NATIONAL INSTRUMENTS IC-3120 Industrial Controller User Guide

NATIONAL INSTRUMENTS IC-3120 Industrial Controller

Product Information: IC-3120 Industrial Controller

The IC-3120 is a high-performance, fanless embedded system  designed for rugged industrial applications. It is used for controlling and monitoring industrial equipment and processes. The device is built to withstand harsh industrial environments and is designed to be reliable and durable. The device comes with installation instructions and guidelines for safe usage.

Contents

• Safety Information
• Electromagnetic Compatibility Guidelines
• Configuring the Hardware

Safety Information
The IC-3120 is a powerful device that must be handled with care. The following safety information must be followed when installing and operating the device:

• Do not operate the device in a manner not specified in the documentation. Misuse of the device may result in a hazard and may compromise the safety protection built into the device.
• If the device is damaged, turn it off and do not use it until service-trained personnel can check its safety. If necessary, return the device to National Instruments for repair.
• Keep away from live circuits. Do not remove equipment covers or shields unless you are trained to do so. Hazardous voltages can exist even when the equipment is turned off.
• Disconnect all field power prior to removing covers or shields.
• Do not install unauthorized parts or modify the device. Use the device only with the chassis, modules, accessories, and cables specified in the installation instructions. All covers and filler panels must be installed while operating the device.
• Clean the device and accessories by brushing off light dust with a soft, nonmetallic brush. Remove other contaminants with a stiff, nonmetallic brush. The unit must be completely dry and free from contaminants before returning it to service.
• You must insulate signal connections for the maximum voltage for which the device is rated. Do not exceed the maximum ratings for the device. Remove power from signal lines before connection to or disconnection from the device.

Electromagnetic Compatibility Guidelines
The IC-3120 complies with regulatory requirements and limits for electromagnetic compatibility (EMC) stated in the product specifications. 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.

Product Usage Instructions

Follow these instructions to install and configure the IC-3120:

1. Read and understand the safety information provided in the user manual before installing or operating the device.
2. Install the device using the specified chassis, modules, accessories, and cables. All covers and filler panels must be installed while operating the device.
3. Connect signal wires to the device after removing field power and insulate signal connections for the maximum voltage for which the device is rated. Do not exceed the maximum ratings for the device.
4. If necessary, configure the hardware using the instructions provided in the user manual.
5. Clean the device and accessories by brushing off light dust with a soft, nonmetallic brush. Remove other contaminants with a stiff, nonmetallic brush. The unit must be completely dry and free from contaminants before returning it to service.
6. Use the device only in industrial locations as it may cause harmful interference when used in residential or commercial areas. Follow electromagnetic compatibility guidelines provided in the user manual to minimize interference with radio and television reception and prevent unacceptable performance degradation.
7. If the device is damaged, turn it off and do not use it until service-trained personnel can check its safety. If necessary, return the device to National Instruments for repair.

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Safety Information

Caution The following paragraphs contain important safety information you must follow when installing and operating the device.

Do not operate the device in a manner not specified in the documentation. Misuse of the device may result in a hazard and may compromise the safety protection built into the device. If the device is damaged, turn it off and do not use it until service-trained personnel can check its safety. If necessary, return the device to National Instruments for repair.
Keep away from live circuits. Do not remove equipment covers or shields unless you are trained to do so. If signal wires are connected to the device, hazardous voltages can exist even when the equipment is turned off. To avoid a shock hazard, do not perform procedures involving cover or shield removal unless you are qualified to do so. Disconnect all field power prior to removing covers or shields.

• Pollution Degree 1—No pollution or only dry, nonconductive pollution occurs. The pollution has no effect.
• Pollution Degree 2—Normally only nonconductive pollution occurs. Occasionally, nonconductive pollution becomes conductive because of condensation.
• Pollution Degree 3—Conductive pollution or dry, nonconductive pollution occurs. Nonconductive pollution becomes conductive because of condensation.

Clean the device and accessories by brushing off light dust with a soft, nonmetallic brush. Remove other contaminants with a stiff, nonmetallic brush. The unit must be completely dry and free from contaminants before returning it to service.
You must insulate signal connections for the maximum voltage for which the device is rated. Do not exceed the maximum ratings for the device. Remove power from signal lines before connection to or disconnection from the device.

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.

Configuring the Hardware

Remove the IC-3120 from the package and inspect the system for damage. Notify National Instruments if the system appears damaged in any way. Do not use a damaged system. Ensure that the AC input to the external power supply is disconnected before plugging in or unplugging any connector. Ground the unit to minimize the possibility of static electricity damage.
Refer to the following figures while configuring the hardware.

Figure 1. IC-3120 Power Connectors and Reset Button

1. Reset Button
2. System Power Connector
3. Isolated Outputs and PoE Power Connector
4. Chassis Grounding Screw

Figure 2. IC-3120 Front Panel Connectors

1. VGA Connector
2. RJ50 Serial Port
3. USB 2.0 Ports
4. RJ45 Network Port
5. Gigabit Ethernet PoE Ports
6. 44-pin Digital I/O Connector

Connecting the System Power Supply
NI recommends the following power supply for the IC-3120.

Complete the following steps to supply power to the IC-3120.

1. Verify the power source is turned off.

2. Install one ferrite across the negative and positive leads of the power source, approximately 50 to 75 mm (2 to 3 in.) from the end of the power input wires.
   Figure 3. Installing a Ferrite on the Power Leads

3. If the power connector plug is connected to the chassis, disconnect it from the device.
   Figure 4. 2-Position Power Screw Terminal Connector

4. V (Positive) Terminal Screw

5. C (Negative) Terminal Screw

6. Connector Screws
   Caution Do not tighten or loosen the terminal screws on the power connector while the power is on.

7. Connect the positive lead of the power source to the V terminal of the power connector plug and tighten the terminal screw to 0.2 to 0.25 N · m (1.8 to 2.2 lb · in.) of torque.

8. Connect the negative lead of the power source to the C terminal of the power connector plug and tighten the terminal screw to 0.2 to 0.25 N · m (1.8 to 2.2 lb · in.) of torque.

9. Install the power connector plug into the SYSTEM power receptacle on the IC-3120 chassis and tighten the connector screws to 0.4 N · m (3.5 lb · in.) of torque.

10. Turn on the external power source.

Connecting the Isolated Outputs Power Supply and PoE Power Supply
NI recommends the following power supplies for the IC-3120.

Complete the following steps to supply power to the PoE ports and the isolated outputs.

1. Verify the power source is turned off.

2. Install one ferrite across the negative and positive leads of the power sources, approximately 50 to 75 mm (2 to 3 in.) from the end of the power input wires. If you are using an isolated output power supply and a PoE power supply, wrap the wires for both power supplies through the same ferrite.
   Figure 5. Installing a Ferrite on the Power Leads

3. If the power connector plug is connected to the chassis, disconnect it from the device.
   Figure 6. 4-Position Power Screw Terminal Connector

4. VPOE (Positive) Terminal Screw

5.  CPOE (Negative) Terminal Screw

6. VISO (Positive) Terminal Screw

7. CISO (Negative) Terminal Screw

8. Connector Screws
   Caution Do not tighten or loosen the terminal screws on the power connector while the power is on.

9. Connect the positive lead of the isolated outputs power source to the V2 terminal of the power connector plug and tighten the terminal screw to 0.2 to 0.25 N · m (1.8 to
   2.2 lb · in.) of torque.

10. Connect the negative lead of the isolated outputs power source to the C2 terminal of the power connector plug and tighten the terminal screw to 0.2 to 0.25 N · m (1.8 to
    2.2 lb · in.) of torque.

11. Connect the positive lead of the PoE power source to the V1 terminal of the power connector plug and tighten the terminal screw to 0.2 to 0.25 N · m (1.8 to 2.2 lb · in.) of torque.

12. Connect the negative lead of the PoE power source to the C1 terminal of the power connector plug and tighten the terminal screw to 0.2 to 0.25 N · m (1.8 to 2.2 lb · in.) of torque.

13. Install the power connector plug into the ISO/PoE power receptacle on the IC-3120 chassis and tighten the connector screws to 0.4 N · m (3.5 lb · in.) of torque.

14. Turn on the external power source.

Configuring the IC-3120 for NI Linux Real-Time

The real-time version of the IC-3120 ships preloaded with NI Linux Real-Time. Complete this section if you are using the real-time version of the IC-3120.

Connecting to the Development Computer
The IC-3120 can connect to the development computer directly or through a network.

Connecting Directly to the Development Computer
Complete the following steps to connect the device directly to the development computer.

1. Verify the development computer is powered on.
2. Connect one end of an Ethernet cable to the network port on the device.
3. Connect the free end of the cable to an Ethernet port on the development computer.
4. Verify the ACTIVITY/LINK LED on the port is on or blinking.
   The device uses a link-local IP address when connected directly to the development computer.

Connecting to the Development Computer Over a Network
To connect over a network, the device must be on the same subnet as the development computer. Complete the following steps to connect the device to the development computer over a network.

1. Verify the development computer is powered on and connected to the network.
2. Connect one end of an Ethernet cable to the network port on the device.
3. Connect the free end of the cable to an Ethernet switch or other network device on the same network as the development computer.
4. Verify the ACTIVITY/LINK LED on the port is on or blinking.

The device negotiates an IP address when connected to a network with a DHCP server or comparable network device.

Using Vision Builder AI with the IC-3120
Complete the following steps to use Vision Builder AI with the IC-3120:

1. Install Vision Builder AI on the development computer.
2. Refer to the How to Configure NI Vision Builder AI Remote Targets section in the Vision Builder for Automated Inspection: Configuration Help.

When using Vision Builder AI, it is not necessary to install the NI Industrial Controller Device Drivers or use NI MAX to set a system password on the target.

Installing the NI Industrial Controller Device Drivers
Before using the IC-3120, install the drivers onto the device. Complete the following steps to install and configure NI Industrial Controller Device Drivers:

1. Install NI Industrial Controller Device Drivers onto the Windows development machine connected to the IC-3120.
2. Run NI MAX.
3. Expand the Remote Systems list in the configuration tree.
4. Select the IC-3120 in the list. By default, MAX lists devices by the model number followed by the serial number, such as IC-3120-XXXXXXXX.
5. Configure the network settings for the IC-3120. Refer to the Remote Systems Help in MAX. Select Help»Help Topics»Remote Systems for instructions about configuring network settings.
6. Install a recommended software set. If you would like to install custom software instead of a recommended software set, proceed to the next step.
7. Expand the IC-3120 under Remote Systems.
8. Click the Software item below the IC-3120 in the configuration tree.
9. Click Add/Remove Software on the MAX toolbar to launch the LabVIEW Real-Time Software Wizard.
10. Enter admin as the username and leave the password field blank.
11. Select NI Industrial Controller under the version of LabVIEW Real-Time you are using.
12. Click Next.
13. Select any additional add-ons you would like to install to the IC-3120.
14. Click Next. Review the list of software to install.
15. Click Next to begin downloading the software to the IC-3120. When MAX finishes downloading the software, the IC-3120 restarts.
16. Click Finish.
17. Install custom software. You do not need to install custom software if you installed a recommended software set.
18. Expand the IC-3120 under Remote Systems.
19. Click the Software item below the IC-3120 in the configuration tree.
20. Click Add/Remove Software on the NI MAX toolbar to launch the LabVIEW Real-Time Software Wizard.
21. Enter admin as the username and leave the password field blank.
22. If you are given a choice of recommended software sets, choose Custom software installation and click Next to proceed with a custom installation.
23. Select the NI Industrial Controller Device Drivers, and any additional software you would like to install on the IC-3120.
24. Click Next. Review the list of software to install.
25. Click Next to begin downloading the software to the IC-3120. When NI MAX finishes downloading the software, the IC-3120 restarts.
26. Click Finish.
27. Connect hardware to the IC-3120. The NI Industrial Controller Device Drivers enable the IC-3120 to detect any hardware connected.
28. Select the target in the configuration tree and click the Refresh button. Refresh the target whenever you connect new hardware.
29. Expand Devices and Interfaces under the IC-3120 in the configuration tree. Select the hardware connected to the IC-3120 from the list. You can view or modify the device settings as allowed by the hardware.

Setting a System Password

Complete the following steps to set a system password.

Note The default username for the IC-3120 is admin. There is no default password for the IC-3120, so you must leave the password field blank when logging
in until you set a system password.

1. In MAX, right-click the IC-3120 and select Web Configuration.
   The NI Web-Based Configuration and Monitoring utility opens in the default browser and is where you set the password. If you have not installed Microsoft Silverlight,
   NI Web-based Configuration and 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.

Configuring the IC-3120 for Windows

The Windows version of the IC-3120 ships preloaded with Windows Embedded Standard 7 64-bit. Complete this section if you are using the Windows version of the IC-3120.

Connecting the IC-3120 to a Network
Complete the following steps to connect the device to a network.

1. Connect one end of an Ethernet cable to the network port on the device.
2. Connect the free end of the cable to an Ethernet hub or other network device.
3. Verify the ACTIVITY/LINK LED on the port is on or blinking.

By default, the operating system automatically attempts to connect to the network using DHCP. If it is unable to initiate a DHCP connection, it connects to the network with a link-local IP address (169.254.x.x).

Installing the NI Industrial Controller Device Drivers
Before using the IC-3120, install other National Instruments software, such as application development environments, and then install the drivers onto the device. If you have an external USB DVD drive, you can use the external DVD drive to install the NI Industrial Controller Device Drivers from the DVD shipped with the device. Otherwise, complete the following steps to download and install the NI Industrial Controller Device Drivers

1. Connect a USB keyboard and a USB mouse to the USB ports on the IC-3120.
2. Connect a monitor to the VGA on the IC-3120.
3. Using the web browser on the IC-3120, navigate to ni.com/drivers.
4. In the Drivers search field, search for NI Industrial Controller Device Drivers.
5. Download the latest version of NI Industrial Controller Device Drivers.
6. Run the NI Industrial Controller Device Drivers installer.

Troubleshooting

The following sections provide instructions for troubleshooting the IC-3120.

(RT Only) The IC-3120 Does Not Appear in MAX

• The IC-3120 may not be powered. Verify that there is system power to the device and that both the IC-3120 and the development computer are properly connected to the network. The PWR/FAULT LED should be lit green and the ACTIVITY/LINK LED on the primary network port should flash green when refreshing the list of devices in MAX.

• Ensure you are connecting to the IC-3120 from a Windows development machine with NI Industrial Controller Device Drivers installed.

• The IC-3120 may have been configured on another network and then moved to the current network. Reconfigure the IC-3120 for the current network.
  Note Connect a monitor and keyboard to the IC-3120 and press to view the current configuration settings of the device.

• Another device on the network is using the IP address assigned to the IC-3120. This can happen when you assign the same static IP to two devices, you assign a static IP that is in the range of the IP address available for DHCP use on your network, or the DHCP assigns the same IP address to another device. Either remove or reconfigure the other device, or reconfigure the IC-3120 to use a different IP address by putting it into the IP RESET state and restarting into the normal state. Refer to the IC-3120 User Manual on ni.com/manuals for instructions on how to perform an IP RESET.

• The cable you are using may be inappropriate for the speed of your network, causing network communication dropout. While 1,000 Mbps communication over short cable lengths can be achieved with the CAT5 cable commonly used for 10 and 100 Mbps, CAT5e and CAT6 cables are more reliable and recommended for 1,000 Mbps links. The IC-3120 has the ability to perform auto-crossover, allowing the use of straight or crossover Ethernet cables, independent of the connection configuration.

• The IC-3120 is configured to acquire an IP address from a DHCP server, but no DHCP server is available. By default, the target will automatically attempt to connect to the network using DHCP. If the target is unable to initiate a DHCP connection, the target connects to the network with a link-local IP address (169.254.x.x).

• You may be experiencing firewall issues. If you are having difficulty detecting the system and setting up the IC-3120 on your network, you must configure the firewall to open the TCP/UDP ports used by the IC-3120 and the host machine. Refer to the following table for more information about TCP/UDP ports.

Table 1. TCP/UDP Ports Used by the IC-3120

locate remote targets.
7749| TCP| Used for remote image display (not reserved).
7750| TCP| Used for NI-IMAQdx remote configuration (not reserved).
3363| TCP/UDP| Reserved as nati-vi-server (NATI VI Server). Used by Vision Builder AI to configure a remote target.

If your firewall is controlled remotely or you are unsure about configuring the firewall, contact your network administrator.

(RT Only) No Software is Installed
MAX reports that no software is installed. Install application and driver software on the IC-3120.

Related Information
Installing the NI Industrial Controller Device Drivers on page 7

Cannot Drive Isolated Outputs
Verify that you have power connected to the VISO and CISO inputs on the IC-3120 isolated power connector and that the contact at the screw terminals is solid. Because these outputs are electrically isolated from the IC-3120 device main supply, they require power in addition to the IC-3120 main supply.

LED Error Indications
The IC-3120 indicates specific error conditions by flashing the STATUS LED a specific number of times.

Table 2. STATUS LED Indications

LED| LED

Color

| LED State| Indication
---|---|---|---
STATUS| Yellow| OFF| The IC-3120 initialized successfully and is ready for use.
2 blinks| (RT only) There is no software installed, which is the out-of-box state, or the IC-3120 has detected an error in its software. The device has automatically started up into safe mode. This usually occurs when an attempt to upgrade the software is interrupted or if system files are deleted from the IC-3120. Reinstall software on the IC-3120.
3 blinks| (RT only) The IC-3120 has booted into safe mode. Refer to the Safe Mode section for information about the safe mode state.
4 blinks| (RT only) The IC-3120 has experienced two consecutive software exceptions. The IC-3120 automatically restarts after an exception. After the second exception, the IC-3120 remains in the exception state, alerting you to resolve the problem. Reinstall software on the IC-3120 or contact NI for assistance. Refer to the IC-3120 Getting Started Guide for information about installing software on the IC-3120.
Continuous blinking| (RT only) The IC-3120 has not booted into NI Linux Real- Time. The controller either booted into an unsupported operating system, was interrupted during the boot process, or detected an unrecoverable software error.
Solid| (RT only) The IC-3120 is booting up. (Windows only) An internal drive is being accessed.

PWR/FAULT LED Is Not Lit When the IC-3120 is Powered On
If the system power supply is properly connected (polarity is not reversed) to the IC-3120, but the PWR/FAULT LED does not light up, check that the power supply is within the specifications listed in the IC-3120 Specifications. Using a power supply that is not within these specifications might result in an unresponsive or unstable system and could damage the device. If the BIOS setting Restore After Power Loss is set to Stay Off, the IC-3120 may be powered, but turned off. Use the power button to turn on the device.

Where to Go Next

The following documents and resources contain information you may find helpful as you use the IC-3120 in an application. Refer to the National Instruments Product Manuals Library at ni.com/manuals for the most recent versions of product documentation.

• • IC-3120 Specifications—Contains detailed specifications for the IC-3120.
  • IC-3120 User Manual—Contains connector pinouts, configuration information, mounting information, and answers to common troubleshooting questions.
  • NI CVS I/O Accessory User Manual—Contains installation and operation instructions for the NI CVS I/O Accessory.

Worldwide Support and Services

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 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 NI product. Product registration facilitates technical support and ensures that you receive important information updates from NI.
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, 78759-3504. NI 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.

Refer to the NI Trademarks and Logo Guidelines at ni.com/trademarks for information on NI trademarks. Other product and company names mentioned herein are trademarks or trade names of their respective companies. For patents covering NI products/technology, refer to the appropriate location: Help»Patents in your software, the patents.txt file on your media, or the National Instruments Patent Notice at ni.com/patents. You can find information about end-user license agreements (EULAs) and third- party legal notices in the readme file for your NI product. Refer to the Export Compliance Information at ni.com/legal/export- compliance for the NI global trade compliance policy and how to obtain relevant HTS codes, ECCNs, and other import/export data. NI MAKES NO EXPRESS OR IMPLIED WARRANTIES AS TO THE ACCURACY OF THE INFORMATION CONTAINED HEREIN AND SHALL NOT BE LIABLE FOR ANY ERRORS. U.S. Government Customers: The data contained in this manual was developed at private expense and is subject to the applicable limited rights and restricted data rights as set forth in FAR 52.227-14, DFAR 252.227-7014, and DFAR 252.227-7015.
© 2016 National Instruments. All rights reserved.
376069A-01 Apr16

References

• Engineer Ambitiously - NI
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• National Instruments Patents - NI
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• NI Trademarks and Logo Guidelines - NI
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• Product Certifications - NI
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• Product Documentation - NI
• Contact Us - NI
• Log In - National Instruments
• NI Services - NI
• Support - NI
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