CompactRIO cRIO-9002/9004 Operating Instructions
Contents
1. wae A a gt N a 1 90 2 mm Ge tr roe 44 2 mm _ 1 74in tS ECT EAN E i 77 3 mm gt i 3 04 in omy A r d O 3 E 88 1 mm O 3 47 in VT LC 44 2 mm ES 1 74 in O Ee SE GE j 1 Ma Thread Figure 2 CompactRIO Controller Front and Bottom Views with Dimensions National Instruments Corporation 3 cRIO 9002 9004 Operating Instructions Complete the following steps to install the controller on the chassis 1 Make sure that no power is connected to the controller or the chassis 2 Align the controller with the chassis as shown in Figure 3 1 Controller 3 Controller Slot 2 Captive Screws 4 Reconfigurable Embedded Chassis Figure 3 Installing the Controller on the Chassis Eight Slot Chassis Shown 3 Slide the controller onto the controller slot on the chassis Press firmly to ensure the chassis connector and the controller connector are mated 4 Using a number 2 Phillips screwdriver tighten the two captive screws on the front of the controller to 1 3 N m 11 5 Ib in of torque cRIO 9002 9004 Operating Instructions 4 ni com Connecting the Controller to a Network Connect t2. 73 23 EEC Electromagnetic Compatibility Directive EMU 89 336 EEC ei 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 ni com certification search by model number or product line and click the appropriate link in the Certification column Cabling Table 4 shows the standard Ethernet cable wiring connections for both normal and crossover cables Table 4 Ethernet Cable Wiring Connections Connector 2 Connector 2 Pin Connector 1 Normal Crossover 1 white orange white orange white green 2 orange orange green 3 white green white green white orange 4 blue blue blue 5 white blue white blue white blue cRIO 9002 9004 Operating Instructions 16 ni com Table 4 Ethernet Cable Wiring Connections Continued Connector 2 Connector 2 Pin Connector 1 Normal Crossover 6 green green orange 7 white brown white brown white brown 8 brown brown brown Connector 1 Connector 2 Pin II Pin 8 Pin 1 gt r fH II Pin 8 Figure 8 Ethernet Connector Pinout National Instruments Corporation 17 cRIO 9002 9004 Operating Instructions National Instruments Contact Information National Instruments corporate headquarters is located at 11500 North Mopac Expressway Austin
3. manually restore the unit to the factory network settings When you reset the controller the IP address subnet mask DNS address gateway and Time Server IP are set to 0 0 0 0 Resetting does not affect power on defaults watchdog settings or VIs Complete the following steps to reset the controller 1 Move the IP Reset DIP switch to the ON position 2 Push the Reset button to cycle power to the controller The Status LED flashes once indicating that the controller IP address is unconfigured 3 Move the IP Reset switch to the OFF position The controller settings are reset You can reconfigure the settings in MAX from a computer on the same subnet Refer to the Measurement amp Automation Explorer Help for more information about configuring the controller Specifications The following specifications are typical for the range 40 to 70 C unless otherwise noted Network Network interface ceseeeceseneeseeeneeees 10BaseT and 100BaseTX Ethernet Compatibility 00 eeeeeeeeeeeteeeeeeees TEEE 802 3 Communication rotes 10 Mbps 100 Mbps auto negotiated Maximum cabling detance 100 m segment Memory cRIO 9002 Nonvolatile 00 ceeeeeseeseeeeseeeneeees 64 MB DRAM EE E 32 MB cRIO 9004 Nonvolatile 00 0 ceeeeeeeeseeeeneeeneeees 512 MB DRAM gust Eeer Sa 64 MB cRIO 9002 9004 Operating Instructions 12 ni com MTBF The following MTBF specifications apply to the cRIO 9002 and cRIO 9004 NN ET E 1 253 788 hours at
4. 25 C Bellcore Issue 6 Method 1 Case 3 Parts Count Method ei Note Contact NI for Bellcore MTBF specifications at other temperatures or for MIL HDBK 217F specifications Go to ni com certification and search by model number or product line for more information about MTBF and other product certifications Power Requirements You must use a National Electric Code NEC Class 2 power source with the cRIO 9002 9004 Recommended power supply 48 W secondary 18 VDC to 24 VDC Power consumption Controller only 7 W max Controller supplying power to 8 CompactRIO modules 17 W Power supply ON POWET Up 9 to 35 V After power up 6 to 35 V ei Note The cRIO 9002 and cRIO 9004 power up only at 9 V or higher but when these devices are powered on they can run on as little as 6 V Physical Characteristics If you need to clean the controller wipe it with a dry towel Screw terminal wing eee 12 to 24 AWG copper conductor wire with 10 mm 0 39 in of insulation stripped from the end Torque for screw terminals 0 0 0 5 to 0 6 N m 4 4 to 5 3 Ib in Welg hf ss ecsisevssssrecsiospeaseorescbnebintanes starsat Approx 488 g 17 2 oz National Instruments Corporation 13 cRIO 9002 9004 Operating Instructions Safety Ei Safety Voltages Connect only voltages that are within these limits Mee Ee eege 35 V max Measurement Category I Measurement Category I is for measurements performed
5. Guidelines Operate the cRIO 9002 9004 only as described in these operating instructions Safety Guidelines for Hazardous Locations view P The cRIO 9002 9004 is suitable for use in Class I Division 2 Groups A B C and D hazardous locations Class I Zone 2 AEx nC IIC T4 and Ex nC IIC T4 hazardous locations and nonhazardous locations only Follow these guidelines if you are installing the cRIO 9002 9004 in a potentially explosive environment Not following these guidelines may result in serious injury or death Caution Do not disconnect the power supply wires and connectors from the controller unless power has been switched off Caution Do not install or remove the controller unless power has been switched off Caution Substitution of components may impair suitability for Class I Division 2 Caution For Zone 2 applications install the CompactRIO system in an enclosure rated to at least IP 54 as defined by IEC 60529 and EN 60529 Special Conditions for Safe Use in Europe This equipment has been evaluated as EEx nC IIC T4 equipment under DEMKO Certificate No 03 ATEX 0324020X Each controller is marked II 3G and is suitable for use in Zone 2 hazardous locations cRIO 9002 9004 Operating Instructions 2 ni com Installing the Controller on the Chassis Figure 2 shows the dimensions of the CompactRIO controller
6. 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 2004 2005 National Instruments Corporation All rights reserved 373561C 01 Aug05
7. V1 terminal and the negative lead to one of the C terminals 3 Connect the positive lead of the other power source to the V2 terminal and the negative lead to one of the C terminals ei Note The controller draws power from either V1 or V2 depending on which terminal has a higher voltage It does not draw power from both terminals UN Caution The C terminals are internally connected to each other Make sure to use two power sources that have a common ground Figure 4 Wiring Power to the Controller cRIO 9002 9004 Operating Instructions 6 ni com Powering On the Controller Boot Options Plug in each power supply to the CompactRIO system The controller runs a power on self test POST During the POST the Power Status and Userl LEDs turn on The User and Status LEDs turn off indicating that the POST is complete If the LEDs do not behave in this way when the controller powers on refer to the Understanding LED Indications section You can configure the controller to launch an embedded stand alone application each time you boot the controller Refer to the LabVIEW Real Time Module User Manual for more information Table 1 lists the reset options available on CompactRIO backplanes such as the cRIO 910x devices Use these options to determine how the CompactRIO controllers such as the cRIO 9002 and cRIO 9004 controllers are reset in various conditions Table 1 CompactRIO Reset Options Backplane
8. 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 V and C terminals to signals within Measurement Categories II Safety Standards The cRIO 9002 9004 is designed to meet the requirements of the following standards of safety for electrical equipment for measurement control and laboratory use e EN 61010 1 IEC 61010 1 e UL61010 1 e CAN CSA C22 2 No 61010 1 Note For UL and other safety certifications refer to the product label or visit ni com certification search by model number or product line and click the appropriate link in the Certification column Hazardous Locations WES QUE E Class I Division 2 Groups A B C D T4 Class I Zone 2 AEx nC IIC T4 Canada CU Class I Division 2 Groups A B C D T4 Class I Zone 2 Ex nC IIC T4 Europe DEMKO oeer EEx nC IIC T4 cRIO 9002 9004 Operating Instructions 14 ni com Environmental The cRIO 9002 9004 is intended for indoor use only For outdoor use mount the CompactRIO system in a suitably rated enclosure Operating temperature IEC 60068 2 1 IEC 60068
9. 2 2 40 to 70 C ei Note To meet this operating temperature range follow the guidelines in the installation instructions for your CompactRIO system Storage temperature IEC 60068 2 1 IEC teg 23 21 40 to 85 C Ingress protection ceeeseeeeseeeeees IP 40 Operating humidity TEC eeng 2 ap 10 to 90 RH noncondensing Storage humidity TEC eeng 2 ap 5 to 95 RH noncondensing Maximum altitude cecceceeeeeee 2 000 m Pollution Degree IEC 60664 2 Shock and Vibration To meet these specifications you must panel mount the CompactRIO system and affix ferrules to the end of the terminal wires Operating vibration random IEC 60068 2 64 ee 5 Sims 10 to 500 Hz Operating shock TEC oO0og 227 30 g 11 ms half sine 50 g 3 ms half sine 18 shocks at 6 orientations Operating vibration sinusoidal IEC 60068 2 6 5 g 10 to 500 Hz National Instruments Corporation 15 cRIO 9002 9004 Operating Instructions Electromagnetic Compatibility IER e EE EN 55011 Class A at 10 m FCC Part 15A above 1 GHz rt ru e Industrial levels per EN 61326 1997 A2 2001 Table A 1 EMC EM Disnea CE C Tick and FCC Part 15 Class A Compliant ei 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 marking as follows Low Voltage Directive safety
10. Real Time engine launches when the controller boots If the switch is in the OFF position the LabVIEW Real Time engine launches Keep this switch in the OFF position during normal operation If the switch is in the ON position when the controller boots the controller launches only the essential services required for updating its configuration and installing software The LabVIEW Real Time engine does not launch Push the Safe Mode switch to the ON position if the software on the controller is corrupted If there is no software installed on the controller the controller automatically boots into safe mode regardless of the position of the safe mode switch The Safe Mode switch must be in the ON position to reformat the drive on the controller Refer to the Measurement amp Automation Explorer Help for more about installing software on a controller and the reformatting the drive on the controller Console Out Switch With a serial port terminal program you can use the Console Out switch to read the IP address and BIOS version of the controller Connect the serial port on the controller to a computer Push the switch to the ON position Make sure that the serial port terminal program is configured to the following settings e 9 600 bits per second e Eight data bits e No parity e One stop bit The serial port terminal program displays the IP address and BIOS version Keep this switch in the OFF position during normal operation IP Reset
11. Reset Option Controller Behavior Do Not Autoload on Reset Does not load the FPGA bit stream from flash memory Autoload on Power On Reset Loads the FPGA bit stream from flash memory to the FPGA when the controller powers on Autoload on Any Device Reset Loads the FPGA bit stream from flash to the FPGA when you reboot the controller either with or without cycling power Connecting Serial Devices to the Controller The controller has an RS 232 serial port to which you can connect devices such as displays or input devices Use the Serial VIs to read from and write to the serial port For more information about the Serial VIs refer to the LabVIEW Help National Instruments Corporation 7 cRIO 9002 9004 Operating Instructions Figure 5 Controller Serial Port Table 2 DB 9 Pin Descriptions Pin Signal DCD TXD DTR GND DSR RTS CTS RI OSIIN IAI ny BB wy bv Configuring DIP Switches ON OFF SAFE MODE CONSOLE OUT IP RESET NOAPP USER1 Figure 6 Controller DIP Switches All of the DIP switches are in the OFF position when the controller is shipped from National Instruments cRIO 9002 9004 Operating Instructions 8 ni com Safe Mode Switch The position of the Safe Mode switch determines whether the embedded LabVIEW
12. Switch Push the IP Reset switch to the ON position and reboot the controller to reset the IP address of the controller to 0 0 0 0 Ifthe controller is on your local subnet and the IP Reset switch is in the ON position the controller appears in MAX with IP address 0 0 0 0 You can configure a new IP address for the controller in MAX Refer to the Resetting the Network Configuration of the Controller section for more information about resetting the IP address You also can push this switch to the ON position to unlock a controller that was previously locked in MAX National Instruments Corporation 9 cRIO 9002 9004 Operating Instructions No App Switch User Switch Push the No App switch to the ON position to prevent a LabVIEW startup application from running on the controller when the controller powers on If you want to permanently disable the application from running when the controller powers on you must disable it in LabVIEW To run an application when the controller powers on push the No App switch to the OFF position create an application using the LabVIEW Application Builder and configure the application in LabVIEW to launch when the controller powers on If you already have an application configured to launch when the controller powers on and you push the No App switch from ON to OFF the power on application is automatically enabled For more information about automatically launching VIs when the controller powers on and disablin
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14. UE OPERATING INSTRUCTIONS CompactRIO cRIO 9002 9004 Intelligent Real Time Embedded Controllers for CompactRIO f D Ka NATIONAL gt INSTRUMENTS 75 re POWER BACKUP IS STATUS USER1 vi vip O e EL O ra 2 a v2 j O o I J Geer S o cf TT O T OIEA 17 W MAX 3 O ON OF 1 SAFE MODE 10 100 ET CONSOLE OUT C IP RESET NOAPP d Be CO USER1 we RESET LINK ACTIVE IE ompactRIO Real Time Contro ler i NS 1 LEDs 4 Reset Button 2 Power Connector 5 RJ 45 Ethernet Port 3 DIP Switches 6 RS 232 Serial Port Figure 1 CompactRIO cRIO 9002 9004 We NATIONAL P INSTRUMENTS These operating instructions describe how to connect the National Instruments cRIO 9002 and cRIO 9004 to a network and how to use the features of the cRIO 9002 and cRIO 9004 For information about installing configuring and programming the controller refer to the CompactRIO Bookshelf at Start All Programs National Instruments CompactRIO Search the CompactRIO Bookshelf Safety
15. g VIs from launching when the controller powers on refer to the LabVIEW Real Time Module User Manual You can define the behavior of the User switch for your application To define the behavior of this switch in your embedded application use the RT Read Switch VI in your LabVIEW RT embedded VI For more information about the RT Read Switch VI refer to the LabVIEW Help Understanding LED Indications Power LED Backup LED ZN AN AN AN POWER DRAR NY w w VY A A BACKUP STATUS USERI Figure 7 CompactRIO Controller LEDs The Power LED is lit while the controller is powered on This LED indicates that the power supply connected to the controller is adequate and that the controller is supplying power to the CompactRIO system The Backup LED is lit when the controller is drawing power from the V2 terminal cRIO 9002 9004 Operating Instructions 10 ni com Status LED The Status LED is off during normal operation The controller indicates specific error conditions by flashing the Status LED a certain number of times as shown in Table 3 Table 3 Status LED Indications Number of Flashes Indication Slow continuous The controller is unconfigured Use MAX to flashing configure the controller Refer to the Measurement one flash every amp Automation Explorer Help for information about couple seconds configuring the controller 2 The controller has detected an error in
16. he controller to an Ethernet network using the RJ 45 Ethernet port on the controller front panel Use a standard Category 5 CAT 5 Ethernet cable to connect the controller to an Ethernet hub or use an Ethernet crossover cable to connect the controller directly to a computer UN Caution To prevent data loss and to maintain the integrity of your Ethernet installation do not use a cable longer than 100 m If you are using 100 Mbps Ethernet National Instruments recommends using a CAT 5 shielded twisted pair Ethernet cable The host computer communicates with the controller over a standard Ethernet connection If the host computer is on a network you must configure the controller on the same subnet as the host computer If neither the host computer nor the CompactRIO controller is connected to a network you can connect the two directly using a CAT 5 crossover cable If you need to build your own cable refer to the Cabling section for more information about Ethernet cable wiring connections In order to configure the controller you must connect it to the same subnet as the host computer If you want to use the controller on a subnet other than the one the host computer is on first connect the controller on the same subnet as the host computer Use DHCP to assign an IP address or reassign a static IP address for the subnet where you want it to be and physically move it to the other subnet The first time you configure the controller you must als
17. its software This usually occurs when an attempt to upgrade the software is interrupted Reinstall software on the controller Refer to the Measurement amp Automation Explorer Help for information about installing software on the controller 3 The controller is in safe mode because the Safe Mode DIP switch is in the ON position Refer to the Configuring DIP Switches section for information about the Safe Mode DIP switch 4 The controller software has crashed twice without rebooting or cycling power between crashes This usually occurs when the controller runs out of memory Review your RT VI and check the controller memory usage Modify the VI as necessary to solve the memory usage issue Continuous flashing The controller has detected an unrecoverable error Contact National Instruments Continuously lit The flash memory card on the controller is corrupt Reformat the hard drive on the controller Refer to Measurement amp Automation Explorer Help for more information about reformatting the hard drive User LED You can define the User LED to meet the needs of your application To define the LED use the RT LEDs VI in LabVIEW For more information about the RT LEDs VI refer to the LabVIEW Help National Instruments Corporation 11 cRIO 9002 9004 Operating Instructions Resetting the Network Configuration of the Controller If the controller is not able to communicate with the network you can
18. o install software on it Refer to the Measurement amp Automation Explorer Help for more information about configuring the controller in Measurement amp Automation Explorer MAX Contact your network administrator if you need assistance configuring the host computer and controller on the same subnet Wiring Power to the Controller UN Caution You must install the controller on a CompactRIO chassis and tighten the captive screws before you apply power to the controller Installing the controller while power is applied to it can cause damage to the chassis The controller requires an external power supply that meets the specifications in the Power Requirements section The controller filters and regulates the supplied power and provides power for all of the I O modules in the chassis You can connect two power sources to the controller The controller draws power from the power source with the higher voltage The controller has one layer of reversed voltage protection The power source National Instruments Corporation 5 cRIO 9002 9004 Operating Instructions you connect to the controller must provide an additional layer of reversed current flow protection Complete the following steps to connect power sources to the controller 1 Install a ferrite across the negative and positive wires for both the V1 and V2 terminals Refer to Figure 4 for an illustration of this step 2 Connect the positive lead of one of the power sources to the
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