Industrial Raspberry Pi: DIN Rail Mounting & Ruggedized Solutions

When I first proposed using a Raspberry Pi for a factory data collection project, the controls engineer looked at me like I’d suggested running production on a toy. Six months later, that same industrial raspberry pi setup has logged over 4,000 hours of continuous operation, survived ambient temperatures from 5°C to 45°C, and replaced a proprietary PLC that cost ten times more.

The gap between hobbyist single-board computers and industrial-grade controllers has narrowed dramatically. Whether you need a simple raspberry pi din rail mount for a control cabinet or a fully certified revpi system for demanding automation applications, solutions exist at every price point and capability level.

Why Industrial Raspberry Pi Solutions?

Consumer Raspberry Pi boards weren’t designed for factory floors. They lack proper mounting, run on 5V USB power, have no industrial I/O, and weren’t tested for electromagnetic interference or temperature extremes. Industrial solutions address these limitations while preserving the Pi’s advantages: familiar Linux environment, massive software ecosystem, and accessible pricing.

Consumer vs Industrial Raspberry Pi Comparison

Feature	Consumer Raspberry Pi	Industrial Raspberry Pi
Power Input	5V USB	24V DC (industrial standard)
Operating Temp	0°C to +50°C	-40°C to +85°C (extended)
Mounting	None standard	DIN rail ready
EMC Testing	Basic CE/FCC	EN61131-2, IEC 61000-6-2
I/O Protection	None	Surge, ESD up to 4kV/8kV
Industrial I/O	Requires add-ons	24V digital, 4-20mA analog
Certifications	CE, FCC	CE, UL, industrial standards
Support	Community	Commercial warranty

Revolution Pi (RevPi): The Industrial Standard

The revpi series from KUNBUS represents the most comprehensive industrial Raspberry Pi platform available. Manufactured in Germany since 2016, Revolution Pi devices have established themselves as legitimate industrial controllers used in manufacturing, building automation, and IIoT applications worldwide.

RevPi Product Line Overview

Model	Compute Module	Key Features	Price Range
RevPi Connect 5	CM5	Dual Gigabit Ethernet, CAN FD, latest performance	~$350-450
RevPi Connect 4	CM4	Dual Ethernet, proven platform	~$300-400
RevPi Core S	CM4S	Compact, cost-effective	~$200-250
RevPi Compact	CM3+	All-in-one with integrated I/O	~$350-400
RevPi Flat S	CM4S	Ultra-slim for tight spaces	~$250-300

RevPi Industrial Specifications

Specification	Value
Operating Temperature	-40°C to +55°C
Protection Class	IP20
Power Supply	24V DC (10.8V to 28.8V)
EMC Compliance	EN61131-2, IEC 61000-6-2
ESD Protection	4kV/8kV contact/air
Certifications	CE, UL, cUL
Mounting	35mm DIN rail (EN 50022)
Warranty	2 years

RevPi Expansion Modules

The modular architecture sets revpi apart from simple DIN rail mounts. Expansion modules connect via the PiBridge backplane, creating integrated systems.

Module Type	Function	Examples
Digital I/O	24V inputs/outputs	RevPi DIO (14 inputs, 14 outputs)
Analog I/O	4-20mA, 0-10V	RevPi AIO (4 inputs, 2 outputs)
Relay	Dry contact switching	RevPi RO (relay outputs)
Fieldbus Gateway	Industrial protocols	PROFINET, EtherCAT, CANopen
Communication	Serial interfaces	RS485, RS232

A complete RevPi system might include a base module flanked by I/O modules on both sides, all connected through simple plug connectors and configured through the PiCtory web interface.

DIY Raspberry Pi DIN Rail Solutions

Not every project requires full industrial certification. For less demanding environments or prototype development, raspberry pi din rail mounting options provide professional installation at lower cost.

DIN Rail Mount Options Compared

Product	Type	Pi Compatibility	DIN Width	Price
DINrPlate 2	Open mount	Pi 4/3/2/B+	32mm	~$15-20
Sequent Type 1	Parallel mount	Pi Zero to Pi 5	Variable	~$10-15
Sequent Type 2	Perpendicular mount	All models + HATs	Variable	~$15-20
Widgetlords VPE-4455	Enclosed	Pi 4 series	3.5″	~$25-30
Phoenix Contact cases	Industrial enclosed	CM4 carriers	Standard	~$100+

DINrPlate 2 Features

The DINrPlate 2 exemplifies purpose-built raspberry pi din rail mounting:

Feature	Specification
Material	6/6 Nylon (industrial grade)
DIN Clips	10mm secure mount
Port Access	All ports and GPIO accessible
Cable Management	Integrated strain relief
SD Access	Easy maintenance access
Color	Industrial grey

Sequent Microsystems Mounting Kits

Sequent offers two mounting approaches:

Type 1 (Parallel): Mounts the Pi parallel to the DIN rail, compact profile, good for tight spaces.

Type 2 (Perpendicular): Mounts Pi and up to 5 HATs perpendicular to rail, better cooling, easier cable access.

Both kits use metal brackets for mechanical stability, critical when stacking industrial HATs that add weight.

Industrial I/O Solutions

Mounting a Pi on DIN rail is only half the equation. Industrial applications require proper I/O interfaces.

Widgetlords PI-SPI Series

Module	Function	Interface
PI-SPI-DIN-8DI	8 Digital Inputs	12-24V DC
PI-SPI-DIN-8DO	8 Digital Outputs	Open collector
PI-SPI-DIN-4AO	4 Analog Outputs	4-20mA
PI-SPI-DIN-8AI	8 Analog Inputs	4-20mA

These modules connect via SPI and stack on standard GPIO headers. Combined with DIN rail enclosures, they create cost-effective industrial I/O systems.

Sequent Microsystems Industrial HATs

Sequent’s stackable HAT system supports up to 8 layers:

HAT Type	Capacity per HAT	Max Stacked
8-Relay	8 relays (250VAC/8A)	8 (64 relays)
8-SSR	8 solid-state relays	8 (64 SSRs)
8-MOSFET	8 power outputs	8 (64 outputs)
8-Thermocouple	8 TC inputs	8 (64 channels)
Building Automation	8 universal I/O	8

The stacking architecture allows building custom I/O configurations while maintaining a compact footprint.

Industrial Software Considerations

Real-Time Operating Systems

Standard Raspberry Pi OS lacks real-time guarantees. Industrial solutions address this:

Solution	Approach	Latency
PREEMPT_RT Patch	Kernel modification	~100μs typical
RevPi OS	Hardened Raspbian + RT	Industrial-grade
Xenomai	Dual-kernel approach	<50μs possible
CODESYS Runtime	Soft PLC on Linux	Cycle times to 1ms

IEC 61131-3 Programming

For traditional PLC-style programming, CODESYS provides IEC 61131-3 languages on Raspberry Pi:

Language	Type	Use Case
Ladder Diagram (LD)	Graphical	Relay logic replacement
Function Block Diagram (FBD)	Graphical	Complex control systems
Structured Text (ST)	Textual	Algorithm implementation
Instruction List (IL)	Textual	Legacy system migration
Sequential Function Chart (SFC)	Graphical	State machine logic

RevPi devices support CODESYS directly through their online store, providing a familiar environment for automation engineers.

Industrial Protocols

Protocol	Support	Application
Modbus TCP/RTU	Native libraries	Universal connectivity
MQTT	Standard packages	IIoT, cloud integration
OPC UA	Open source stacks	Enterprise systems
PROFINET	RevPi Gateway	Siemens ecosystems
EtherCAT	RevPi Gateway	High-speed motion
CANopen	RevPi Gateway	Distributed I/O

Thermal Management

Industrial environments stress cooling systems. Fanless operation requires careful thermal design.

RevPi Thermal Performance

Condition	CPU Behavior
Ambient <20°C	Full speed, all cores
Ambient 20-40°C	Occasional throttling under load
Ambient 40-55°C	Managed throttling
Above 55°C	Significant throttling

For DIY installations, active cooling becomes important in enclosed cabinets:

Cooling Method	Temperature Reduction	Noise
Passive heatsink	10-15°C	Silent
Active heatsink + fan	25-35°C	Audible
Cabinet ventilation	Variable	External

Useful Resources

Resource	URL	Description
Revolution Pi	revolutionpi.com	Official RevPi documentation
KUNBUS Shop	shop.kunbus.com	RevPi hardware purchase
DINrPlate	dinrplate.com	DIN rail mounts
Sequent Microsystems	sequentmicrosystems.com	Industrial HATs and mounts
Widgetlords	widgetlords.com	Industrial I/O modules
CODESYS Store	store.codesys.com	PLC runtime software
RevPi Forum	forum.revolutionpi.com	Community support

Frequently Asked Questions

Is RevPi certified for industrial use?

Yes, revpi devices carry CE and UL certifications and are tested to EN61131-2 (PLC standard) and IEC 61000-6-2 (industrial EMC immunity). They include protection against ESD (4kV/8kV), surge, and burst transients. The -40°C to +55°C operating range covers most industrial environments. This certification level distinguishes RevPi from DIY solutions using consumer Pi boards.

Can I use a regular Raspberry Pi in industrial applications?

For prototyping and non-critical monitoring, yes, with appropriate mounting and protection. However, consumer Raspberry Pi boards lack industrial certifications, operate on 5V power instead of 24V, have limited temperature ratings, and no I/O protection. For production systems where reliability matters, purpose-built industrial raspberry pi solutions provide necessary protection and support.

What’s the maximum number of I/O points on a RevPi system?

A RevPi Connect base module supports up to 10 expansion modules (5 per side). With RevPi DIO modules providing 28 points each (14 inputs + 14 outputs), a fully loaded system handles 280 digital I/O points plus analog channels from AIO modules. For larger systems, multiple RevPi units can network together.

Do I need CODESYS for industrial Raspberry Pi applications?

No, CODESYS is optional. Many industrial applications run successfully using Python, Node-RED, or custom C/C++ code on standard Linux. CODESYS becomes valuable when you need IEC 61131-3 programming languages familiar to automation engineers, or when integrating with existing PLC ecosystems. RevPi systems also support traditional Linux programming alongside CODESYS.

What’s the cost difference between RevPi and DIY industrial setups?

A basic raspberry pi din rail mount with Pi 4 costs approximately $75-100 total. Adding industrial I/O modules (Widgetlords or Sequent) brings the total to $200-400 depending on I/O count. A comparable RevPi Connect system starts around $300-400 but includes industrial certification, integrated features, and commercial support. For production deployments, RevPi’s certification and warranty often justify the premium. For prototyping or less critical applications, DIY solutions offer excellent value.

Installation Best Practices

Proper installation ensures long-term reliability for any raspberry pi din rail deployment.

Cabinet Environment Guidelines

Factor	Recommendation
Clearance above/below	Minimum 30mm
Clearance left/right	Minimum 20mm
Cabinet ventilation	Required for >3 modules
Cable routing	Separate power and signal
Grounding	Connect shield to cabinet ground

Wiring Considerations

Industrial environments generate electrical noise. Protect your installation:

Cable Type	Maximum Length	Shield Required
Ethernet	100m	Optional (STP recommended)
RS485	1200m at 9600 baud	Yes, >30m
Analog 4-20mA	300m	Yes
Digital 24V	500m	Optional

Always route signal cables away from power cables and variable frequency drives. Use shielded cables for any run leaving the cabinet.

Choosing Your Industrial Solution

The right industrial raspberry pi approach depends on your application requirements. For certified production systems, RevPi provides peace of mind with proven hardware and commercial support. For development, prototyping, or non-critical monitoring, DIY DIN rail solutions deliver capability at lower cost.

What started as skepticism from that controls engineer became appreciation when the Raspberry Pi-based data collector outlasted proprietary equipment installed the same month. Industrial certification matters for critical systems, but the underlying technology has proven itself across thousands of deployments worldwide.

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Option 1 (155 characters): Industrial Raspberry Pi guide covering RevPi, DIN rail mounting, and ruggedized solutions. Compare certified systems vs DIY options for automation projects.

Option 2 (153 characters): Deploy raspberry pi din rail solutions in industrial environments. RevPi specifications, mounting options, I/O modules, and certification requirements explained.

Option 3 (149 characters): Complete guide to industrial raspberry pi options including RevPi Connect, DIN rail mounts, and ruggedized enclosures for factory automation and IIoT.