Embedded controller runs LabVIEW Real-Time for deterministic control, data logging, and analysis 800 MHz processor, 4 GB nonvolatile storage, 512 MB DDR2 memory Dual Ethernet ports with embedded Web and file servers for remote user interfacing	Hi-Speed USB host port for connection to USB flash and memory devices RS232 serial port for connection to peripherals; dual 9 to 35 VDC supply inputs -40 to 70 °C operating temperature range

Overview

The NI cRIO-9025 embedded real-time controller is part of the high-performance CompactRIO programmable automation controller (PAC) platform. It features an industrial 800 MHz real-time Freescale processor for deterministic, reliable real-time applications and contains 512 MB of DDR2 RAM and 4 GB of nonvolatile storage for holding programs and logging data.

Requirements and Compatibility

OS Information VxWorks

Driver Information NI-RIO

Software Compatibility LabVIEW LabVIEW FPGA Module LabVIEW Professional Development System LabVIEW Real-Time Module

Application and Technology

System Configuration

The NI cRIO-9025  rugged, reliable controller is designed for low-power consumption with dual 9 to 35 VDC supply inputs that deliver isolated power to the CompactRIO chassis/modules and a -40 to 70 °C operating temperature range. The cRIO-9025 accepts 9 to 35 VDC power supply inputs on power up and 6 to 35 VDC power supply inputs during operation, so it can function for long periods of time in remote applications using a battery or solar power.

The controller provides two Ethernet 10/100 ports that you can use to conduct programmatic communication over the network and built-in Web (HTTP) and file (FTP) servers. The ports also are compatible with the NI 9144 C Series expansion chassis, so you can connect more deterministic I/O for your application.

To create additional storage capability for your embedded logging applications, the cRIO-9025 has a Hi-Speed USB host port to which you can connect external USB-based storage media (flash drives and hard drives). In addition, the controller features a fault-tolerant file system that provides increased reliability for data-logging applications.

 

Embedded Software

The cRIO-9025 runs NI LabVIEW Real-Time Module software on the Wind River VxWorks real-time operating system (RTOS) for extreme reliability and determinism. You can now use leading VxWorks RTOS technology and LabVIEW graphical programming tools to quickly design, prototype, and deploy a customizable, commercial off-the-shelf embedded system.

You can synchronize embedded code execution to an FPGA-generated interrupt request (IRQ) or an internal millisecond real-time clock source. The LabVIEW Real-Time ETS OS provides reliability and simplifies the development of complete embedded applications that include time-critical control and acquisition loops in addition to lower-priority loops for postprocessing, data logging, and Ethernet/serial communication. Built-in elemental I/O functions such as the FPGA Read/Write function provide a communication interface to the highly optimized reconfigurable FPGA circuitry. Data values are read from the FPGA in integer format, and then converted to scaled engineering units in the controller.

 

Figure1: CompactRIO Software Architecture

 

Built-In Servers

In addition to programmatic communication via TCP/IP, UDP, Modbus/TCP, IrDA, and serial protocols, the CompactRIO controllers include built-in servers for Virtual Instrument Software Architecture (VISA), HTTP, and FTP. The VISA server provides remote download and communication access to the reconfigurable I/O (RIO) FPGA over Ethernet. The HTTP server provides a Web browser user interface to HTML pages, files, and the user interface of embedded LabVIEW applications through a Web browser plug-in. The FTP server provides access to logged data or configuration files.ools.

Software Recommendations

LabVIEW Professional Development System for Windows	Advanced software tools for large project development Automatic code generation using DAQ Assistant and Instrument I/O Assistant Tight integration with a wide range of hardware Advanced measurement analysis and digital signal processing Open connectivity with DLLs, ActiveX, and .NET objects Capability to build DLLs, executables, and MSI installers	NI LabVIEW FPGA Module	Create your own I/O hardware without VHDL coding or board design Graphically configure FPGAs on NI reconfigurable I/O (RIO) hardware targets Define your own control algorithms with loop rates up to 300 MHz Execute multiple tasks simultaneously and deterministically Implement custom timing and triggering logic, digital protocols, and DSP algorithms Incorporate existing HDL code and third-party IP including Xilinx CORE Generator functions
NI LabVIEW Real-Time Module	Design deterministic real-time applications with LabVIEW graphical programming Download to dedicated NI or third-party hardware for reliable execution and a wide selection of I/O Take advantage of built-in PID control, signal processing, and analysis functions Automatically take advantage of multicore CPUs or set processor affinity manually Includes real-time operating system (RTOS), development and debugging support, and board support Purchase individually or as part of an NI Developer Suite bundle

Support and Services

System Assurance Programs

NI system assurance programs are designed to make it even easier for you to own an NI system. These programs include configuration and deployment services for your NI PXI, CompactRIO, or Compact FieldPoint system. The NI Basic System Assurance Program provides a simple integration test and ensures that your system is delivered completely assembled in one box. When you configure your system with the NI Standard System Assurance Program, you can select from available NI system driver sets and application development environments to create customized, reorderable software configurations. Your system arrives fully assembled and tested in one box with your software preinstalled. When you order your system with the standard program, you also receive system-specific documentation including a bill of materials, an integration test report, a recommended maintenance plan, and frequently asked question documents. Finally, the standard program reduces the total cost of owning an NI system by providing three years of warranty coverage and calibration service. Use the online product advisors at ni.com/advisor to find a system assurance program to meet your needs.

Calibration

NI measurement hardware is calibrated to ensure measurement accuracy and verify that the device meets its published specifications. To ensure the ongoing accuracy of your measurement hardware, NI offers basic or detailed recalibration service that provides ongoing ISO 9001 audit compliance and confidence in your measurements. To learn more about NI calibration services or to locate a qualified service center near you, contact your local sales office or visit ni.com/calibration.

Technical Support

Get answers to your technical questions using the following National Instruments resources.

• Support - Visit ni.com/support to access the NI KnowledgeBase, example programs, and tutorials or to contact our applications engineers who are located in NI sales offices around the world and speak the local language.
• Discussion Forums - Visit forums.ni.com for a diverse set of discussion boards on topics you care about.
• Online Community - Visit community.ni.com to find, contribute, or collaborate on customer-contributed technical content with users like you.

Repair

While you may never need your hardware repaired, NI understands that unexpected events may lead to necessary repairs. NI offers repair services performed by highly trained technicians who quickly return your device with the guarantee that it will perform to factory specifications. For more information, visit ni.com/repair.

Training and Certifications

The NI training and certification program delivers the fastest, most certain route to increased proficiency and productivity using NI software and hardware. Training builds the skills to more efficiently develop robust, maintainable applications, while certification validates your knowledge and ability.

• Classroom training in cities worldwide - the most comprehensive hands-on training taught by engineers.
• On-site training at your facility - an excellent option to train multiple employees at the same time.
• Online instructor-led training - lower-cost, remote training if classroom or on-site courses are not possible.
• Course kits - lowest-cost, self-paced training that you can use as reference guides.
• Training memberships and training credits - to buy now and schedule training later.

Visit ni.com/training for more information.

Extended Warranty

NI offers options for extending the standard product warranty to meet the life-cycle requirements of your project. In addition, because NI understands that your requirements may change, the extended warranty is flexible in length and easily renewed. For more information, visit ni.com/warranty.

OEM

NI offers design-in consulting and product integration assistance if you need NI products for OEM applications. For information about special pricing and services for OEM customers, visit ni.com/oem.

Alliance

Our Professional Services Team is comprised of NI applications engineers, NI Consulting Services, and a worldwide National Instruments Alliance Partner program of more than 700 independent consultants and integrators. Services range from start-up assistance to turnkey system integration. Visit ni.com/alliance.

Detailed Specifications

The following specifications are typical for the entire operating temperature range, – 40 to 70 °C, unless otherwise noted.
CPU
Real-time processor		800 MHz Freescale MPC8377
Network
Network interface
Ethernet port 1		10BaseT and 100BaseTX Ethernet
Ethernet port 2		10BaseT and 100BaseTX Ethernet
Compatibility		IEEE 802.3
Communication rates
Ethernet port 1		10 Mbps, 100 Mbps, auto-negotiated
Ethernet port 2		10 Mbps, 100 Mbps, auto-negotiated
Maximum cabling distance		100 m/segment
RS-232 DTE Serial Port
Baud rate		600–230,400 bps
Data bits		5, 6, 7, 8
Stop bits		1, 1.5, 2
Parity		Odd, even, mark, space, none
Flow control		RTS/CTS, XON/XOFF, DTR/DSR, none
USB Port
Maximum data rate		480 Mb/s
Maximum current		500 mA
Memory
Nonvolatile		4 GB
For information about the life span of the nonvolatile memory and about best practices for using nonvolatile memory, go to ni.com/info and enter the info code SSDBP.
DRAM		512 MB
Internal Real-Time Clock
Accuracy		200 ppm; 35 ppm at 25 °C
Integrated Voltage Input Monitor
The integrated voltage input monitor underreports the voltage at the power connector by up to 400 mV because of voltage drops across internal circuits.
Power Requirements
Caution You must use a National Electric Code (NEC) UL Listed Class 2 power supply with the cRIO-9025.
Recommended power supply		55 W secondary, 35 VDC max
Power consumption
Controller only		17 W
Controller supplying power to eight CompactRIO modules		35 W
Voltage requirement
On powerup		9 to 35 V
After powerup		6 to 35 V
Note The cRIO-9025 is guaranteed to power up when 9 V is applied to V and C. After powerup, it can operate on as little as 6 V.
Physical Characteristics
If you need to clean the controller, wipe it with a dry towel.
Screw-terminal wiring		12–18 AWG copper conductor wire with 10 mm (0.39 in.) of insulation stripped from the end
Torque for screw terminals		0.5 to 0.6 N · m, (4.4 to 5.3 lb · in.)
Weight		Approx. 609 g (21.5 oz)
Environmental
The cRIO-9025 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 60068-2-2)		– 40 to 70 °C
Caution For information about how mounting configuration can affect the accuracy of C Series modules, go to ni.com/info and enter the info code rdcriotemp.
Storage temperature (IEC 60068-2-1, IEC 60068-2-2)		– 40 to 85 °C
Ingress protection		IP 20
Operating humidity (IEC 60068-2-56)		10 to 90% RH, noncondensing
Storage humidity (IEC 60068-2-56)		5 to 95% RH, noncondensing
Maximum altitude		2,000 m
Pollution Degree (IEC 60664)		2
Shock and Vibration
To meet these specifications for shock and vibration, you must panel mount or wall mount the CompactRIO system, affix ferrules to the ends of all terminal wires, install a strain relief on the power cable, and install tie wraps on the Ethernet and power cables. You can order the NI 9979, a strain-relief kit for the power cable, from National Instruments. The kit is NI part number 196939-01. For information about using the USB port in high shock and vibration environments, contact National Instruments.
Operating vibration
Random (IEC 60068-2-64)		5 grms, 10 to 500 Hz
Sinusoidal (IEC 60068-2-6)		5 g, 10 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
Safety
Safety Voltages
Connect only voltages that are within these limits.
V-to-C		35 V max, 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 low-voltage sources, and electronics. Caution Do not connect to signals or use for measurements within Measurement Categories II, III, or IV.
Safety Standards
This product is designed to meet the requirements of the following standards of safety for electrical equipment for measurement, control, and laboratory use: IEC 61010-1, EN 61010-1 UL 61010-1, CSA 61010-1 Note For UL and other safety certifications, refer to the product label or the Online Product Certification section.
Electromagnetic Compatibility
This product meets the requirements of the following EMC standards for electrical equipment for measurement, control, and laboratory use: EN 61326 (IEC 61326): Class A emissions; Industrial Immunity EN 55011 (CISPR 11): Group 1, Class A emissions AS/NZS CISPR 11: Group 1, Class A emissions FCC 47 CFR Part 15B: Class A emissions ICES-001: Class A emissions Note For the standards applied to assess the EMC of this product, refer to the Online Product Certification section. Note For EMC compliance, operate this product according to the documentation.
CE Compliance
This product meets the essential requirements of applicable European Directives, as amended for CE marking, as follows: 2006/95/EC; Low-Voltage Directive (safety) 2004/108/EC; Electromagnetic Compatibility Directive (EMC)
Online Product Certification
Refer to Declaration of Conformity (DoC) for this product 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.
Environmental Management
National Instruments is committed to designing and manufacturing products in an environmentally responsible manner. NI recognizes that eliminating certain hazardous substances from our products is beneficial not only to the environment but also to NI customers. For additional environmental information, refer to the NI and the Environment 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 products must be sent to a WEEE recycling center. For more information about WEEE recycling centers, National Instruments WEEE initiatives, and compliance with WEEE Directive 2002/96/EC on Waste Electrical and Electronic Equipment, visit ni.com/environment/weee.htm.

Pinouts/Front Panel Connections

Controller Serial Port

DB-9 Pin Descriptions Pin Signal 1 DCD 2 RXD 3 TXD 4 DTR 5 GND 6 DSR 7 RTS 8 CTS 9 RI