cRIO-9045 and cRIO-9040 status Led 2 blinking red after deployment.

[Braggel]

Hi all,

I'm having a curious problem with the cRIO-9040 and cRIO-9045.

On my development setup, I have everything working. I take an image (folder based) of a 9040 and a 9045 and later I want to deploy this image to several other cRIOs.

But as soon as I deploy the image to other cRIOs, after the last reboot of the deployment, the 9040 and 9045 blink red with status led 2. I checked on the NI site what the red blinking means and it's power supply related. So I check the power supply (a Phoenix Contact QUINT4-PS/1AC/24DC/10 - 2904601). It's 240 Watt output that powers only the 2 cRIOs and some Phoenix Contact galvanic insulators, so there's no lack of power. I measured with a scope at power on/startup/boot, I don't see the 24V level changing whatsoever (no sudden spiky dips, nothing). To get the cRIO back when this red led is blinking, you have to 'hard reset' twice (waiting 10 seconds between resets) by pressing the reset button. The first reset, it will blink red, the second reset typically it will reboot normally. After the deployment and fixing the red blinking led, to reproduce this problem I just have to change some setting in NI Max (e.g. Disable RT startup app) and after triggering the reboot of this change, I'll have the blinking red led again.

I tried to revert everything to the 'out-of-the-box' situation, I formatted the cRIOs, I reflashed the firmware but the problem persists now... So my 2 cRIO became virtually unusable now.

So I have two questions.

How could I fix my 2 cRIOs?

What's going wrong here? I'm just flashing software that works on another 9040 and 9045,...

Thanks!

Kind regards,

Filip.

[NIRebecca]

Hey Filip, 

As you mention and as per cRIO-9045 LEDs the status LED blinking red shows: 

This indicates a hardware error. An internal power supply has failed. Check front-panel I/O and C Series module connections for shorts. Remove any shorts and cycle power the cRIO-9045. If the problem persists, contact NI.

The recommended power supply for the cRIO-904X is: 100 W, 24 V DC so I'd suggest the 240W maybe too high for these chassis. Do you have a power supply that is within the specs to try the chassis with individually? Perhaps from the other 9040 and 9045 you mention?

Let us know how it goes,
Rebecca

[Braggel]

Hi Rebecca,

Thanks for your suggestions. I'll try on Monday to unplug all modules, power the cRIO with a 100 Watt power supply and see what it does then.

I'll keep you posted!

Kind regards,

Filip.

[Braggel]

The other power supply didn't fix the problem. But I noticed now that it's as if a thermal fuse blows and cures over time. The 9045 worked for a while and then started showing these symptoms again. I have to admit that the chassis is probably quite loaded (power wise) since it's an 8 slot CRIO with 8x NI9229 modules plugged in. I can imagine that this is a nice load for the CRIO, but it should be no problem to handle this.

So again the symptoms:

- I start working with the CRIO, it works fine for everything.

- After a while I get the red blinking led typically after a settings change in NI Max and reboot.

- When resetting it multiple times it comes back to function sometimes.

- As soon as it's running fine, the red led never happens (at least not to my knowledge).

And the search continues...

[NIRebecca]

Hey Braggel, 

The 9045 should operate within -20 °C to 55 °C, and the STATUS LED should show solid RED if the internal temperature is being exceeded, rather than blinking. Is it just in a normal(ish) temperature/humidity/pressure etc environment?

Also just checking the power supply again:

• Are we using a connecting cable no longer than 3 m (10 ft)?
• Are we using the ferrite (included in the shipping kit) on the negative and positive leads of the power supply?
• How have you wired the power connector?

Could you also clarify what you meant by "As soon as it's running fine, the red led never happens (at least not to my knowledge)." Do you mean just during that test run... or that chassis is then fine?

Cheers, 

Rebecca

[Braggel]

Hi Rebecca,

Thanks for your reaction.

It's in a quite well controlled Lab environment so it should be 20°C, 50% relative humidity and outside world atmospheric pressure.

I'm using a cable of about 25cm.

I'm not using the ferrite.

The power connector is only wired to V1 and C.

I don't have any problems whatsoever with this set-up on other CompactRIOs.

When I say that the CRIO is running fine, everything is working as it should. I can deploy images, I can run the software on it. I can reconfigure with NI MAX and reboot. If I once had the blinking red led, then every reboot is a risk of having the blinking red led again (through the manual reboot switch or through NI MAX).

Kind regards,

Filip.

[NIRebecca]

Hey Filip, 

I'd suggest if you're still seeing this behaviour and it's causing issues within the application the best next step would be to contact our Technical Support and the devices to be sent for repair. If the power is with spec and your still seeing the Status LED flash red then it would suggest a hardware fault. 

You can create a service request by calling your local NI office, or visiting www.ni.com/ask . I'd reference this forum so they can see our discussion too! 

Thanks,

Rebecca