.
Tip If you encounter any problems during setup, refer to the Tips and Troubleshooting section for
assistance.
Contents
NI 9502 Overview ............................................................................................................................... 2
NI 9502 Commutation Mode....................................................................................................... 2
NI 9502 Connections ................................................................................................................... 4
NI 9502 to AKM Cable ............................................................................................................... 5
Connecting and Using the NI 9502 in Trapezoidal Commutation Mode ............................................ 6
What You Need to Get Started ....................................................................................................6
Hardware Installation and Configuration .................................................................................... 7
Software Installation and Configuration...................................................................................... 12
Connecting and Using the NI 9502 in Field Oriented Control Commutation Mode........................... 16
What You Need to Get Started ....................................................................................................16
Hardware Installation and Configuration .................................................................................... 17
Software Installation and Configuration...................................................................................... 21
Tips and Troubleshooting .................................................................................................................... 23
I/O Nodes Are Broken or Unavailable ........................................................................................ 23
Motor Responds Poorly ............................................................................................................... 24
NI AKM Motor Specifications .................................................................................................... 26
NI AKM Motor Thermal Sensor PTC Resistance Versus Temperature Curve........................... 27
Related Documentation........................................................................................................................ 28
Worldwide Support and Services ........................................................................................................ 28

Getting Started with the NI 9502 and AKM Motors 2 ni.com
NI 9502 Overview
The NI 9502 is a brushless servo motor drive that provides outputs to drive a brushless servo motor,
inputs for Hall Effect sensors, and power connections. Depending on software settings, the NI 9502 can
operate in either Trapezoidal or Field Oriented Control (FOC) commutation mode. Table 1 shows the
hardware and software differences between the NI 9502 commutation modes.
NI 9502 Commutation Mode
Specify the NI 9502 commutation mode in the C Series Module Properties dialog box, available by
right-clicking the NI 9502 C Series module in the Project Explorer window and selecting Properties
from the shortcut menu. The I/O nodes available to the module change depending on which
commutation mode is selected.
Trapezoidal Commutation
Trapezoidal commutation involves sending current through two of the three motor phases at any time.
The phase transitions are controlled by the Hall Effect sensor state changes. With trapezoidal
commutation, one electrical revolution is divided into six steps of 60 degrees each.
The NI 9502 performs trapezoidal commutation based on the Hall Effect sensor inputs. For proper phase
switching to occur, the Hall Effect sensors from the motor must be connected to the correct Hall inputs
on the NI 9502 module. The Hall Effect sensor phase sequence is motor-dependent, so selecting the
correct inputs requires manual testing. Refer to the Connecting and Using the NI 9502 in Trapezoidal
Commutation Mode section for a detailed walkthrough using an example VI for assistance in
determining the proper Hall input connections to the NI 9502 module.
Figure 1 shows the NI 9502 module block diagram when it is used in Trapezoidal commutation mode
for velocity control.
Table 1. NI 9502 Commutation Options
Trapezoidal Commutation
Field Oriented Control
Commutation
NI AKM Motor
Direct Connectivity
Yes Ye s
Torque Ripple Up to 15% Negligible
High-Speed Performance Limited Full motor capability
Feedback Required Velocity control—No
Position control—Yes
Velocity control—Yes
Position control—Yes
Optimized Current Loop Gains
Provided for NI AKM Motors
No Yes
NI SoftMotion Module
Requirement
None NI SoftMotion Module
Premium
Hall Phasing Manual configuration Automatic configuration (using
NI SoftMotion Module
provided example)
Trajectory Generator User-supplied setpoints or velocity
control
NI SoftMotion Module
trajectory generator

©National Instruments Corporation 3 Getting Started with the NI 9502 and AKM Motors
Figure 1. NI 9502 Trapezoidal Commutation Mode Block Diagram
If your application requires position feedback you can also use an additional I/O module, such as the
NI 9411, for encoder feedback as shown in Figure 2.
Figure 2. NI 9502 Trapezoidal Commutation Mode Block Diagram with Encoder Feedback
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
Position
Loop
Velocity
Loop
Current
Loop
Fault
Monitor
Bridge
Controller
Fault
Detection
3-Phase
Bridge
Current
Sense
Encoder
Feedback
Motor
Velocity
Command
Current
Command*
Position
Setpoint
LabVIEW FPGA Module
NI 9502
Encoder
Feedback
Position
Decoder
Motor
Current
Velocity
Feedback
Position
Feedback
Velocity
Estimator
* Proportional to Torque
PWM
Generator
Hall
Inputs
C Series I/O Module

Getting Started with the NI 9502 and AKM Motors 4 ni.com
Trapezoidal commutation produces a torque ripple of up to 15% at slow speeds, which is not the case
with Field Oriented Control commutation.
Field Oriented Control
Field Oriented Control (FOC) commutation mode uses a more advanced algorithm that allows smooth
motion at slow speeds and better efficiency at high speeds. LabVIEW NI SoftMotion Module Premium
provides VIs and example programs that provide quick setup and application development when using
the NI 9502 with FOC commutation mode. Your LabVIEW Platform DVD includes a free 30-day
evaluation of NI SoftMotion Module Premium that you can install to evaluate using the NI 9502 in FOC
commutation mode.
Figure 3 shows the NI 9502 module block diagram when it is used in FOC commutation mode.
Figure 3. NI 9502 FOC Commutation Mode Block Diagram
NI 9502 Connections
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 4 for the pin assignments.
The NI 9502 requires a a 9 to 30 VDC power supply connection, provided on the screw-terminal
connector. Refer to the NI 9502 Operating Instructions and Specifications for power supply
requirements and other important information.
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 LabVIEW NI SoftMotion Module Premium
FOC = Field Oriented Control
SVPWM = Space Vector PWM
SVPWM**
Generators
(3 Total)
Hall
Inputs
C Series I/O Module
3-Phase
Bridge

©National Instruments Corporation 5 Getting Started with the NI 9502 and AKM Motors
Caution To ensure EMC compliance, special considerations are required for all cable connections.
Refer to the Cable Requirements for EMC Compliance section in the NI 9502 Operating Instructions
and Specifications for more information.
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.
Figure 4. NI 9502 Screw Terminal Connector and LEDs
NI 9502 to AKM Cable
The NI 9502 to AKM Cable kit connects an NI 9502 C Series brushless servo motor drive module to an
NI AKM servo motor available from National Instruments. The kit consists of two cables, one for motor
power and one for Hall Effect sensor and encoder feedback, with motor connectors on one end and
pigtail connectors to the NI 9502 C Series module and a separate encoder module on the other end. The
required cable connections differ depending on the NI 9502 commutation mode. Refer to the
Connecting and Using the NI 9502 in Trapezoidal Commutation Mode or Connecting and Using the
NI 9502 in Field Oriented Control Commutation Mode section for cable information.
1Enabled LED (Green)
2Vsup (Motor Power) LED (Green)
3User LED (Yellow)
4Fault LED (Red)
5Screw Terminal Connector
0
1
2
3
4
5
6
7
8
9
Phase U
Phase V
Phase W
Reserved
Hall 1
Hall 2
Hall 3
COM
Vsup
(Chassis Ground)
1 2 3 4
5

Getting Started with the NI 9502 and AKM Motors 6 ni.com
Connecting and Using the NI 9502 in Trapezoidal Commutation Mode
This section explains how to connect and use the NI 9502 module in Trapezoidal commutation mode,
using an installed example to help you set up and configure your system.
What You Need to Get Started
You need the following items to get started.
Hardware
❑NI 9502 C Series brushless servo drive module
❑NI CompactRIO real-time controller
❑24 V power supply (such as the NI PS-15) for the CompactRIO controller
(NI part number 781093-01)
❑24 V power supply (such as the NI PS-16) for the NI 9502 module
(NI part number 781094-01)
Note NI recommends the NI PS-16 power supply, which is designed for motor bus power, for use
with the NI 9502 module. Refer to Regeneration Consideration Using the NI C Series Drive Modules
at zone.ni.com for more information.
❑5 V power supply (such as the NI PS-6) for the Hall Effect sensors
(NI part number 780577-01)
Note If you are connecting the optional encoder and using an NI 9411 C Series module for encoder
connections, you can use the +5 V output on the NI 9411 module to power the encoder and Hall
Effect sensors on the NI AKM motor.
❑Ethernet connection and cable for the CompactRIO controller
❑NI 9502 to AKM Cable
(NI part number 153108-03)
❑NI AKM servo motor
❑(Optional) NI 9411 C Series module for encoder connections and +5 V output
(NI part number 779005-01)
❑(Optional) NI 9935 15pin D-Sub connector kit for connecting the NI 9411
(NI part number 779016-01)
Software
❑LabVIEW 2011 or later
❑LabVIEW 2011 Real-Time Module or later
❑NI-RIO 4.0.0 or later with CompactRIO Module Support 4.0.1 installed
❑(Optional) LabVIEW NI SoftMotion Module 2011 f1 or later
Note LabVIEW NI SoftMotion Module Premium provides FPGA Motor Control VIs that you can
use with the NI 9502. Your LabVIEW Platform DVD includes a free 30-day evaluation of
NI SoftMotion Module Premium that you can install. Refer to ni.com/info and enter nismpkg
for more information about the NI SoftMotion Module.

©National Instruments Corporation 7 Getting Started with the NI 9502 and AKM Motors
Figure 5 shows the hardware connections when the NI 9502 is used in Trapezoidal commutation mode
for velocity control.
Figure 5. NI 9502 Trapezoidal Commutation Connections
Hardware Installation and Configuration
This section covers the hardware setup for the CompactRIO system, NI 9502 C Series servo drive
module, and NI AKM brushless servo motor.
Step 1: Set Up the CompactRIO System
Complete the following steps to set up the CompactRIO hardware.
1. Install the real-time CompactRIO controller on the chassis if you are not using an integrated
controller and chassis.
Note Write down the controller serial number before installing the controller onto the chassis.
You will be unable to read the serial number after you install the controller.
a. Make sure that no power is connected to the controller or the chassis.
Feedback Connections
(Encoder connections
not used)
Ethernet
Cable
Motor Connections
NI RT Controller
(NI cRIO-9014 shown)
and NI 9502 Module
+24 V Power Supply
(NI PS-15 Shown)
9 to 30 V Power Supply
(NI PS-16 Shown)
5 V Power Supply
(NI PS-6 recommended)

Getting Started with the NI 9502 and AKM Motors 8 ni.com
b. Align the controller with the chassis as shown in Figure 6.
Figure 6. Installing the Controller on the Chassis (Eight-Slot Chassis Shown)
c. Slide the controller onto the controller slot on the chassis. Press firmly to ensure the chassis
connector and the controller connector are mated.
d. Using a number 2 Phillips screwdriver, tighten the two captive screws on the front of the
controller.
2. Connect the controller to a power supply and an Ethernet network on the same subnet as the
development computer. Refer to the controller operating instructions for information about wiring
the controller to the power supply and Ethernet network.
Note Do not plug in or turn on any power to the system until after all hardware connections are
complete.
3. Install the NI 9502 module in slot 1 of the chassis, if available.
Note The NI 9502 example programs are configured for slot 1. If the NI 9502 module is installed
in a different slot, modify the examples accordingly.
4. (Optional) Install an NI 9411 module for encoder feedback, if using.
1 Controller
2Captive Screws
3Controller Slot
4 Reconfigurable Embedded Chassis
5Grounding Screw
4
1
3
2
5

©National Instruments Corporation 9 Getting Started with the NI 9502 and AKM Motors
Step 2: Connect the NI 9502 to the NI AKM Motor
Connect the NI AKM motor to the NI 9502 C Series module using the NI 9502 to AKM Motor Cables.
Figure 7 shows the NI 9502 to AKM Motor Cable connectors.
Figure 7. NI 9502 to NI AKM Motor Cables
Note Encoder feedback is optional when using the NI 9502 in trapezoidal commutation mode for
velocity control applications and required when using the NI 9502 in FOC commutation mode. Refer
to the Connecting and Using the NI 9502 in Field Oriented Control Commutation Mode section for
connecting an NI 9411 C Series module for encoder feedback.
1 Connector to NI AKM Feedback Connector
2Pigtail Connector to C SeriesModule for Encoder Feedback
3Pigtail Connector to NI 9502 Module for Hall Effect Sensors
4Pigtail Connector to NI 9502 for Motor Phase Connections
5 Connector to NI AKM Motor Connector
2
4
5
3
1

Getting Started with the NI 9502 and AKM Motors 10 ni.com
Tables 2, 3, and 4 provide the NI 9502 to AKM Motor cable screw terminal lead descriptions for the
motor, encoder, and Hall Effect sensor connections, respectively. Tables 2 and 4 show NI 9502
connections, and Table 3 shows an example NI 9411 connection.
Table 2. NI 9502 to AKM Motor Connector Screw Terminal Lead Descriptions
NI 9502 Connection Wire Color Signal Name Signal Description
0Black Phase U Motor Phase U.
1White Phase V Motor Phase V.
2Red Phase W Motor Phase W.
7Green COM Motor COM.
—Clear Drain Connected to the NI AKM motor
case. NI recommends leaving the
drain wire disconnected; some
applications may find it beneficial to
connect the drain wire to the NI 9502
chassis ground to improve EMC
immunity or emissions.
Table 3. NI 9502 to AKM Feedback Cable Screw Terminal Lead Descriptions (Encoder Portion)
NI 9411 Connection
(NI 9411 Signal
Name) Wire Color Signal Name Signal Description
1 (DI0a) White/Orange Stripes Encoder Phase A Differential encoder Phase A/A–
signals.
9 (DI0b) Orange/White Stripes Encoder Phase A–
2 (DI1a) White/Blue Stripes Encoder Phase B Differential encoder Phase B/B–
signals.
10 (DI1b) Blue/White Stripes Encoder Phase B–
3 (DI2a) White/Green Stripes Encoder Index Differential encoder Index/Index–
signals.
11 (DI2b) Green/White Stripes Encoder Index–
12 (COM) White/Brown Stripes COM Encoder ground.
4 (Supply (+5 Vout)) Brown/White Stripes +5 V +5 V supply for encoder and Hall
Effect sensors.

©National Instruments Corporation 11 Getting Started with the NI 9502 and AKM Motors
—White/Grey Stripes NI AKM Motor
Thermal Sensor
Internal thermistor connection within
the motor which you can connect to
an external device for monitoring.
Under normal operating conditions at
a motor winding temperature of
140 °C or lower, the resistance is less
than or equal to 100 Ω. When the
motor winding temperature exceeds
the NI AKM thermal trip point of
140 °C the resistance rapidly
increases. Refer to the Tips and
Troubleshooting section for more
information.
—Grey/White Stripes NI AKM Motor
Thermal Sensor
—Clear Drain Connected to the ground of the
encoder inside the NI AKM motor. NI
recommends connecting this drain
wire to the COM terminal on the
NI 9411; some applications may find
it beneficial to disconnect the drain
wire from the NI 9411 to improve
EMC immunity or emissions.
Table 4. NI 9502 to AKM Feedback Cable Screw Terminal Lead Descriptions (Halls Portion)
NI 9502
Connection Wire Color Signal Name Signal Description
4Red Hall 1 Hall Effect sensor 1.
5Green Hall 2 Hall Effect sensor 2.
6White Hall 3 Hall Effect sensor 3.
7Black COM Hall Effect sensor COM.
—Clear Drain Connected to the ground of the Hall
Effect sensor case inside the NI AKM
motor. NI recommends connecting this
drain wire to the COM terminal on the
NI 9502; some applications may find it
beneficial to disconnect the drain wire
from the NI 9502 to improve EMC
immunity or emissions.
Table 3. NI 9502 to AKM Feedback Cable Screw Terminal Lead Descriptions (Encoder Portion) (Continued)
NI 9411 Connection
(NI 9411 Signal
Name) Wire Color Signal Name Signal Description

Getting Started with the NI 9502 and AKM Motors 12 ni.com
Complete the following steps to connect the NI 9502 to the NI AKM motor.
1. Connect the motor connector on the cable to the NI AKM motor connector.
2. Connect the motor Phase U, Phase V, and Phase W, and COM wires to the NI 9502.
3. Connect the feedback connector on the cable to the NI AKM feedback connector.
4. Connect the Hall 1, Hall 2, Hall 3, and COM wires from the Halls portion of the cable to the
NI 9502.
5. Connect the +5 V and COM wires from the encoder portion of the cable to a 5 V power supply.
6. Connect the COM from the 5 V power supply to the NI 9502 COM, to provide a common reference.
Software Installation and Configuration
This section covers installing and configuring the software for the NI 9502 servo drive module. It
assumes that all required software from the What You Need to Get Started section is installed.
Step 1: Install Software on and Configure the NI RT Controller
Complete the following steps to configure the controller and install software on it.
1. Launch Measurement & Automation Explorer (MAX) on the development computer by clicking
the MAX icon on the desktop, or by selecting Start»All Programs»National Instruments»
Measurement & Automation.
2. Select the controller under Remote Systems in the Configuration pane. If you do not see the
controller, you may need to disable the firewall on the development computer.
3. Verify that the Serial Number in the Identification section matches the serial number on the
device.
4. If you do not want to format the disk on the controller, eliminating all installed software and files,
power on the controller and skip to step 12.
5. Set the Safe Mode switch on the controller to the On position.
6. Power on the controller. If it is already powered on, press the Reset button on the controller to
reboot it.
7. Right-click the controller under Remote Systems in the Configuration pane and select Format
Disk. Click Yes on the dialog box that appears.
8. When MAX finishes formatting the disk, set the Safe Mode switch to the Off position and press
the Reset button on the controller to reboot it.
9. Select the System Settings tab and type a descriptive name for the system in the Name field.
10. (Optional) Complete this step only if the target has an empty IP address (0.0.0.0). Select the
Network Settings tab and select DHCP or Link Local from the Configure IPv4 Address list to
assign an IP address or select the Static to specify a static IP address in the IPv4 Address section.
11. Click Save on the toolbar and let MAX reboot the system.
12. When the new system name appears under Remote Systems, expand the controller item in the tree,
right-click Software, and select Add/Remove Software.
13. Select a recommended software set that includes NI-RIO 4.0 or later.
14. Click Next.
15. (Optional) Select LabVIEW NI SoftMotion Module 11.0.1 or later from the add-ons list.
16. Click Next to install the selected software on the controller. Click Help if you need information
about installing recommended software sets.
17. Close MAX.

©National Instruments Corporation 13 Getting Started with the NI 9502 and AKM Motors
Step 2: Configuring Hall Effect Sensors and Tuning the Motor
For proper phase switching to occur during Trapezoidal commutation mode, the Hall Effect sensors
from the motor must be connected to the correct Hall inputs on the NI 9502 module. The Hall Effect
sensor phase sequence is motor-dependent, so selecting the correct inputs requires manually testing the
motor wiring.
The following tutorial walks you through the Hall Effect sensor connections for the NI 9502 using the
9502 Trapezoidal Commutation example installed in the labview\examples\CompactRIO\
Module Specific\NI 9502\Trapezoidal Commutation directory. This example shows how
to operate the NI 9502 module in Trapezoidal commutation mode using velocity and current control loops.
1. Connect the motor and Hall Effect sensor inputs to the drive, but do not connect the motor to a load.
2. Open the 9502 Trapezoidal Commutation example.
3. Configure the example to work with your hardware:
a. Add your CompactRIO device to the LabVIEW project by right-clicking the Project:9502
Trapezoidal Commutation.lvproj item in the LabVIEW Project Explorer window and
selecting New»Targets and Devices.
b. Select your target from the Add Targets and Devices dialog box.
c. Click OK.
d. Select LabVIEW FPGA Interface from the Select Programming Mode dialog box.
e. Click Continue.
f. Click Discover in the Discover C Series Modules? dialog box, if it appears.
g. Locate the FPGA VI and move it from the example FPGA target to the FPGA target under
your device.
h. Select the example target and remove it from the project.
i. Rename the FPGA target from FPGA Target 2 to FPGA Target.
j. Right-click the NI 9502 module item in the Project Explorer window and select Properties
to open the C Series Module Properties dialog box.
k. Change the Commutation Mode from Field Oriented Control to Trapezoidal.
l. (Optional) Remove the unavailable I/O nodes from under the NI 9502 item the Project
Explorer window.
m. If the NI 9502 is not in slot 1 of the CompactRIO chassis, update the I/O nodes in the FPGA
VI to point to the correct location.
4. Compile the 9502 Trapezoidal Commutation FPGA VI.
5. Open the 9502 Trapezoidal Commutation desktop VI and run the VI.
Note If the VI is not executable, right-click the Open FPGA VI reference function and select
Configure Open FPGA VI Reference from the shortcut menu, then browse to the FPGA VI and
click OK.
6. With the hall wiring property set to the default of 1, 2, 3, enter a small positive velocity (such as
20 RPM) in the Velocity Setpoint (rpm) control.
7. Click the Enable button to enable the drive and move the motor.

Getting Started with the NI 9502 and AKM Motors 14 ni.com
8. Record the highest velocity returned in the Positive Velocity column in Table 5. The velocity is
returned in the Velocity (rpm) graph on the front panel:
Figure 8. 9502 Trapezoidal Commutation Front Panel
Note If the motor moves erratically or not at all, place an X in both velocity columns in Table 5, as
this wiring scheme can be eliminated.
9. Click the Enable button again to disable the drive and stop the motor.
10. Enter the same velocity as a negative number in the Velocity Setpoint control.
11. Click the Enable Drive button to enable the drive and move the motor.
12. Record the highest velocity returned in the Negative Velocity column in Table 5.
13. Click the Enable Drive button again to disable the drive and stop the motor.
14. Repeat steps 8 through 15 for the other five possible wiring combinations.
15. Stop the VI using the Stop button.

©National Instruments Corporation 15 Getting Started with the NI 9502 and AKM Motors
16. Look for the hall wiring value in Table 5 where the velocities in both directions were closest to the
setpoint. This is the setting to use for your system. If these steps did not provide a conclusive result,
repeat the test with a higher Velocity Setpoint.
17. Set hall wiring to the correct value, if necessary.
18. Connect a load to the system and tune the velocity gains using the 9502 Trapezoidal
Commutation VI. Refer to the Tips and Troubleshooting section for tuning tips.
19. (Optional) Tune the current gains using the same principles in the Tips and Troubleshooting section
used to tune the velocity loop.
Table 5. Hall Wiring Property Results
Hall Wiring Property Setting Positive Velocity Negative Velocity
1, 2, 3
1, 3, 2
2, 1, 3
2, 3, 1
3, 1, 2
3, 2, 1

Getting Started with the NI 9502 and AKM Motors 16 ni.com
Connecting and Using the NI 9502 in Field Oriented Control Commutation Mode
This section explains how to connect and use the NI 9502 module in Field Oriented Control (FOC)
commutation mode, using an installed example to help you set up and configure your system.
What You Need to Get Started
You need the following items to get started.
Hardware
❑NI 9502 C Series brushless servo drive module
❑NI CompactRIO real-time controller
❑24 V power supply (such as the NI PS-15) for the CompactRIO controller
(NI part number 781093-01)
❑24 V power supply (such as the NI PS-16) for the NI 9502 module
(NI part number 781094-01)
Note NI recommends the NI PS-16 power supply, which is designed for motor bus power, for use
with the NI 9502 module. Refer to Regeneration Consideration Using the NI C Series Drive Modules
at zone.ni.com for more information.
❑Ethernet connection and cable for the CompactRIO controller
❑NI 9502 to AKM Cable
(NI part number 153108-03)
❑NI AKM servo motor
❑NI 9411 C Series module for encoder connections and +5 V output
(NI part number 779005-01)
❑(Optional) NI 9935 15pin D-Sub connector kit for simplified NI 9411 connections
(NI part number 779016-01)
Software
❑LabVIEW 2011 or later
❑LabVIEW 2011 Real-Time Module or later
❑NI-RIO 4.0.0 or later with CompactRIO Module Support 4.0.1 installed
❑LabVIEW NI SoftMotion Module 2011 f1 or later
Note LabVIEW NI SoftMotion Module Premium provides VIs and example programs that make it
easier to use the NI 9502 in FOC commutation mode. Your LabVIEW Platform DVD includes a free
30-day evaluation of NI SoftMotion Module Premium that you can install. Refer to ni.com/info
and enter nismpkg for more information about the NI SoftMotion Module.

©National Instruments Corporation 17 Getting Started with the NI 9502 and AKM Motors
Figure 5 shows the hardware connections when the NI 9502 is used in FOC commutation mode.
Figure 9. NI 9502 FOC Commutation Connections
Hardware Installation and Configuration
This section covers the hardware setup for the CompactRIO system, NI 9502 C Series servo drive
module, and NI AKM brushless servo motor.
Step 1: Set Up the CompactRIO System
Complete the following steps to set up the CompactRIO hardware.
1. Install the real-time CompactRIO controller on the chassis if you are not using an integrated
controller and chassis.
Note Write down the controller serial number before installing the controller onto the chassis.
You will be unable to read the serial number after you install the controller.
a. Make sure that no power is connected to the controller or the chassis.
Feedback Connections
Ethernet
Cable
Motor Connections
NI RT Controller
(NI cRIO-9014 shown)
with NI 9502 and
NI 9411 Modules
+24 V Power Supply
(NI PS-15 Shown)
9 to 30 V Power Supply
(NI PS-16 Shown)

Getting Started with the NI 9502 and AKM Motors 18 ni.com
b. Align the controller with the chassis as shown in Figure 10.
Figure 10. Installing the Controller on the Chassis (Eight-Slot Chassis Shown)
c. Slide the controller onto the controller slot on the chassis. Press firmly to ensure the chassis
connector and the controller connector are mated.
d. Using a number 2 Phillips screwdriver, tighten the two captive screws on the front of the
controller.
2. Connect the controller to a power supply and an Ethernet network on the same subnet as the
development computer. Refer to the controller operating instructions for information about wiring
the controller to the power supply and Ethernet network.
Note Do not plug in or turn on any power to the system until after all hardware connections are
complete.
3. Install the NI 9502 module in slot 1 of the chassis, if available.
Note The NI 9502 example programs are configured for slot 1. If the NI 9502 module is installed
in a different slot, modify the examples accordingly.
4. Install an NI 9411 module for encoder feedback, and to provide 5 V power for the encoder and Hall
Effect sensors.
1 Controller
2Captive Screws
3Controller Slot
4 Reconfigurable Embedded Chassis
5Grounding Screw
4
1
3
2
5

©National Instruments Corporation 19 Getting Started with the NI 9502 and AKM Motors
Step 2: Connect the NI 9502 and NI 9411 to the NI AKM Motor
Connect the NI AKM motor to the NI 9502 and NI 9411 C Series modules using the NI 9502 to AKM
Motor Cables. Figure 7 shows the NI 9502 to AKM Motor Cable connectors.
Figure 11. NI 9502 to AKM Motor Cables
Tables 6, 7, and 8 provide the NI 9502 to AKM Motor cable screw terminal lead descriptions for the
motor, encoder, and Hall Effect sensor connections, respectively.
1 Connector to NI AKM Feedback Connector
2Pigtail Connector to C SeriesModule for Encoder Feedback
3Pigtail Connector to NI 9502 Module for Hall Effect Sensors
4Pigtail Connector to NI 9502 for Motor Phase Connections
5 Connector to NI AKM Motor Connector
Table 6. NI 9502 to AKM Motor Connector Screw Terminal Lead Descriptions
NI 9502 Connection Wire Color Signal Name Signal Description
0Black Phase U Motor Phase U.
1White Phase V Motor Phase V.
2Red Phase W Motor Phase W.
7Green COM Motor COM.
—Clear Drain Connected to the NI AKM motor
case. NI recommends leaving the
drain wire disconnected; some
applications may find it beneficial to
connect the drain wire to the NI 9502
chassis ground to improve EMC
immunity or emissions.
2
4
5
3
1

Getting Started with the NI 9502 and AKM Motors 20 ni.com
Table 7. NI 9502 to AKM Feedback Cable Screw Terminal Lead Descriptions (Encoder Portion)
NI 9411 Connection
(NI 9411 Signal
Name) Wire Color Signal Name Signal Description
1 (DI0a) White/Orange Stripes Encoder Phase A Differential encoder Phase A/A–
signals.
9 (DI0b) Orange/White Stripes Encoder Phase A–
2 (DI1a) White/Blue Stripes Encoder Phase B Differential encoder Phase B/B–
signals.
10 (DI1b) Blue/White Stripes Encoder Phase B–
3 (DI2a) White/Green Stripes Encoder Index Differential encoder Index/Index–
signals.
11 (DI2b) Green/White Stripes Encoder Index–
12 (COM) White/Brown Stripes COM Encoder ground.
4 (Supply (+5 Vout)) Brown/White Stripes +5 V +5 V supply for encoder and Hall
Effect sensors.
—White/Grey Stripes NI AKM Motor
Thermal Sensor
Internal thermistor connection within
the motor which you can connect to
an external device for monitoring.
Under normal operating conditions at
a motor winding temperature of
140 °C or lower, the resistance is less
than or equal to 100 Ω. When the
motor winding temperature exceeds
the NI AKM thermal trip point of
140 °C the resistance rapidly
increases. Refer to the Tips and
Troubleshooting section for more
information.
—Grey/White Stripes NI AKM Motor
Thermal Sensor
—Clear Drain Connected to the ground of the
encoder inside the NI AKM motor. NI
recommends connecting this drain
wire to the COM terminal on the
NI 9411; some applications may find
it beneficial to disconnect the drain
wire from the NI 9411 to improve
EMC immunity or emissions.