Setting Up the Measurement Rack

The measurement rack arrives pre-assembled and wired. Before system bring up, visually inspect the measurement rack and ensure that the following are true:

  • All hardware components are installed.
  • All internal Ethernet wiring is connected.
  • All internal power wiring is connected.
  • All internal ground wiring is connected.
  • All GPIB-serial converter boxes are connected (if applicable).

Follow all installation requirements listed in the following topics before connecting the hardware:

Preparing the Uninterruptible Power Supply

Complete the following steps to remove the screen cover and install the front panel bezel (included in the system kit) on the uninterruptible power supply (UPS).

  1. Locate the orange screen cover on the UPS.
  2. Remove the four screws labeled on the screen cover to remove the cover from the unit.
  3. Align the bezel with the front panel and install it on the UPS. Refer to the APC UPS Operation Manual, which ships on disc with the Battery Test System, for bezel installation orientation.

Opening the Drawers

Complete the following steps to open the drawers to access and make signal connections to the cRIO-9047 controller, cDAQ-9189 chassis, C Series modules, and cRIO-9805 Ethernet switches.

  1. Remove the four #10-32 Phillips pan head mounting screws on the front panel of the drawer using a #2 Phillips screwdriver.
  2. Pull the drawer out using the handle.
    Note The drawers lock into place when fully extended. Press the lock-in disconnect tab on each slide to close the drawers.

Connecting the Rack to Earth Ground

Complete the following steps to connect the measurement rack to earth ground.

  1. Connect the ground lug, located on the power entry panel (PEP) of the measurement rack, to the facility earth ground.
    Note The ground lug connection requires 2.1 mm2(14 AWG) copper wire with a minimum torque of 1.29 N · m (11.5 lb · in).
  2. Verify that there is electrical continuity between the measurement rack functional earth ground lug and the facility earth ground using a handheld digital multimeter.

Connecting the Rack to Power

  1. Use the power cable included in your kit to connect the measurement rack to power.
  2. Attach the cable to the IEC 60320 C20 power inlet connector on the power entry panel (PEP).
    Notice Adhere to all safety requirements in Safety Requirements.

Configuring the Remote EPO Connector

You must configure the remote emergency power off (EPO) connector before using the system. The system will not power on unless you configure the remote EPO connector.

  1. Use mating components to create an external safety loop with all external instruments in your measurement rack.
  2. Use the EPO loopback dongle included your kit if you are not creating an external safety loop.
  3. Align the connectors and attach by tightening the captured nut.

Connecting Devices to the PS-16 Power Terminal Block

Complete the following steps to connect devices to the PS-16 terminal block. Use 0.14 mm² to 4 mm² gauge (12 AWG to 26 AWG) power signal wires.
  1. Ensure that no wires are connected to live power.
  2. Connect the power signal wires to the device.
  3. Strip 9 mm (0.35 in.) from one end of the wires.
  4. Twist wires leaving 60 mm (2.36 in.) from the end of the wires at the terminal block.
  5. Connect the positive lead (V) of the device to the +24 V terminal of terminal block and tighten the terminal screw to a torque of 0.5 N · m to 0.6 N · m (4.43 lb · in. to 5.31 lb · in.).
  6. Connect the negative lead (C) of the device to the COM terminal of the terminal block and tighten the terminal screw to a torque of 0.5 N · m to 0.6 N · m (4.43 lb · in. to 5.31 lb · in.).
If the power source is connected to the power connector using long wiring with high DC resistance, the voltage at the power connector may be significantly lower than the specified voltage of the power source.

Connecting the cRIO-9047 to the Lab PC

NI recommends using the USB-to-Type-A cable included in the kit for easy discovery of the cRIO-9047. Complete the following steps to connect the cRIO-9047 to the Lab PC.

  1. Connect the Type-C connector of the USB cable to the USB Type-C Dual Role port on the cRIO-9047.
  2. Connect the Type-A connector of the USB cable to the Lab PC.
After system bring up, the instrument driver software automatically detects the cRIO-9047. The USB driver creates a virtual network interface card and assigns an IP address to the cRIO-9047 in the format of 172.22.11.x.
Note After the cRIO-9047 is discovered and configured in Measurement & Automation Explorer (MAX), you can remove the USB cable.

Setting Up Temperature Input Devices

Complete the following steps to set up the FD-11613/11614 temperature input devices.
  1. Align and connect one end of the Ethernet cable to an Ethernet port on the temperature input device, and the other end to the cRIO-9805 Ethernet switch or cDAQ-9189 chassis Ethernet port in the measurement rack.
  2. Power on the device. You can connect the device power to your own external power supply or use the PS-16 in the measurement rack.

Connect Signals

Refer to the documentation for your instrument at ni.com/manuals for more information about signal connections.

Table 11. System Hardware Components Signal Connection Information
Type Example Device Connection Information Location
AI current HVIL monitor NI-9227 NI-9227 Operating Instructions and Specifications
AI voltage Cell/module voltage measurements NI-9224 NI-9224 Getting Started Guide
NI-9225 NI-9225 Operating Instructions and Specifications
NI-9228 NI-9228 Getting Started Guide
CAN/LIN BMS communication NI-9860 NI-9860 Getting Started Guide
DC power supply BMS supply voltage RMX-4101 RMX-410x User Manual
Digital input Contactor state, etc. NI-9375 NI-9375 Getting Started Guide
Digital input HVIL monitor NI-9422 NI-9422 Operating Instructions and Specifications
Digital output Ignition signal, etc. NI-9375 NI-9375 Getting Started Guide
NI-9475 NI-9475 Getting Started Guide
GPIB/RS-232 Third party instrument communication GPIB-RS232 NI GPIB-Serial Converter Help [1]
PWM input HVIL monitor NI-9423 NI-9423 Getting Started Guide
NI-9437 NI-9437 Getting Started Guide
PWM output Crash signal NI-9475 NI-9475 Getting Started Guide
RS-232 Third party instrument communication NI-9870 NI-9870 Getting Started Guide
SPST, relay HVIL control NI-9482 NI-9482 User Manual and Specifications
Thermocouple DUT temperature measurements NI-9212 NI-9212 and TB-9212 Getting Started Guide
NI-9213 NI-9213 Getting Started Guide
FD-11613 FD-11613 User Guide
FD-11614 FD-11614 User Guide

NI includes required backshell and terminal block kits for C Series modules in your system kit. You can find these kits in the accessory/documentation compartment of the shipping crate.

Table 12. C Series Module Terminal Blocks and Backshells
C Series Module Accessory
NI-9212 TB-9212—Isothermal terminal block
TB-9212 with mini-TC—Isothermal terminal block
NI-9213 NI-9940—Backshell for 36-position spring terminal connector
NI-9224 NI-9939—Backshell for 16-position screw terminal connector
NI-9228
NI-9422
NI-9225 NI-9971—Backshell for 2-position connector
NI-9227
NI-9375 NI-9923—Front-mount terminal block for 37-pin DSUB
NI-9423 NI-9927—Strain relief and operator protection
NI-9437
NI-9482
NI-9475 NI-9924—Front-mount terminal block for 25-pin DSUB
NI-9860 TRC-8543—NI-XNET CAN XS transceiver cable
TRC-8546—NI-XNET LIN transceiver cable

1 Access this help file on your host computer at Start » National Instruments.