National Instruments NI DCM-23 Series User manual

GETTING STARTED GUIDE
NI DCM-23XX
Embedded Direct Injector Control and Measurement (DCM) Device
with Real-Time Processor and Reconfigurable FPGA
Hazardous Voltage This device sources hazardous voltages up to 250V. You must
take the following precautions. A hazardous voltage is a voltage greater than 42.4
Vpk voltage or 60 VDC to earth ground.
Caution Ensure that hazardous voltage wiring is performed only by qualified
personnel adhering to local electrical standards.
Caution Do not mix hazardous voltage circuits and human-accessible circuits in
the same cable unless the cables are properly insulated for min. 250V.
Caution Ensure that devices and circuits connected to the module are properly
insulated from human contact.
Caution Except for the isolated RS232, CAN, IGND, IO Lock terminals, and the
Ethernet Port, all I/O terminals are hazardous voltage LIVE (> 42.4 Vpk/60 VDC) or
could be at hazardous potential. You must ensure that devices and circuits connected
to the module are properly insulated from human contact. External protection must
be provided to protect any other devices connected to the BATT, DRVP, and MPRD
supplies.

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Caution Do not operate the DCM 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.
Caution Do not disconnect the power supply wires and connectors from the
controller unless power has been switched off.
About This Manual
This document explains how to begin using the National Instruments DCM family of devices.
The scope is limited to focus on initial DCM startup and basic operation using the DCM Starter
Harness and DSI software. For more detailed information on DCM hardware or software, refer
to the Related Documentation section of this guide.
Preparing the Environment
Ensure that the environment in which you are using the DCM meets the following specifications.
Note Refer to the device specifications on ni.com/manuals for complete
specifications.
Identifying the Hardware
The following section includes identification of DCM kit contents and all other required
components.
Verifying Kit Contents
Verify that the following item(s) are included in the DCM kit:
• DCM with rack-mount end plates
• NI DCM-23XX Getting Started Guide
• NI DCM-23XX Specifications Guide
Operating temperature
(IEC 60068-2-1, IEC 60068-2-2)
0 °C to 55°C
Operating humidity (IEC 60068-2-56) 10% RH to 90% RH, non-condensing
Pollution Degree (IEC 60664) 2
Maximum altitude 2,000 m

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Required Components (Not Included)
The following items are necessary to set up and use the NI DCM using this document:
• Host/Development PC running Windows 7/8.1/10
• DCM Starter Harness
• PDU-2300
• 12 V or 24 V DC power supply, 180 W1 minimum DC power supply
Software Installation
The DCM may be used with several different software personalities. Each personality requires
different software packages to be installed on the host computer which may need to be
individually licensed.
NI Powertrain Controls supports the following software personalities for the DCM:
• DCM Default Software Image (DSI)
• NI LabVIEW
• NI VeriStand
DCM Default Software Image (DSI)
Before using the DCM DSI, you must install the following application software and device
drivers on the host computer in this order:
• NI CompactRIO Device Drivers 16.0 or later
• Software Calibration Management (SCM) Toolkit 2016 or later (evaluation license)
Note The DCM is shipped supporting the latest version of SCM. If you have
trouble launching the DCM DSI with the latest available version of SCM on ni.com,
the software on your DCM may need to be updated. Refer to the NI DCM-23XX DSI
User Guide for more information.
For minimum software support information, visit ni.com/info and enter the Info Code
swsupport.
DCM With LabVIEW
Before using the DCM with LabVIEW, you must install the following application software and
device drivers on the host computer in this order:
• LabVIEW 2016 or later
• LabVIEW Real-Time Module 2016 or later
• LabVIEW FPGA Module 2016 or later
1 Minimum power supply requirements assume basic operation; actual power supply requirements will
vary depending on hardware and software configuration.

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• NI CompactRIO Device Drivers 16.0 or later
• NI Powertrain Controls Device Drivers 2.160.0.0 or later
The NI Powertrain Controls Device drivers may be installed using JKI Software’s VI Package
Manager. For minimum software support information, visit ni.com/info and enter the Info
Code swsupport.
DCM With VeriStand
Before using the DCM with VeriStand, you must install the following application software and
device drivers on the host computer in this order:
• VeriStand 2016 or later
• NI DAQmx 16.0 or later
• NI VISA 16.0 or later
• NI CompactRIO Device Drivers 16.0 or later
• NI Powertrain Controls DCM Custom Device for NI VeriStand
For minimum software support information, visit ni.com/info and enter the Info Code
swsupport.
Hardware Installation
Mounting the DCM
The DCM is designed to be flexible in its mounting position. The following mounting methods
are supported by NI Powertrain Controls:
•Rack-mount: Rack-mounted in a standard 19-in. chassis, 5U
– Requires: Rack-mount kit (included, PN: 785246-01)
•Panel-mount: Firmly secured on a clean, flat surface with connector facing out or up
– Requires: Panel mount kit (optional, PN: 785247-01)
Connecting the DCM Chassis Ground Lug to Facility
Ground
You must connect the DCM chassis ground lug to the grounding electrode system of the facility.
What to Use
• Wire, 1.63 mm2 (14 AWG) or larger, or braided grounding strap
• Screwdriver, flat 3/16-in.

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What to Do
Complete the following steps to ground the DCM.
1. Remove the screw from the chassis ground lug on the DCM.
2. Insert wire or braided grounding strap into the side of the chassis ground lug
3. Tighten the grounding screw to 1.4 N · m (12 lb · in.) of torque.
4. Attach the other end of the wire to the grounding electrode system of your facility using a
method that is appropriate for your application.
For more information about ground connections, visit ni.com/info and enter the Info Code
emcground.
Connecting the DCM Starter Harness
The DCM Starter Harness contains all connections required to begin using the DCM with
one solenoid injector and one piezo injector. The DCM Starter Harness should connect with
the devices as shown in Figure 1.
What to Use
• DCM Starter Harness
• Hex Driver, 4 mm
• PDU-2300
• Emergency Stop (E-Stop)
What to Do
Complete the following steps to connect the DCM Starter Harness.
1. Ensure that the PDU is disconnected from all power sources.
2. Connect the harness to DCM Connector 1, being sure to orient the connector appropriately.
3. Tighten the DCM connector terminal fastener to 5 N · m (44 lb · in.) of torque using a 4 mm
Hex Driver.
4. Ensure your PDU is correctly configured for 12 V or 24 V, whichever is used. Refer to the
Configuring the PDU-2300 section for more information.
5. Connect the harness to the PDU (blue connector).
6. Connect the harness to the emergency stop.

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Figure 1. DCM Starter Harness Connections
Note All I/O terminals come unpopulated in the DCM Starter Harness kit. These
connections must be populated by the user in order for the relevant functions to be
used. For more information about wiring I/O, refer to the NI DCM User Guide.
Configuring the PDU-2300
The PDU-2300 may be configured for 12 V or 24 V systems. The PDU ships configured for 12 V
systems by default. Complete the following steps to configure the PDU for 24 V systems. See
Figure 2 below for illustration of fuse placement for 12 V and 24 V setup.
1. Open the PDU cover to expose the various relays and fuses.
2. Remove 7.5 A fuses from slots F12 and F13 and set aside.
3. Fill slot F14 (empty by default) with one of the 7.5 A fuses removed in the previous step.
4. Save the remaining fuse as a replacement.
1 PDU-2300 5 Heavy-duty power supply cables
2 Light-duty power supply cables 6 Emergency stop
3 Power supply 7 RS-232
4 DCM
7
6
1
2
4
3
5

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Caution Damage may occur if the PDU-2300 is not appropriately configured for
the selected supply voltage before connecting power.
Figure 2. Fuse Placement for 12 V and 24 V Setup
Connecting the DCM to Power
Powering the DCM with the DCM Starter Harness and PDU-2300 requires a 12 V or 24 V, 180
W minimum, external DC power supply. Recommended power supplies are listed in Table 1
below. The light-duty power supply leads (14 AWG) included in the DCM Starter Harness kit
are recommended only for bench-top applications which require less than 15 A of current. The
heavy-duty leads (8 AWG) included in the DCM Starter Harness kit are recommended for all
other applications.
What to Use
• Starter harness light-duty (<15A) or heavy-duty power supply leads
• Wrench, 1/2-in.
• NI recommended power supply
Table 1. Recommended Power Supplies
Power Supply Part Number
PULS QS10.121 Power Supply
(12 VDC, 15 A, 100-240 VAC/110-150 VDC Input)
783168-01
NI PS-17 Industrial Power Supply
(24 VDC, 20 A, 100-240 VAC/110-150 VDC Input)
781095-01
Tripp Lite PR 60
(13.8 VDC, 60 A, 120 VAC Input)
PR 60
TDK Lambda Genesys 1500W
(0-30 VDC Variable, 0-50 A Variable, 85-265 VAC input)
GEN 30-50
12 V Setup
F12
7.5 A Fuse
F14
Empty
F13
7.5 A Fuse
24 V Setup
F12
Empty
F14
7.5 A Fuse
F13
Empty

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What to Do
Complete the following steps to connect power to the DCM.
• Ensure the DCM Starter Harness is connected as discussed in the Connecting the DCM
Starter Harness section.
• Connect power supply leads terminated with properly rated ring terminals to the PDU
Positive (+) and Negative (-) input studs.
• Tighten terminal fasteners to 10.2 N · m (90 lb · in.) using a 1/2-in. wrench.
• Connect power supply leads to the power supply. If connecting to a battery, always connect
the Negative (-) lead last. When disconnecting the battery, always disconnect the
Negative (-) lead first.
Connecting the DCM to the Host Computer
Complete the following steps to connect the DCM to the host computer or Ethernet network
using the RJ-45 Gigabit Ethernet port.
• Power on the host computer or Ethernet hub.
• Connect the RJ-45 Gigabit Ethernet port on the DCM to the host computer or Ethernet hub
using a standard Category 5 (CAT-5) or better shielded, twisted-pair Ethernet cable.
Caution To prevent data loss and to maintain the integrity of your Ethernet
installation, do not use a cable longer than 100 m (328 ft).
Note The DCM attempts to initiate a DHCP network connection the first time you
connect using Ethernet. The DCM connects to the network with a link-local IP
address with the form 169.254.x.x if it is unable to initiate a DHCP connection.
Powering on the DCM
When you power on the DCM for the first time, the device boots DCM DSI. The POWER LED
illuminates, the STATUS LED illuminates briefly, and then the USER1 LED blinks steadily
once the DSI executable has booted. Overall boot time is approximately 60 seconds.
Configuring the DCM in Measurement and
Automation Explorer (MAX)
Complete the following steps to find your DCM in MAX.
• Ensure that any anti-virus or firewall software running on the host computer allows
connections to the host computer.
Note MAX uses UDP 44525. Refer to the documentation of your firewall software
for information about configuring the firewall to allow communication through
UDP 44525.
• Launch MAX on the host computer.

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• Expand Remote Systems in the configuration tree and location your system.
• Select your target.
Setting a System Password
Complete the following steps to set a system password.
Note The default username for the DCM is admin. There is no default password
for the DCM, so you must leave the password field blank when logging in until you
set a system password.
1. Right-click your system and select Web Configuration.
Note The NI Web-Based Configuration and Monitoring utility opens in your
default browser and is where you set the password. If you have not installed
Microsoft Silverlight, NI Web-based Configuration & Monitoring prompts you
to do so.
2. Enter a unique name for your system in the Hostname field.
3. Click the Security Configuration icon.
4. Click Login.
5. In the Login dialog box, enter the username admin and leave the password field blank.
6. Click OK.
7. Click Change Password.
8. Enter and re-enter a new password.
9. Click OK.
10. Click Save.
11. Click OK to confirm you are changing the password.
Caution NI cannot recover lost system passwords. If you forget the password, you
must contact NI and reformat the controller.
Installing Software on the DCM (LabVIEW or VeriStand
Personalities)
Complete the following steps to install software on the DCM for LabVIEW or VeriStand
personalities. If using DCM DSI, skip this section.
Note The DCM ships with the DSI pre-installed. In order to run non-DSI
personalities, the DCM must be formatted. To reinstall the DCM DSI after
formatting, refer to the NI DCM-23XX DSI User’s Manual for more information.
1. In MAX, right-click on your DCM target under Remote Systems.

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Caution Any files, including calibrations, present on the DCM during formatting
will be lost. Prior to formatting, any files present on the DCM must be backed up in
order to be saved. Files may be copied from the DCM by WebDAV file transfer.
a. Select Format Disk.
Tip You must log in if you set a system password.
b. Select Attempt to restart into safe mode.
c. Select the desired option to manage network adapter settings.
d. Click Format.
e. Wait for the formatting process to finish, then click OK.
2. In MAX, expand your system under Remote Systems.
a. Right-click Software.
b. Select Add/Remove Software to launch the LabVIEW Real-Time Software Wizard.
Tip You must log in if you set a system password.
c. Select the recommended software set for your LabVIEW and NI-RIO Device Drivers
versions.
d. Click Next.
e. Verify that the summary of software to install is correct.
f. Click Next.
g. Click Finish when the installation is complete.
3. To install NI VeriStand or NI SCM on the target, continue with the following steps.
a. In MAX, right-click Software as before.
b. Select Add/Remove Software to launch the LabVIEW Real-Time Software Wizard.
Tip You must log in if you set a system password.
c. Select Custom software installation.
d. Click Yes.
e. Select any additional software to install (VeriStand Engine, SCM, etc.)
f. Click Next.
g. Verify that the summary of software to install is correct.
h. Click Next.
4. Click Finish when the installation is complete.
Launching DCM DSI
Complete the following steps to launch and begin using DCM DSI.