[dmellich]

Here's what worked for us:

1. Put cRio in safe mode (hold reset button down for several seconds)
2. Launch NI imaging tool - select appropriate radio button in "Development Environment" and "Format Controller" checkbox and click apply.
3. A dialog box will pop up that says the cRio is in safe mode and cannot be imaged but gives the option to format. Click "format cRio"
4. The "Reconfiguring Device" dialog box comes up and first says it is formatting (maybe 30sec) then rebooting (another 30sec).
5. After the reboot completes, the same dialog box will indicate the format is complete.
6. Power down the cRio, turn safe mode off (dip switch on 8 slot - power cycle for 4 slot), turn on cRio. NOTE: when you turn on the cRio, the status light will flash 2 times (repeating). This indicates the chassis has detected an error in its software. Not to worry.
7. Click apply on the imaging tool - the "Reconfiguring Device" dialog box comes back up indicating it's formatting (maybe 20sec) then rebooting (maybe 30sec).
8. If all wen well it should then start re-imaging the cRio.