National Instruments cRIO-9002, cRIO-9004 User Manual

National Instruments cRIO-9004 Manual

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USER MANUAL AND SPECIFICATIONS

NI cRIO-9002/9004

Intelligent Real-Time Embedded Controller for CompactRIO

Figure 1. CompactRIO cRIO-9002/9004

2

6

1

3

45

INPUT
9–35 V
17 W MAX

__

---

1. LEDs

2. Power Connector

3. DIP Switches

4. Reset Button

5. RJ-45 Ethernet Port

6. RS-232 Serial Port

This document describes how to connect the cRIO-9002/9004 to a network and how to use the
features of the cRIO-9002/9004. This document also contains specifications for the
controllers.

Safety Guidelines

Caution Do not operate the cRIO-9002/9004 in a manner not specified in this

document. Product misuse can result in a hazard. You can compromise the safety
protection built into the product if the product is damaged in any way. If the product
is damaged, return it to NI for repair.

Safety Guidelines for Hazardous Locations

The cRIO-9002/9004 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
cRIO-9002/9004 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.

Caution For Division 2 and Zone 2 applications, install the system in an enclosure

rated to at least IP54 as defined by IEC/EN 60079-15.

Special Conditions for Hazardous Locations Use in Europe and
Internationally

The cRIO-9002/9004 has been evaluated as Ex nA IIC T4 Gc equipment under DEMKO
Certificate No. 03 ATEX 0324020X and is IECEx UL 14.0089X certified. Each device is
marked II 3G and is suitable for use in Zone 2 hazardous locations, in ambient temperatures
of -40 °C ≤ Ta ≤ 70 °C.

Caution You must make sure that transient disturbances do not exceed 140% of

the rated voltage.

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.

2 | ni.com | NI cRIO-9002/9004 User Manual and Specifications

Electromagnetic Compatibility Guidelines

This product was tested and complies with the regulatory requirements and limits for
electromagnetic compatibility (EMC) stated in the product specifications. These requirements
and limits provide reasonable protection against harmful interference when the product is
operated in the intended operational electromagnetic environment.

This product is intended for use in industrial locations. However, harmful interference may
occur in some installations, when the product is connected to a peripheral device or test object,
or if the product is used in residential or commercial areas. To minimize interference with
radio and television reception and prevent unacceptable performance degradation, install and
use this product in strict accordance with the instructions in the product documentation.

Furthermore, any changes or modifications to the product not expressly approved by National
Instruments could void your authority to operate it under your local regulatory rules.

Special Conditions for Marine Applications

Some products are Lloyd’s Register (LR) Type Approved for marine (shipboard) applications.
To verify Lloyd’s Register certification for a product, visit ni.com/certification and search for
the LR certificate, or look for the Lloyd’s Register mark on the product.

Caution In order to meet the EMC requirements for marine applications, install the

product in a shielded enclosure with shielded and/or filtered power and input/output
ports. In addition, take precautions when designing, selecting, and installing
measurement probes and cables to ensure that the desired EMC performance is
attained.

Installing the Controller on the Chassis

The following figure shows the dimensions of the cRIO-9002/9004.

NI cRIO-9002/9004 User Manual and Specifications | © National Instruments | 3

Figure 2. cRIO-9002/9004, Front and Bottom View with Dimensions

77.3 mm
(3.04 in.)

90.2 mm
(3.55 in.)

44.2 mm
(1.74 in.)

88.1 mm
(3.47 in.)

44.2 mm
(1.74 in.)

1

1. M4 Thread

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 the following figure.

4 | ni.com | NI cRIO-9002/9004 User Manual and Specifications

Figure 3. Installing the cRIO-9002/9004 in the Chassis

1

4

3

2

1. Controller

2. Captive Screws

3. Controller Slot

4. Reconfigurable Embedded Chassis

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 lb · in.) of torque.

Connecting the Controller to a Network

Connect the controller to an Ethernet network using the RJ-45 Ethernet port on the controller
front panel. Use a standard Category 5 (CAT-5) or better shielded, twisted-pair Ethernet cable
to connect the chassis to an Ethernet hub, or use an Ethernet crossover cable to connect the
chassis directly to a computer.

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 or better shielded
twisted-pair Ethernet cable.

If you need to build your own cable, refer to the Cabling section for more information about
Ethernet cable wiring connections.

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

NI cRIO-9002/9004 User Manual and Specifications | © National Instruments | 5

host computer. If neither the host computer nor the CompactRIO controller is connected to a
network, you can connect the two directly using a crossover cable.

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 also install
software on it. Refer to the Measurement & Automation Explorer Help for more information
about configuring the controller in Measurement & 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

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 cRIO-9002/9004 requires an external power supply that meets the specifications in the

Power Requirements section. The cRIO-9002/9004 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 cRIO-9002/9004. The cRIO-9002/9004 draws power from the power source
with the higher voltage. The cRIO-9002/9004 has one layer of reversed-voltage protection.
The power source you connect to the cRIO-9002/9004 must provide an additional layer of
reversed-current flow protection. Complete the following steps to connect power sources to
the cRIO-9002/9004.

1. Install a ferrite across the negative and positive wires for both the V1 and V2 terminals.

6 | ni.com | NI cRIO-9002/9004 User Manual and Specifications

Figure 4. Wiring Power to the cRIO-9002/9004

V1

V2

C

C

2. Connect the positive lead of one of the power sources to the 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.

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.

Caution The C terminals are internally connected to each other. Make sure to

use two power sources that have a common ground.

Powering On the cRIO-9002/9004

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 User1 LEDs turn on. The User1 and Status
LEDs turn off, indicating that the POST is complete.

Boot Options

You can configure the controller to launch an embedded stand-alone application each time you
boot the controller. Refer to the LabVIEW Help for more information.

The following table 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-9002/9004 controllers, are reset in various conditions.

NI cRIO-9002/9004 User Manual and Specifications | © National Instruments | 7

Table 1. CompactRIO Reset Options

Backplane 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
cRIO-9002/9004

The cRIO-9002/9004 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 from a
LabVIEW Real-Time application. For more information about the Serial VIs, refer to the
LabVIEW Help.

Figure 5. Controller Serial Port

Pin 1

Pin 5

Pin 6

Pin 9

Table 2. DB-9 Pin Descriptions

Pin Signal

1 DCD

2 RXD

3 TXD

4 DTR

5 GND

6 DSR

7 RTS

8 CTS

9 RI

8 | ni.com | NI cRIO-9002/9004 User Manual and Specifications

Configuring DIP Switches

Figure 6. DIP Switches

SAFE MODE

CONSOLE OUT

IP RESET

NO APP

USER1

ON OFF

All of the DIP switches are in the OFF position when the chassis is shipped from National
Instruments.

SAFE MODE Switch

The position of the SAFE MODE switch determines whether the embedded LabVIEW Real­Time engine launches at startup. 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 at startup, the cRIO-9002/9004 launches only the essential services
required for updating its configuration and installing software. The LabVIEW Real-Time
engine does not launch.

If the software on the controller is corrupted, you must put the controller into safe mode and
reformat the controller drive. You can put the controller into safe mode by powering it up
either with the SAFE MODE switch in the ON position or with no software installed on the
drive. Refer to the Measurement & Automation Explorer Help for more information about
installing software on a controller and 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 firmware version of the controller. Use a null-modem cable to connect the serial
port on the chassis to a computer. Push the switch to the ON position. Make sure that the
serial-port terminal program is configured to the following settings:

• 9,600 bits per second

• Eight data bits

• No parity

• One stop bit

The serial-port terminal program displays the IP address and firmware version. Keep this
switch in the OFF position during normal operation.

IP RESET Switch

Push the IP RESET switch to the ON position and reboot the controller to reset the IP address
and other TCP/IP settings of the controller to the factory defaults. Refer to the Troubleshooting
Network Communication section for more information about resetting the IP address. You also

NI cRIO-9002/9004 User Manual and Specifications | © National Instruments | 9

can push this switch to the ON position to unlock a chassis that was previously locked in
MAX.

NO APP Switch

Push the NO APP switch to the ON position to prevent a LabVIEW Real-Time startup
application from running at startup. If you want to permanently disable a LabVIEW Real-Time
application from running at startup, you must disable it in LabVIEW. To run an application at
startup, 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 at
startup. If you already have an application configured to launch at startup and you push the
NO APP switch from ON to OFF, the startup application is automatically enabled. For more
information about automatically launching VIs at startup and disabling VIs from launching at
startup, refer to the LabVIEW Help.

USER1 Switch

You can define the USER1 switch for your application. To define the purpose of this switch in
your embedded application, use the RT Read Switch VI in your LabVIEW Real-Time
embedded VI. For more information about the RT Read Switch VI, refer to the LabVIEW
Help.

Understanding LED Indications

Figure 7. cRIO-9002/9004 LEDs

1 2 3 4

1. POWER

2. BACKUP

3. STATUS

4. USER1

POWER LED

The POWER LED is lit while the cRIO-9002/9004 is powered on. This LED indicates that the
power supply connected to the chassis is adequate.

BACKUP LED

The Backup LED is lit when the controller is drawing power from the V2 terminal.

STATUS LED

The STATUS LED is off during normal operation. The cRIO-9002/9004 indicates specific
error conditions by flashing the STATUS LED a certain number of times every few seconds, as
shown in the following table

10 | ni.com | NI cRIO-9002/9004 User Manual and Specifications

Number of Flashes

Every Few

Seconds Indication

Slow, continuous
flashing (one flash
every couple
seconds)

The controller is unconfigured. Use MAX to configure the controller.
Refer to the Measurement & Automation Explorer Help for
information about configuring the controller.

2

The controller has detected an error in its software. This usually
occurs when an attempt to upgrade the software is interrupted.
Reinstall software on the controller. Refer to the Measurement &
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 or there is no software installed on the controller.

4

The 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 memory usage. Modify
the VI as necessary to solve the memory usage issue.

Continuously
blinking

The controller has detected an unrecoverable error. Contact National
Instruments.

Solid

The flash memory card on the controller is corrupt. Reformat the hard
drive on the controller. Refer to Measurement & Automation Explorer
Help for more information about reformatting the hard drive.

USER1 LED

You can define the USER1 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.

Resetting the Network Configuration of the
Controller

If the controller is not able to communicate with the network, you can 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.

NI cRIO-9002/9004 User Manual and Specifications | © National Instruments | 11

3. Move the IP Reset switch to the OFF position.

The network settings are restored. You can reconfigure the settings in MAX from a
computer on the same subnet. Refer to the Measurement & Automation Explorer Help for
more information about configuring the controller.

cRIO-9002/9004 Specifications

The following specifications are typical for the range -40 °C to 70 °C unless otherwise noted.

Caution Do not operate the cRIO-9002/9004 in a manner not specified in this

document. Product misuse can result in a hazard. You can compromise the safety
protection built into the product if the product is damaged in any way. If the product
is damaged, return it to NI for repair.

Network

Network interface 10Base-T and 100Base-TX Ethernet

Compatibility IEEE 802.3

Communication rates 10 Mbps, 100 Mbps, auto-negotiated

Maximum cabling distance 100 m/segment

RS-232 Serial Port

Maximum baud rate 115,200 bps

Data bits 5, 6, 7, 8

Stop bits 1, 2

Parity Odd, Even, Mark, Space

Flow control RTS/CTS, XON/XOFF, DTR/DSR

Memory

cRIO-9002

Nonvolatile 64 MB

DRAM 32 MB

cRIO-9004

Nonvolatile 512 MB

DRAM 64 MB

12 | ni.com | NI cRIO-9002/9004 User Manual and Specifications

MTBF

The following MTBF specifications apply to the cRIO-9002/9004.

MTBF 1,253,788 hours at 25 °C; Bellcore Issue 6,

Method 1, Case 3, Parts Count Method

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 maximum

Controller supplying power to eight
CompactRIO modules

17 W

Power supply

On powerup 9 V to 35 V

After powerup 6 V to 35 V

Note The cRIO-9002/9004 powers 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 module, wipe it with a dry towel.

Tip For two-dimensional drawings and three-dimensional models of the C Series

module and connectors, visit ni.com/dimensions and search by module number.

Screw-terminal wiring

Gauge 0.5 mm 2 to 2.1 mm2 (20 AWG to 14 AWG)

copper conductor wire

Wire strip length 7 mm (0.28 in.) of insulation stripped from the

end

Temperature rating 85 °C

Torque for screw terminals 0.5 N · m to 0.6 N · m (4.4 lb · in. to

5.3 lb · in.)

Wires per screw terminal One wire per screw terminal

Ferrules 0.25 mm2 to 1.5 mm

2

NI cRIO-9002/9004 User Manual and Specifications | © National Instruments | 13

Connector securement

Securement type Screw flanges provided

Torque for screw flanges 0.3 N · m to 0.4 N · m (2.7 lb · in. to

3.5 lb · in.)

Dimensions 90.2 mm × 77.3 mm × 88.1 mm

(3.6 in. × 3.0 in. × 3.5 in.)

Weight 488 g (17.2 oz)

Safety Voltages

Connect only voltages that are within the following limits:

V terminal to C terminal 35 V maximum, 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 low­voltage sources, and electronics.

Note Measurement Categories CAT I and CAT O are equivalent. These test and

measurement circuits are not intended for direct connection to the MAINS building
installations of Measurement Categories CAT II, CAT III, or CAT IV.

Caution Do not connect the cRIO-9002/9004 to signals or use for measurements

within Measurement Categories II, III, or IV.

Safety and Hazardous Locations Standards

This product is designed to meet the requirements of the following electrical equipment safety
standards 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 Certification section.

14 | ni.com | NI cRIO-9002/9004 User Manual and Specifications

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 (ATEX) and International (IECEx) Ex nA IIC T4 Gc

Electromagnetic Compatibility

• EN 55011 Class A at 10 m FCC Part 15A above 1 GHz

• Industrial levels per EN 61326:1997 + A2:2001, Table A.1

• CE, C-Tick, and FCC Part 15 (Class A) Compliant

Caution To ensure the specified EMC performance, operate this product only with

shielded cables and accessories.

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 model number or product line, and click the appropriate link in the

Certification column.

Shock and Vibration

To meet these specifications, you must panel mount the system.

Operating vibration

Random (IEC 60068-2-64) 5 g

rms

, 10 Hz to 500 Hz

Sinusoidal (IEC 60068-2-6) 5 g, 10 Hz 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 cRIO-9002/9004 User Manual and Specifications | © National Instruments | 15

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 °C to 70 °C

Storage temperature
(IEC 60068-2-1, IEC 60068-2-2)

-40 °C to 85 °C

Ingress protection IP40

Operating humidity (IEC 60068-2-78) 10% RH to 90% RH, noncondensing

Storage humidity (IEC 60068-2-78) 5% RH to 95% RH, noncondensing

Pollution Degree 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.

Waste Electrical and Electronic Equipment (WEEE)

EU Customers At the end of the product life cycle, all NI products must be

disposed of according to local laws and regulations. For more information about
how to recycle NI products in your region, visit ni.com/environment/weee.

电子信息产品污染控制管理办法（中国 RoHS）

中国客户 National Instruments 符合中国电子信息产品中限制使用某些有害物

质指令(RoHS)。关于 National Instruments 中国 RoHS 合规性信息，请登录

ni.com/environment/rohs_china。(For information about China RoHS

compliance, go to ni.com/environment/rohs_china.)

Cabling

The following table shows the standard Ethernet cable wiring connections for both normal and
crossover cables.

16 | ni.com | NI cRIO-9002/9004 User Manual and Specifications

Table 3. Ethernet Cable Wiring Connections

Pin Connector 1 Connector 2 (Normal) Connector 2 (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

6 green green orange

7 white/brown white/brown white/brown

8 brown brown brown

Figure 8. Ethernet Connector Pinout

Connector 1 Connector 2

Pin 1 Pin 1 Pin 8Pin 8

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The NI 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
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Visit ni.com/services for NI Factory Installation Services, repairs, extended warranty, and
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Visit ni.com/register to register your NI product. Product registration facilitates technical
support and ensures that you receive important information updates from NI.

NI cRIO-9002/9004 User Manual and Specifications | © National Instruments | 17

A Declaration of Conformity (DoC) is our claim of compliance with the Council of the
European Communities using the manufacturer’s declaration of conformity. This system
affords the user protection for electromagnetic compatibility (EMC) and product safety. You
can obtain the DoC for your product by visiting ni.com/certification. If your product supports
calibration, you can obtain the calibration certificate for your product at ni.com/calibration.

NI corporate headquarters is located at 11500 North Mopac Expressway, Austin, Texas,
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373561E-01 Feb16