National Instruments CMS-9024 User manual

MAINTAINING HARDWARE
NI CMS-9024
NI Condition Monitoring System for NI InsightCM™Enterprise
This document describes how to maintain the CMS-9024 NI Condition Monitoring System.
The CompactRIO-based CMS-9024 is a bundle of hardware and software that includes the
following components and features:
• cRIO-9024 controller and cRIO-9114 chassis
• NI C Series modules installed in the chassis
• Pre-installed NI InsightCM Server software
• Network configuration via USB drive
Note Complete the steps in the NI CMS-9024 and CMS-9068 Quick Start before
using this document.
Contents
CompactRIO Reconfigurable Embedded System.....................................................................2
Controller Front Panel...............................................................................................................2
Mounting the Chassis................................................................................................................3
Precautions to Take before Mounting the Chassis............................................................ 4
Measuring the Ambient Temperature of the Chassis........................................................ 4
Accommodating Air Circulation and Cabling Clearance................................................. 4
Mounting the Chassis Directly on a Flat Surface Using the Mounting Holes..................6
Mounting the Chassis the NI Panel Mounting Kit............................................................6
Mounting the Chassis on a DIN Rail................................................................................ 7
Mounting the Chassis on a Desktop..................................................................................8
Installing C Series I/O Modules in the Chassis.........................................................................8
I/O Module Arrangements................................................................................................ 9
Removing I/O Modules from the Chassis.........................................................................9
Connecting to a Network........................................................................................................ 10
Grounding the Chassis............................................................................................................ 10
Wiring Power to the Controller...............................................................................................10
Precautions to Take When Wiring Power to the Controller............................................11
Powering On the Controller.................................................................................................... 12
Understanding LED Indications on the Controller................................................................. 12
POWER LED..................................................................................................................12
FPGA LED......................................................................................................................12
STATUS LED..................................................................................................................13
USER1 LED....................................................................................................................13
Troubleshooting Network Communication.............................................................................13
Resetting the Network Configuration of the Controller..................................................14

Where to Go Next................................................................................................................... 15
Worldwide Support and Services............................................................................................ 15
CompactRIO Reconfigurable Embedded
System
The following figure shows the components of the CompactRIO reconfigurable embedded
system.
Figure 1. CompactRIO Reconfigurable Embedded System
1
2
3
1. cRIO-9024 intelligent real-time embedded controller
2. cRIO-9114 eight-slot reconfigurable embedded chassis
3. C Series I/O module
Controller Front Panel
The following figure shows the I/O ports and other features of the cRIO-9024 controller.
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Figure 2. cRIO-9024 Controller Front Panel
NI cRIO-9024
CompactRIO Real-Time Controller
DO NOT SEPARATE CONNECTORS WHEN ENERGIZED IN HAZARDOUS LOCATIONS
SAFE MODE
CONSOLE OUT
IP RESET
NO APP
USER1
1: POWER
2: FPGA
3: STATUS
4: USER1
INPUT
9-35 V
35 W MAX
OFF
10/100
ACT/LINK
ACT/LINK
10/100/1000
1
2
1 2 3 4 V1
C
V2
C
RESET ON
3
9
8
7
6
5
4
2
1
1. LEDs
2. Power connector
3. RS-232 Serial port
4. USB port
5. USB retention standoff
6. Reset button
7. DIP Switches
8. RJ-45 Ethernet port 1
9. RJ-45 Ethernet port 2
Note NI Condition Monitoring Systems do not use the DIP switches. Leave these
switches in the OFF position.
Mounting the Chassis
To obtain the maximum allowable ambient temperature of 70 °C, mount the chassis
horizontally on a flat, vertical, metallic surface such as a panel or wall. You can mount the
chassis directly to the surface or you can use the NI Panel Mounting Kit.
You can also mount the chassis in other orientations, on a nonmetallic surface, on a 35-mm
DIN rail, on a desktop, or in a rack, but mounting the chassis in these or other configurations
Maintaining NI CMS-9024 Hardware for an NI InsightCM System | © National Instruments | 3

can reduce the maximum allowable ambient temperature and can affect the typical accuracy of
modules in the chassis.
Note For more information about typical accuracy specifications for modules, visit
ni.com/info and enter the Info Code criotypical.
Refer to the following sections of this document for more information about mounting the
chassis in these configurations. Refer to the following table for additional resources you can
use when you consider an appropriate mounting configuration for your application.
Table 1. Additional Resources for Mounting Configurations
Consideration Resource
How can different mounting configurations
cause temperature derating?
Visit ni.com/info and enter the Info
Code criomounting.
How can different mounting configurations
affect the accuracy of C Series modules?
Visit ni.com/info and enter the Info
Code rdcriotemp.
What do I need to know about mounting the
chassis in environments with high shock and
vibration?
Visit ni.com/info and enter the Info
Code criomounting.
Precautions to Take before Mounting the Chassis
Before you mount the chassis, ensure that you have taken the following precautions:
• Record the serial number from the back of the chassis so that you can identify the
NI Condition Monitoring System in software. You cannot read the serial number after
you have mounted the chassis.
• Ensure that the chassis does not contain any I/O modules.
Measuring the Ambient Temperature of the Chassis
Measure the ambient temperature at each side of the chassis, 63.5 mm (2.5 in.) from the side
and 25.4 mm (1 in.) forward from the rear of the chassis.
Accommodating Air Circulation and Cabling Clearance
Your installation must meet the following requirements for space and cabling clearance:
• Allow 25.4 mm (1 in.) on the top and the bottom of the chassis for air circulation, as
shown in the following figure.
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Figure 3. cRIO-9114 Front View with Dimensions and Air Circulation Requirements
1 2 3 4 5 6 7 8
88.1 mm
(3.47 in.)
Cooling Outline
25.4 mm (1.00 in.)
Cooling Outline
25.4 mm (1.00 in.)
165.1 mm (6.50 in.)
36.4 mm
(1.43 in.)
51.7 mm
(2.04 in.)
19.0 mm
(0.75 in.)
4.1 mm
(0.16 in.)
• Allow 50.8 mm (2 in.) in front of modules for cabling clearance for common connectors,
such as the 10-terminal, detachable screw terminal connector, as shown in the following
figure.
Figure 4. cRIO-9114 Cabling Clearance Requirements
274.0 mm (10.79 in.)
Minimum
144.0 mm
(5.7 in.)
Cabling Clearance
50.8 mm (2.00 in.)
93.1 mm
(3.66 in.)
4.1 mm (0.16 in.)
Refer to the following table for additional resources about system dimensions and cabling
clearance considerations.
Maintaining NI CMS-9024 Hardware for an NI InsightCM System | © National Instruments | 5

Table 2. Additional Resources for System Dimensions and Cabling Clearance
Consideration Resource
Where can I find more information about dimensions
of the system, included detailed dimensional
drawings?
Visit ni.com/dimensions.
Where can I find more information about the
minimum cabling clearance for C Series modules with
other connector types?
Visit ni.com/info and enter the
Info Code rdcrioconn.
Mounting the Chassis Directly on a Flat Surface Using
the Mounting Holes
Complete the following steps to mount the chassis directly on a flat, rigid surface using the
mounting holes in the chassis. National Instruments recommends that you mount the chassis in
this manner for environments with high shock and vibration.
1. Use the dimensions provided in this document to prepare the surface for mounting the
chassis.
2. Align the chassis on the surface.
3. Fasten the chassis to the surface using two M4 or number 10 panhead screws appropriate
for the surface, as shown in the following figure. Screws must be longer than
19 mm (0.75 in.) to pass all the way through the chassis. National Instruments does not
provide these screws with the chassis.
Figure 5. Mounting the cRIO-9114 Directly on a Flat Surface
1 2 3 4 5 6 7 8
Caution Ensure that the chassis does not contain any I/O modules before you
remove it.
Mounting the Chassis the NI Panel Mounting Kit
Complete the following steps to use the NI panel mounting kit (part number 779558-01) to
mount the chassis on a flat surface.
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1. Fasten the panel mounting plate to the chassis using a number 2 Phillips screwdriver and
M4 × 22 screws. National Instruments provides these screws with the panel mounting kit.
You must use these screws because they are the correct depth and thread for the panel
mounting plate. Tighten the screws to a maximum torque of 1.3 N · m (11.5 lb · in.).
2. Fasten the panel mounting plate to the surface using the screwdriver and screws that are
appropriate for the surface. The maximum screw size is M5 or number 10.
Caution Ensure that the chassis does not contain any I/O modules before you
remove it.
Mounting the Chassis on a DIN Rail
Complete the following steps to use the NI 9915 DIN rail mounting kit (part number
779018-01) to mount the chassis on a standard 35-mm DIN rail.
1. Fasten the DIN rail clip to the chassis using a number 2 Phillips screwdriver and M4 × 22
screws, as shown in the following figure. National Instruments provides these screws
with the DIN rail mounting kit. Tighten the screws to a maximum torque of
1.3 N · m (11.5 lb · in.).
Figure 6. Installing the DIN Rail CLIP on the cRIO-9114
2. Insert one edge of the DIN rail into the deeper opening of the DIN rail clip, as shown in
the following figure.
Maintaining NI CMS-9024 Hardware for an NI InsightCM System | © National Instruments | 7

Figure 7. One Edge of the DIN Rail Inserted in a Clip
3
2
1
1. DIN rail clip
2. DIN rail
3. DIN rail spring
3. Press down firmly on the chassis to compress the spring until the clip locks in place on
the DIN rail.
Caution Ensure that the chassis does not contain any I/O modules before you
remove it.
Mounting the Chassis on a Desktop
You can use the NI 9901 desktop mounting kit to mount the chassis on a desktop. Install the
adapter bracket using two M3 × 20 screws. National Instruments provides the adapter bracket
and screws with the desktop mounting kit. Refer to the NI 9901 documentation for more
information about mounting the chassis on a desktop.
Installing C Series I/O Modules in the Chassis
Note Before you install a C Series I/O module in the chassis, ensure that no
I/O-side power is connected to the module. If the system is in a nonhazardous
location, the chassis power can be on when you install modules.
Complete the following steps to install a C Series I/O module in the chassis.
1. Align the module with a slot in the chassis, as shown in the following figure. The module
slots are labeled 1 to 8, left to right.
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Figure 8. Installing a C Series I/O Module in the Chassis
1
2
1. Insertion groove
2. Latch
2. Squeeze the latches and insert the module into the slot.
3. Press firmly on the connector side of the module until the latches lock the module into
place.
4. Repeat these steps to install additional modules.
I/O Module Arrangements
NI InsightCM Server supports only dynamic C Series I/O modules, such as the NI 9232,
installed on the CMS-9024. You must fill module slots in ascending order starting with slot 1.
You cannot skip any slots but you do not have to use every slot.
Note You must connect tachometers to the module in slot 1. Do not connect any
other sensors to the module in slot 1.
Removing I/O Modules from the Chassis
Note Before you remove a C Series I/O module from the chassis, ensure that no
I/O-side power is connected to the module. If the system is in a nonhazardous
location, the chassis power can be on when you install modules.
Maintaining NI CMS-9024 Hardware for an NI InsightCM System | © National Instruments | 9

To remove a C Series I/O module from the chassis, squeeze the latches on both sides of the
module and pull the module from the chassis.
Connecting to a Network
Use a standard Category 5 (CAT-5) or better shielded, twisted-pair Ethernet cable to connect
the RJ-45 Ethernet port on the cRIO-9024 to an Ethernet hub.
Caution To prevent data loss and to maintain the integrity of your Ethernet
installation, do not use a cable longer than 100 m.
The first time you power up the cRIO-9024, it attempts to initiate a DHCP network
connection. If the cRIO-9024 cannot initiate a DHCP connection, it connects to the network
with a link-local IP address with the form 169.254.x.x. After the chassis powers up, you
must configure the network settings in Systems Manager.
Grounding the Chassis
Complete the following steps to connect the chassis grounding terminal to the grounding
electrode system of your facility.
1. Attach a ring lug to a 2.0 mm2 (14 AWG) or larger wire.
2. Remove the grounding screw from the grounding terminal on the right side of the chassis.
3. Attach the ring lug to the grounding terminal.
4. Tighten the grounding screw to 0.5 N · m (4.4 lb · in.) of torque.
5. Attach the other end of the wire to the grounding electrode system of your facility using a
method appropriate for the application.
Note If you use shielded cabling to connect to a C Series I/O module with a plastic
connector, attach the cable shield to the chassis grounding terminal using
1.3 mm2 (16 AWG) or larger wire. Attach a ring lug to the wire and attach the wire
to the chassis grounding terminal. Solder the other end of the wire to the cable
shield. Use shorter wire for better EMC performance.
For more information about ground connections, visit ni.com/info and enter the Info Code
emcground.
Wiring Power to the Controller
The cRIO-9024 requires an external power supply that meets device specifications. The
cRIO-9024 filters and regulates the supplied power and provides power for all I/O modules
installed in the chassis. The cRIO-9024 has one layer of reverse-voltage protection.
The following figure shows the terminal screws, which secure the wires in the screw terminals,
and the connector screws, which secure the power connector on the front panel.
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Figure 9. COMBICON Power Connector
C
V2
C
V1
2
1
2
1. Terminal screws
2. Connector screws
Complete the following steps to connect a power supply to the chassis.
1. Install the ferrite provided with the controller across the negative and positive leads of the
power supply, approximately 50–75 mm (2–3 in.) from the ends of the leads near the
controller, as shown in the following figure.
Figure 10. Installing a Ferrite on the Power Supply Wires
2. Connect the positive lead of the power supply to the V1 or V2 terminal of the
COMBICON power connector installed on the front panel of the cRIO-9024 and tighten
the terminal screw.
3. Connect the negative lead of the power supply to one of the C terminals of the power
connector and tighten the terminal screw.
4. Optionally, connect the positive lead of another power supply to the other V terminal and
the negative lead to one of the C terminals.
5. Tighten the connector screws.
Precautions to Take When Wiring Power to the
Controller
Note If you connect power to both the VI and V2 terminals, ensure that the voltage
difference between the two power inputs, measured at the controller power
connector, is at least 500 mV.
Note The controller draws power from either the V1 or V2 terminals depending on
which terminal has a higher voltage. The controller does not draw power from both
Maintaining NI CMS-9024 Hardware for an NI InsightCM System | © National Instruments | 11

terminals. The controller switches between the V1 and V2 terminals without
affecting operation.
Caution The C terminals are internally connected to each other. If you use two
power supplies, ensure that they share a common ground.
Caution The C terminals are internally connected to the controller to prevent a
faulty ground connection from causing the chassis ground to float. If you reverse the
input voltage, the positive input voltage is connected directly to the chassis. The
controller provides built-in reversed-voltage protection, but reversed voltage can
damage connected peripherals if the chassis ground is not reliably connected to earth
ground.
Caution Do not tighten or loosen the terminal screws on the power connector
while the power connector is plugged in to the controller or while the power supply
is on.
Powering On the Controller
When you apply power to the CompactRIO system, the controller runs a power-on self test
(POST). The Power and Status LEDs turn on briefly. When the Status LED turns off, the
POST is complete. If the LEDs do not behave in this way when the system powers on, refer to
the information in this document about understanding LED indications.
Understanding LED Indications on the
Controller
The following figure shows the LEDs on the cRIO-9024.
Figure 11. LEDs on the cRIO-9024
1 2 3 4
1. POWER
2. FPGA
3. STATUS
4. USER1
POWER LED
The POWER LED is lit while the cRIO-9024 is powered on. This LED indicates that the
power supply connected to the controller is adequate.
FPGA LED
NI Condition Monitoring Systems do not use the FPGA LED.
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STATUS LED
The STATUS LED is off during normal operation. After the device powers on, the cRIO-9024
indicates specific error conditions by flashing the STATUS LED a certain number of times
every few seconds. If you observe this behavior after the device powers on, contact National
Instruments support.
USER1 LED
The USER1 LED can display the indications described in the following table:
Table 3. USER1 LED Indications
Indication Description
Flashing rapidly Indicates an error condition. Open Systems Manager to the Dashboard
page to see the device status.
Flashing steadily Indicates normal operation.
Solid Indicates that USB operations are in progress, such as reading or writing
the connection information file. You can safely remove the USB drive
when this LED resumes blinking steadily.
Note This device polls USB drives every 15 seconds, so you
might need to wait up to 15 seconds after a USB operation
begins for the LED to light.
Troubleshooting Network Communication
If the CMS-9024 does not connect to NI InsightCM Server with a status of Online, try the
following troubleshooting tips:
• Check the Ethernet cable connections on the CMS-9024, host computer, and router.
• If you have network firewalls or other security software enabled, try temporarily turning
them off. You might also need to add an exception for NI InsightCM Server by
completing the following steps:
1. Navigate to the standard Microsoft Windows Control Panel utility for managing
firewall settings.
2. Click Allow a program or feature through Windows Firewall.
3. Click Allow another program.
4. Select NI InsightCM and click Add.
5. Click OK and close the firewall settings.
• Ensure that the ports listed in the following table are open to communication on the host
computer. If you are using an intelligent switch on the network, ensure that the switch is
not disabling these ports.
Maintaining NI CMS-9024 Hardware for an NI InsightCM System | © National Instruments | 13

Table 4. Host Computer Ports That Must Remain Open
Port Type
5353 UDP (inbound and outbound rules)
6342 TCP (inbound and outbound rules)
44515 UDP (inbound and outbound rules)
44516 TCP (outbound rule)
44525 UDP (inbound and outbound rules)
80/443 TCP (outbound rule)
• If you have multiple network cards on the host computer, ensure that you use the
Windows Control Panel to disable all other network adapters, such as wireless adapters.
Turning off the wireless antenna is insufficient.
Resetting the Network Configuration of the Controller
Complete the following steps to reset the IP address and connection type of the controller.
1. Insert a USB drive into the USB port on the controller front panel.
The USER1 LED lights solid, which indicates that the controller is writing a text file to
the USB drive. The text file contains network and connection properties.
Tip You can use the blank USB drive included in the NI InsightCM Server kit.
2. Remove the USB drive from the controller when the USER1 LED returns to blinking
steadily, which indicates that the operation is complete.
3. Insert the USB drive into a USB port on a computer.
4. Browse the file structure of the drive for the InsightCM folder and open the text file
whose filename matches the device hostname, which is the format of NI-cRIO-
ModelNumber-SerialNumber.
5. In the [Ethernet Adapter 0] section of the file, complete the following steps.
a) Configure the following properties to set a static IP address:
IP Address Request Mode = "Static"
IP Address = "x.x.x.x"
where x.x.x.x is the desired IP address.
b) Enter True for the following item:
ChangeSettings = False
6. Save and close the file.
7. Insert the USB drive back into the USB port on the controller front panel.
The controller reads and applies the new properties.
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Where to Go Next
The following figure describes additional documentation and resources as you develop an
application with the CMS-9024.
Figure 12. Where to Go Next
NI InsightCM™
Server Configuration
and Monitoring Help
1Help system with instructions for configuring NI InsightCM Server and monitoring
NI Condition Monitoring Systems. To launch this help, open Systems Manager
in a web browser and click the Help link in the top-right corner of the page.
CompactRIO
Controller and
Chassis Datasheets
2
3
Device specifications, including power requirements, physical characteristics,
safety and environmental information, and other important information.
Visit ni.com/info and enter one of the following Info Codes for your device:
crio9024datasheet, crio911xdatasheet, crio9068datasheet
C Series Module
Documentation
Operating instructions and device specifications for C Series modules that you
can install in a CompactRIO chassis. These documents describe how to
connect sensors, actuators, and other devices to C Series modules.
Visit ni.com/info and enter the Info Code insightcmdocs to access
documentation for C Series modules that are compatible with NI InsightCM.
Worldwide Support and Services
The National Instruments 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 email and phone assistance from NI Application Engineers.
Visit ni.com/services for NI Factory Installation Services, repairs, extended warranty, and
other services.
Visit ni.com/register to register your National Instruments product. Product registration
facilitates technical support and ensures that you receive important information updates from
NI.
National Instruments corporate headquarters is located at 11500 North Mopac Expressway,
Austin, Texas, 78759-3504. National Instruments also has offices located around the world.
For telephone support in the United States, create your service request at ni.com/support or
dial 1 866 ASK MYNI (275 6964). For telephone support outside the United States, visit the
Worldwide Offices section of ni.com/niglobal to access the branch office websites, which
provide up-to-date contact information, support phone numbers, email addresses, and current
events.
Maintaining NI CMS-9024 Hardware for an NI InsightCM System | © National Instruments | 15

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covering National Instruments products/technology, refer to the appropriate location: Help»Patents in your software, the
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374735A-01 Nov14