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TECHNICAL M ANUAL
2017-12-07
CrossFire IX
Technical manual
www.crosscontrol.com
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Contents
1. Introduction ................................................................................................................3
1.1. Product models.....................................................................................................3
1.2. Conventions and defines.......................................................................................4
1.3. Identification.........................................................................................................5
1.4. Maintenance and care.........................................................................................5
1.5. Supporting documentation ...................................................................................5
2. CrossFire IX device overview .......................................................................................6
3. Mechanical i nstallation ...............................................................................................7
3.1. Mounting ..............................................................................................................7
3.2. Installation position ................................................................................................7
3.3. Heat dissipation ....................................................................................................7
3.4. Environmental considerations ................................................................................8
4. Electrical installation ....................................................................................................9
4.1. Connectors...........................................................................................................9
4.2. Power supply installation...................................................................................... 11
5. Basic operations........................................................................................................ 13
5.1. Software and installation ..................................................................................... 13
5.2. Starting up .......................................................................................................... 13
5.3. Shutting down..................................................................................................... 13
6. Interface overview .................................................................................................... 14
7. Interface Characteristics............................................................................................ 15
7.1. Power interface .................................................................................................. 15
7.2. Communication interfaces .................................................................................. 16
7.3. Analog inputs 1-8 ................................................................................................ 17
7.4. Digital inputs 1-4 .................................................................................................. 17
7.5. Frequency inputs 1-2 ........................................................................................... 18
7.6. Outputs 1-8 ......................................................................................................... 18
7.7. Wi-Fi.................................................................................................................... 21
7.8. Sensor supply ...................................................................................................... 21
7.9. Ignition signal ...................................................................................................... 21
7.10. Firmware update .......................................................................................... 22
7.11. Digital inputs as ID interface .......................................................................... 22
7.12. Status LED indicator ...................................................................................... 22
7.13. Memory ....................................................................................................... 24
7.14. RTC and back-up battery ............................................................................. 24
7.15. Diagnostics................................................................................................... 24
8. Software overview ..................................................................................................... 25
9. Specifications............................................................................................................ 26
9.1. Environmental specifications ............................................................................... 26
9.2. Certifications....................................................................................................... 27
9.3. Weight and dimensions ....................................................................................... 28
10.Technical Support...................................................................................................... 30
11.Trademark, etc. ......................................................................................................... 31
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1. Introduction
CrossFire IX is the 2nd product o n CrossControl’s new I/O Controller platform. It is a compact 32-
bit I/O module, designed for advanced hydraulics c ontrol in Agricultural and Construction
equipment. It offers 22 I/O channels, versatile and configurable in software. Fieldbus network
capabilities include both CANopen and J1939 (planned). Wireless communication is offered as an
option, making this module into a Smart connect interface in highly cost sensitive systems.
Business rationale:
Smaller I/O module based upon the high-end Crossfire SX.
Accuracy on inputs and outputs gives an outstanding performance in machine c ontrol.
A smaller I /O count and a much lower price makes this product a perfect CANopen slave or
J1 939 device (planned) in a sub system or on machines where less I/O is needed.
A strong companion with our displays when serious I/O capabilities are needed.
Rich feature list. Can solve most tasks including hydraulic valve control, sensor inputs,
button decoding, lamps and more.
Tec hnical summary:
CF IX is able to drive 4 proportional valves with current feedback and 4 on-off v alves
simultaneously. On-off outputs can be also used in PWM mode with limited current feedback
which c an be used for diagnostics. CrossFire IX contains 8 analog inputs, which c an be
configured individually to accept voltage (0-10V/0-32V) and 4-20mA current signals. In
addition there are 6 dedicated digital inputs of which 2 can be configured for frequency input
or to form a dual c hannel encoder input. A ll inputs (digital and analog) c an be individually
configured to have pull-up or pull-down resistor activated.
This technical manual provides important information regarding the device’s hardware and its
basic usage. For software, please see chapter 1.5 Supporting documentation.
1.1. Product models
Crossfire IX is based upon the CrossFire SX, a very flexible platform that easily can be adapted.
Reduced complexity is a guiding principle in the design with the purpose to facilitate ease o f:
adaptability, testing, code readability and to further raise the quality.
CrossFire IX is built in three product variants that share the same hardware architecture, enclosure
and connectors. The PCB is the same for all versions but is populated differently.
Part nr.
Product variant
C000141-40
Crossfire IX, wireless (customer branded)
C000141-50
Crossfire IX, CANopen slav e
C000141-70
Crossfire IX, CANopen slav e with data logger option
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Feature
C000141-40
C000141-50
C000141-70
Analog inputs
81
82
82
Digital inputs
4 4 4
Frequency inputs
- 2 2
Standard PWM
2 4 4
Adv anced PWM
- 4 4
CAN
1 1 1
Protocol
CANopen
CANopen
CANopen
FRAM
2kbyte
8 kbyte
8 kbyte
FLASH
4 Mbyte
-
4 Mbyte
Wi-Fi
YES - YES
12V sensor supply
-
YES
YES
Status LED
-
YES
YES
Real Time Clock w ith battery
- - YES
1
Voltage (0..10V), Current (4..20mA)
2
V oltage (0..10/32V), Current (4..20mA), Pull up/down
1.1.1. Customized modules
The platform enables additional customization of hardware and software. Described herein are the
features included using product models described above. Any additional feature will b e described in
model specific documentation.
1.2. Conventions and defines
The following definitions are used to separate model specific details within this document. The
observe symbol is also used to highlight such difference.
The ‘observe’ symbol is used to highligt information regarding differences between product
models and options.
The ‘exclamation’ symbol is used to highlight information that is especially important for the
end-user.
Different text formats used in this document are described in the table below:
Format
Use
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It alics
Names, desi gnat ions and references.
Bolded
Important information.
1.3. Identification
Each device has a label with article number, serial number and revision which identify your unique
device. Take note of these numbers. During service and other contact with the supplier it is
important to be able to provide this information.
1.4. Maintenance and care
Handle the device with care and pay attention to the following handling directives:
Disconnect all cables to the device during welding or when performing other service to the
machine imposing a risk of damaging electronic devices.
Service and repair to the device shall only be made by authorised personnel. If the device is
opened by unauthorised personnel, its warranty will be voided.
Avoid using alkaline, alcoholic o r other chemicals for cleaning; doing so may damage the
device. However, small amount isopropyl alcohol may be used for removing harsh stains.
Avoid spray o r apply water or alcohol directly to the device. Instead, dampen the cloth
lightly before using it for cleaning the device.
Nev er use high-pressure air, water or steam to clean the device.
1.5. Supporting documentation
This technical manual provides important information regarding the device’s hardware, properties
and basic usage. It’s very important to read this manual before installation and usage of the unit.
Not following the instructions around installation, and operation of the unit may lead to reduced
safety of operators and machinery.
In addition to this document other supporting documents are available on our support site:
CrossFire IX - CANopen Slave Developers Guide.docx
- Describes the software specifics for the Crossfire I X, CA Nopen slave product
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2. CrossFire IX device overview
The top side of CrossFire IX holds a label with information about product article number, serial
number and revision. I t also displays a status LED, see chapter 7.12 Status LED indicator.
On the connector side of the device there are one AMP 35-pin multi-pin connectors mounted
holding the CrossFire IX I/O interface. More Information about c onnectors c an be found in
chapter 4.1 - Connectors
The enclosure is built in glass fibre reinforced nylon. For extreme moisture and condense
protection, the unit is filled with a silicone gel. This potting also improves the shock and vibration
resistance.
Identification
label
Status LED
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3. Mechanical installation
This chapter contains recommendations for mechanical installation of the CrossFire IX device.
3.1. Mounting
CrossFire I X is designed with a three pod mounting footprint that allows for flexible mounting.
However, fastening the unit to an uneven surface may stress the enclosure, or possibly even flex the
circuit board inside, leading to a premature failure.
Ensure the mounting bolts are of grade 8.8 or higher. The mounting holes have clearance for M6
bo lts.
The recommended torque for the screws is 9.8Nm fo r a mounting plate in steel or when using a
nut.
Note: recommended torque must be checked against mounting plate material.
Ensure there is adequate clearance to insert/remove all o f the connectors.
3.2. Installation position
Align CrossFire IX so that the cable entries of the connectors are not face upwards.
3.3. Heat dissipation
To enable sufficient c ooling, the device must be installed to allow ambient air to circulate around it.
A clearance of at least 50 mm around the device is recommended.
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Ask CrossControl for recommendations about sandwich mounting.
3.4. Environmental considerations
To ensure proper and reliable operation of the device, follow the recommendations below:
The device shall be placed in a way that prevents the unit from direct exposure to water or
sunlight.
To enable sufficient cooling, the device must be installed to allow ambient air to circulate
around it. A clearance o f at least 50 mm around the device is recommended.
Avoid installing the device near hot air vents or in direct sunlight.
To maintain the device’s IP classification, the connector must b e attached. Blind plugs for
not connected signals/cables are also necessary.
Loose mounting bolts are a common cause for excessive vibration. They may come loose
due to improper mounting techniques such as omitting thread locker o r lock washers, overor under-tightening. Proper tightening requires clean dry bolts and a torque wrench.
Install the device and its cables in such a way that they are not subject to excess vibrations
or other mechanical stress.
If the unit is exposed to chemicals, water, dirt, etc it’s recommended to clean it according
to chapter 1 .4 Maintenance and care as soon as possible.
Crossfire IX product C000141-70 and C000141-40 that includes a Wi-Fi module should be
installed and operated with minimum distance of 20cm to your body to comply with
radiation exposure limits for an uncontrolled environment.
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4. Electrical installation
This chapter contains details and recommendations for electrical installation of the CrossFire I X
device.
4.1. Connectors
The connector is accessible from the side of the CrossFire IX unit. The connector, an A MP 35-pin
multi-pin connector, is marked 1(X1 ).
X1 connector black, TE connectivity 1 -776163-1 (Mating connector, e.g. 776164-1)
Use caution and avoid plugging/unplugging of connectors when the CrossFire IX unit is powered
up. Always replace damaged c ables.
4.1.1. Connector layout
Note that descriptions herein refer to the connectors located on the device and not the cable-side
connectors which are attached to the device. Though, the pinout numbering and signal descriptions
are the same.
1
AIN 1
2
AIN 2
3
AIN 3
4
DIN 1
5
DIN 2
6
UB 7 HS1 8 HS2 9 HS3
10
HS4
11
HS5
12
HS6
13
AIN 4
14
AIN 5
15
AIN 6
16
DIN 3
17
FIN 1
18
UB
19
IGN
20
12V
21
12V
22
12V
23
HS7
24
AIN 7
25
AIN 8
26
GND
27
DIN 4
28
FIN 2
29
GND
30
GND
31
GND
32
CANH
33
CANL
34
CANS
35
HS8
HS x
High side output 1-4 (standard PWM)
HS x
High side output 5-8 (current controlled PWM)
GND
Ground
UB
Battery input
CAN_L
CAN bus x low
CAN_H
CAN bus x high
CAN_S
CAN bus x shield
AIN x
Analog input 1-8
DIN x
Digital input 1-4
FIN x
Frequency input 1-2
IGN
Ignition input
12V
12V sensor supply
X1 connec tor
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Pin
Signals C000141-40
Signals C000141-50
1
Analog input 1
Analog input 1
2
Analog input 2
Analog input 2
3
Analog input 3
Analog input 3
4
Digital input 1
Digital input 1
5
Digital input 2
Digital input 2
6
Battery input
Battery input
7
High side output 1 (standard
PWM)
High side output 1 (standard PWM)
8
High side output 2 (standard
PWM)
High side output 2 (standard PWM )
9
[No signal]
High side output 3 (standard PWM )
10
[No signal]
High side output 4 (standard PWM )
11
[No signal]
High side output 5 (current controlled PWM)
12
[No signal]
High side output 6 (current controlled PWM)
13
Analog input 4
Analog input 4
14
Analog input 5
Analog input 5
15
Analog input 6
Analog input 6
16
Digital input 3
Digital input 3
17
[No signal]
Frequency input 1
18
Battery input
Battery input
19
Ignition input
Ignition input
20
Sensor supply 12 V
Sensor supply 12 V
21
Sensor supply 12 V
Sensor supply 12 V
22
Sensor supply 12 V
Sensor supply 12 V
23
[No signal]
High side output 7 (current controlled PWM)
24
Analog input 7
Analog input 7
25
Analog input 8
Analog input 8
26
Ground
Ground
27
Digital input 4
Digital input 4
28
[No signal]
Frequency input 2
29
Ground
Ground
30
Ground
Ground
31
Ground
Ground
32
CAN high
CAN high
33
CAN low
CAN low
34
CAN shield
CAN shield
35
[No signal]
High side output 8 (current controlled PWM)
4.1.2 Cable installation
Cables shall be installed in such a way that they don’t run any risk of being damaged, pinched o r
worn.
Avoid excessive bending and twisting of cables.
Use strain-relief on cables near the device to minimize stress on cables and connectors.
Pro perly snap the c onnectors to give good c ontact and avoid unnecessary strain.
Shielded cables are recommended and in some c ases necessary to ensure reliable
communication and appliance with industrial EMC standards.
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4.2. Power supply installation
This chapter describes installation of CrossFire IX in vehicles or other machines. The principle is
the same also for other types of installations.
For connector pinout, see chapter 4.1 Connectors.
Before installing the device into a vehicle or other machinery, carefully read through the
instructions below:
Wire gauge for the supply input shall be dimensioned with respect to cable length, supply
voltage, maximum allowed voltage drop, start-up current and maximum c urrent
consumption of the device. As a guideline:
o In applications which use several o utputs at a time, with medium to high loads, the
recommended power supply c able area is 1.31 mm2 (AWG 16)
o In applications which use many outputs at a time, with medium to high loads or
long cable harness length, two power supply cables are recommended.
o In applications which use none or few outputs at a time, with low loads, the power
supply cable area might be 0.5 mm2
When connecting the device to a vehicle’s o r machine’s battery (or other power source with
high current c apability), always apply fusing to prevent cable fire in case o f short circuit.
o The fuse shall be located as close to the battery/power source as possible.
o Fuse rating shall be dimensioned with respect to wire gauge maximum c urrent
rating and inrush current of the load.
o As a guideline, a fuse with 2 A - 10 A current rating should be used depending on
application, wiring and fuse characteristics.
The device’s external o n/off c ontrol signal (connector X1, pin 19) should be connected to
the positive supply line via the vehicles turnkey switch o r a separate on/off switch (see “S2”
in schematic below).
o Remember to apply fusing also to the on/off control signal.
o Sev eral CrossFire IX devices may be controlled by the same external on/off switch
by joining their external on/off c ontrol signals. The current drawn from this signal
(when turned ON) is up to 3.0 mA for each device attached. The fuse rating and
wire gauge shall be dimensioned for the total switch current.
o It is possible to disable the handling of the ignition signal through o bject dictionary
for the CANopen version.
If the vehicle or machine has a main power switch (see “S1” in schematic below), the
device’s power supply and o n/off signal shall be connected after this switch. Observe that
this switch shall n ot be used for switching the device o n/off during normal o peration. I t is
only intended for disconnecting the battery to prevent draining o f the battery during
prolonged stalling intervals o f the vehicle o r machine.
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F1
2A - 10 A
S1
Main switch
Battery
F2
xx A
X1.6
X1.29
S2
Ignition switch
X1.19
AWG 16
AWG 16
CrossFire IXGND Ub
S1
Main switch
Battery
F2
xx A
X1.6
X1.18
X1.29
X1.30
S2
Ignition switch
X1.19
AWG 16
AWG 16
CrossFire IXGND Ub
2A – 7.5A
By connecting the power supply according to the illustration above, with the main switch S1
normally closed, the device will automatically start when the ignition switch S2 is turned on and
shut down when the switch is turned o ff.
4.2.1. Precautions
It is not recommended to shut of power during storage of parameter data. If this is done, stored
data might be corrupt and unit will return to default values.
Be advised that the device consumes a small amount of power (1.1 mA @ 24 V, 1.4 mA @ 1 2 V) from
the main supply when shutdown (low level on the ignition signal). Therefore, if the device has been
attached for a long period of time without the vehicle motor running, the battery may be drained,
resulting in inability to start up the v ehicle. A main switch for disconnecting the device’s main
supply is highly recommended in such situations.
Sc hematic examples for pow er supply installation of CrossFire IX in ve h icles or other machines.
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5. Basic operations
This section covers basic operation of the device such as software and installation, start-up, shutdown and status notification. For additional information on device usage and operation also see the
software user guides for the different product versions specified in chapter 1.5 Supporting
doc umentation.
5.1. Software and installation
For the CANopen slave version, the unit comes with all software preinstalled. All IO needs to be
configured with SDOs, as default all inputs and all outputs are disabled.
5.2. Starting up
Make sure that the instructions for mechanical and electrical installation described in chapter 3
and 4 are followed before starting up the CrossFire IX unit the first time.
For information about CAN node id and baud rate, see chapter 7.2.1 CAN.
The CrossFire I X will start up when power is connected and active, and the voltage level on the
ignition pin is above 4V.
For the CANopen slave version of CrossFire IX the status LED on the unit will indicate unit status
according to the LED status table described in chapter 7.12 Status LED indicator.
During the startup, unit self-test and diagnostic are performed. If any error is detected the status
LED will flash red, see chapter 7.12 Status LED indicator.
When the CANopen slave v ersion of CrossFire IX is started up configuration can b e done using
SDO commands.
5.3. Shutting down
Removing power will shut down the Crossfire I X directly. CrossFire IX has no support for
controlled shutdown when removing power. Setting the ignition signal low while keeping power
will make the CrossFire IX shut down in a controlled fashion.
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6. Interface overview
This section describes the overall various interfaces of the device.
35 pin connector
Analog inputs x8
Digital inputs x4
Frequency
inputs x2
Standard PWM
outputs x4
Advanced PWM
outputs x4
STM32
RTC
Battery
WiFi module
FRAM
Flash
Temperature
sensor
DC/DC
CAN
12V sensor
supply output
Shift register
IO expansion
Ignition signal
input
Status LED
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7. Interface Characteristics
This section describes the basic interfaces on the CrossFire IX unit
7.1. Power interface
The CrossFire I X device is specified for a total of up to 12 A output c urrent and special care must be
taken with supplying power to the device. The device o perates with a supply voltage of 8-32 VDC.
7.1.1. Supply pins
Each pin in the connector is rated for 17A and a maximum of AWG 16 (1.31 mm2) can be used.
There are two pins, X1.6 and X1.18, fo r power input that are connected internally. In most cases it
sho uld be sufficient to use only one of these.
7.1.2. Ground pins
There are also 4 ground pins X1 .26, X1.29, X1.30 and X1.31 that are connected internally together.
The ground pins X1.29 and X1.30 in the connector close to the power pins are intended to be used
for power ground when needed. Lo ads on high side outputs can be grounded directly to vehicle
ground and cause almost no ground return current.
7.1.3. Recommended ground connection scheme
Note once more that all ground pins are c onnected internally and the connection scheme below is
intended to facilitate the harness design and to minimize voltage drop on analog sensor returns due
to ground currents.
X1.29 GND
X1.26 GND
X1.30 GND
Sensor y
ground
Sensor y
power input
X1.6 UB
X1.18 UB
Vehicle
power
0V
12V/24V
X1.20/21/22
12V Sensor
supply
CrossFire IX has all ground pins
connected together internally
*Power ground
HS OUT xLoad x
Load x return
*
Sensor z
ground
Sensor z
output
Input z
Input y
Sensor y
output
Ground pin X1.26 is intended fo r sensor supply ground/analog input ground. Ground pin X1.31 is
intended for CAN ground or additional ground for inputs.
7.1.4. Power filter and power architecture overview
An overview of the power filter and power architecture is shown below.
Filter
capacitors
11 µF
Power
input pins
X1.6
X1.18
Transient
voltage
suppressor
Reverse
polarity
protection
Output
drivers
600
µF
Internal
DC/DC
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When connecting power to the unit the 11 µF of filter capacitors and 600 µF of bulk capacitors are
charged causing a short initial current peak.
With power connected and the ignition signal low the device will consume typically 1.1 mA at 24V
and 1.4 mA at 12V.
When the ignition signal is set high the DC/DC converters for the processing and logic are enabled
and the unit will c onsume typically 0.03A at 24V with inputs and outputs not c onnected for the
variant without Wi-Fi. The variant with Wi-Fi will consume typically 0.05A at 24V.
7.2. Communication interfaces
7.2.1. CAN
The CrossFire I X device contains one CAN port that meet the CAN ISO 11898 2.0B specification.
Supported CAN baud rates are 20 – 1000 Kbit/s. The device is optimized for baud rates up to 250
Kbit/s with a common mode input capacitance on CAN bus signals of approximately 150 pF. The
usable baud rate depends o n the CAN bus topology in terms of bus length, number of CAN nodes
etc.
The CAN ports have short circuit protection allowing DC sho rt circuit up to 32V without damage to
the unit. There is no device-internal CA N bus termination. CA N bus termination must be provided
for externally.
The unit has passed the electrical testing with standard CAN twisted pair c ables, but it is advisable
to use shielded c ables for the CAN interfaces, especially when utilizing high bit rates and/or long
cables. Each CAN port has its own CAN shield pin which is connected internally via a resistor and
capacitor to ground as shown in the figure below. If shielded CAN c able is used the CAN c able
shield shall be connected to ground at a single point to avoid ground loops.
At first start up the CAN node id for CAN1 is 1. The device c an be configured to use the digital
inputs as node ID address pins (connector X1:4/5/16/27). If these address pins are used but
unc onnected (floating) the no de id for CAN1 will be set to 16 as default. For information about how
the pin pattern relates to node id, see chapter 7.11 Digital inputs as ID interface.
CAN node id can also be configured through software. CAN baud rate is set to 250kbit /s as default.
To set the CAN baud rate and node id through software see the software user guides for the
different product versions specified in chapter 1.5 Supporting documentation
L1
51uH 230mA
1
4
2
3
100p 100V 100p 100V
680 nF 50V
1
CAN shield
connection
for J1939
CAN1F_H
CAN1F_L
CAN1_L[1]
CAN1_H[1]
CAN1_S[1]
NUP3105LT1G
1
2
3
CAN transceiv er
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7.3. Analog inputs 1-8
There are 8 configurable inputs that can be configured individually by software to accept different
input ranges. A simplified schematic for the inputs is shown below. A 10 nF input capacitor and
transient voltage suppressing diode handles ESD and other transients.
A 100 Ohm sense resistor is used for 4-20 mA input range.
Digital input modes are managed with a comparator and 9K1 pull-up o r pull-down resistor
can be enabled for sensor without push-pull o utputs.
Different voltage ranges are managed by enabling different resistor dividers.
Filter
capacitor
1 nF
Input pin
Transient
voltage
suppressor
9K1
9K1
27K
10K 2K7
ADC
100
Filtered
supply
All input ranges provides protection from short circuit and overload (0.. Ub).
Input type
Range
Accuracy
Specification
Accuracy
Typical
Impedance
Current input
4..20 mA
1 % ± 30 µA
<0.2% ov er temp
100 Ω
Voltage input
0..10V
1 % ± 10 mV
<0.4% ov er temp
37.0 KΩ
Voltage input
0..32V
1 % ± 30 mV
<0.2% ov er temp
29.7 KΩ
7.3.1. Analog inputs
For the analog voltage and current input modes the ADC operates with a resolution of 16-bits.
For the 4-20 mA current input range over current (over voltage) protection of the 100 Ohm sense
resistor is implemented in software. I f the input current is above 30 mA (equivalent to a voltage on
the input above 3 V) for a c ertain time the 100 Ohm sense resistor will be disconnected for a time to
allow the resistor to cool down before testing again for an over-current (over-voltage).
Each analog input have configurable pull-up and pull-down resistor for using the analog input with
sensors other than analog o nes such as for example switches and position sensors.
7.4. Digital inputs 1-4
There are 4 digital inputs with selectable pull-up or pull-down resistor. A comparator circuit with
1V of hysteresis is used to determine the input level.
For the input to change from high to low the input voltage must fall below ~2V.
For the input to change from low to high the input voltage must rise above ~3V.
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Filter
capacitor
1 nF
Input pin
Transient
voltage
suppressor
9K1
9K1
20K
Comparator with
1V hysteresis
Filtered
supply
7.5. Frequency inputs 1-2
There are 2 frequency inputs with selectable pull-up or pull-down resistor. The frequency inputs A
comparator circuit with 1V of hysteresis is used to determine the input level.
For the input to change from high to low the input voltage must fall below ~2V.
For the input to change from low to high the input voltage must rise above ~3V.
Filter
capacitor
1 nF
Input pin
Transient
voltage
suppressor
9K1
9K1
20K
Comparator with
1V hysteresis
Filtered
supply
The 2 frequency inputs can either be used as independent frequency inputs or be combined in to an
encoder input.
The bandwidth of the frequency input is more than 20 kHz for sensors with push-pull or opendrain with pull-up. When using sensors with high side output and pull-down resistor the
bandwidth is 11-17 kHz depending on the supply voltage. The bandwidth difference for the modes is
due to the 2-3 V threshold level.
The time base for the timers in the microcontroller is better than 1 00 ppm over temperature.
7.6. Outputs 1-8
The 8 outputs (4 x Standard High-Side PWM + 4 x Advanced High-Side PWM) are individually and
independently configurable through software. The total o utput current is specified to a maximum
of 12A.
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7.6.1. Standard High-Side PWM outputs 1-4
The block diagram for Standard High-Side output 1-4 which are rated for 2 A is shown below. The
output stage has current limitation with approximately 9 A at 27V and room temperature. The
current limit is higher at low temperature and lower at high temperatures. This output is capable of
capacitive loads such as LED lamps and other units with high input capacitance on the input as well
as inductive and resistive loads.
400 Hz
Output stage
200K
100 nF
Current sense
Processing
Power in Output
The current sense is not very accurate and mainly intended fo r diagnostics and open-load detection
in on state. Off-state o pen load detection is done by connecting a 9K1 pull-up resistor to the output
and check the voltage on the output.
In digital o utput mode when the output is enabled the output is allowed to be current limiting o r
hav e an output current above ~2.7A for up to 100 ms before turning off the output.
In PWM output mode when the PWM is enabled the output is not allowed to be current limiting or
hav e an output current above ~2.7A in order to limit the number of activations into a short circuit.
Common features
Operating voltage range
8..32 V DC
Current per output
0...2000 mA
All outputs can be used as an ON/OFF out put s
PWM output
Frequency
50…400 Hz
Duty cycle
0…100%, resolution 0,1%
Loads
Inductiv e, resistive, capacitiv e
Current Sense
±16% at 0.4A
±12% at 1.0A
±10% at 2.0A
Accuracy is v alid at 100% duty
cycle
Ov er current limit
~2.7A
Open load detection
Off-state (yes/no)
On-state (current sense)
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7.6.2. Advanced High-Side PWM output 5-8
The block diagram for Advanced High-Side PWM output which is rated for 2 A is shown below.
The output stage is capable of fast switching for inductive and resistive loads.
High side
current sense
5 kHz Output
stage
10K
100 nF
Processing
Power in Output
Common features
Operating v oltage range
8 VDC to 32 VDC
Rated current per output
2 A
Current sense range
0 to 2180 mA (min)
Current ov er load limit
2180 mA (min) 2360 mA (max)
Current controlled
output (P WMi)
Output frequency
Fixed high frequency, 5.2kHz
Dither frequency range
25…400 Hz, adjustable in fixed
steps
Dither current
Adjustable up to 400 mA
Hardware output resolution
0.6 mA
Software output resolution
1.0 mA
Loads
Inductiv e, resistive
Accuracy (design target)
ca ± 1% ± 10 mA
PWM output
Frequency
50…400 Hz
Duty cycle
0…100%, resolution 0,1%
Loads
Inductiv e, resistive
Current Sense
ca ± 1% ± 5 mA
The actual value is dependent many factors such as output current, dither frequency and solenoid type.
Pro tection from short c ircuit and overload (0..Ub).
7.6.3. PWM output
PWM outputs are adjustable individually for each output between 50-400Hz. Duty cycle is
adjustable between 0-100% in 0.1% steps.
7.6.4. Digital output
All outputs might also be used in digital mode (on/off).
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7.6.5. Current controlled output (PWMi)
PWMi mode is used to get a constant current through a solenoid. Because the resistance o f the
solenoid is affected by the temperature, the actual c urrent is measured and the PWM duty cycle is
automatically adjusted to get the desired c urrent. In PWMi mode the desired current in mA is given
directly as reference value.
PWMi o utputs use a fixed high frequency PWM – 5.2kHz. This frequency is so high that the natural
dither of the current will be very low. Instead an adjustable dither is superimposed on the PWM
signal. The frequency and amplitude of this dither is adjustable. Also the parameter for the PID
regulator used for current c ontrol c an b e adjusted if necessary. A ll PWMi settings are individually
adjustable fo r all outputs.
7.7. Wi-Fi
The CrossFire I X product C000141-70 and C000141-40 includes a Wi-Fi module to facilitate
wireless communication to and from the module.
The Wi-Fi module is based on the ESP8266 chip, UDP, TCP/IP network stacks and interfaces for
communicating with STM32 are embedded in this module.
Wi-Fi chip protocol and communication specification:
Items
Specification
Radio certificates
CE, IC, FCC, KCC, NCC, SRRC, TELEC
Wi-Fi protocols
802.11 b/g/n
Frequency range
2.412 – 2.484 GHz
Temperature range
The Wi-Fi circuitry is operational in the CrossFire IX’s full
temperature range
Security
WPA2
Encryption
WEP/TKIP/AES
Output power at 72.2 Mbps
14 dBm
Output power in 11b mode
20 dBm
7.7.1. Radiation exposure statement
Crossfire IX product C000141-70 and C000141-40 that includes a Wi-Fi module should be installed
and operated with minimum distance of 20cm to your body to comply with radiation exposure
limits for an uncontrolled environment.
7.8. Sensor supply
The unit has a sensor supply output (connector X1 .20/21/22) which provides a linear regulated
output (typical 11.98V) for powering sensors or potentiometers. The output is current limited to
ty pically 159 mA (+/- 10%) and withstands short to ground and short to 32V. There is voltage read
back for diagnostics and application usage.
7.9. Ignition signal
The ignition pin (connector X1:19) controls the start-up and shutdown of the unit and is intended
to be connected to the ignition switch. In installations without ignition switch the ignition signal
can be connected to the power supply input pins and the unit will start-up when power is applied.
The ignition input has a 20 kΩ pull-down resistor. The threshold level for on/off is typically 3 V.
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7.10. Firmware update
The CrossFire I X contains a CAN bootloader to allow for firmware upgrade over CAN. The CAN
bo otloader has to be activated through a CAN command before upgrade c an be made. A specific PC
tools needs to be used to perform the upgrade.
For more information about the firmware upgrade see supporting document CrossFire I X –
Firmware upgrade instructions.docx.
7.11. Digital inputs as ID interface
For the CANopen v ersion, the digital input pins X1:4/5/16/27 can alternatively be used as id pins
setting the CANopen no de id.
The table below show the CA N node id is set up by the digital input pins in connector X1:4/5/16/27
CANopen Node ID
D4
D3
D2
D1
1
0 0 0
0
2
0 0 0
1 3 0 0 1
0
4
0 0 1
1
….
16
1 1 1
1
Reading node id from digital pins needs to be activated in object dictionary.
State 0 is reached by wiring corresponding pin to GND.
State 1 is reached by leaving corresponding pin disconnected.
It is possible to configure in software which of the digital inputs will affect the node id
through the nod id pins mask in the object dictionary.
7.12. Status LED indicator
The table below describes the default behaviour o f the status notification for different operational
states.
Erro rs are signaled through the RED/ GREEN led or through the CAN bus (application specific).
During boot-up phase it is the boot loader that is responsible for controlling the LED. After the boot
phase the application takes over the LED c o ntrol. Read the respective application manual for more
information.
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7.12.1. Start up and normal operation indications
These tables present the status LED indication for the CANopen slave version during operation.
Run LED – Green
CANopen mode
State
Blinking Pattern
Operational
LED ON
Constantly ON
Pre-Operational
LED Blinking
Iso-phase on and off w ith a frequency of
approximately 2,5 Hz: (ON 200ms, OFF 200ms)
Initializing
Stopped
LED Single Flash
One short flash: (ON 200ms, OFF 1000ms)
Error LED – Red
CANopen mode
State
Blinking Pattern
CAN Bus-Off
LED ON
Constantly ON
CAN Bus Warning
LED Single Flash
One short flash: (ON 200ms, OFF 1000ms)
Output Port Error
LED Blinking
Iso-phase on and off w ith a frequency of
approximately 2,5 Hz: (ON 200ms, OFF 200ms)
The red error blinking is only show n during interleaving 2,5
seconds intervals.
7.12.2. Boot mode indications
These tables present the status LED indication if boot mode is activated.
Green LED – IX Boot mode LED
IX Boot mode
Blinking
Pattern
Description
IDLE
LED Slow -Blinking
In boot mode and no upgrade in progress
This state is usually an indication that
a manual restart is needed after a firmw are
upgrade (ON 1000ms, OFF 44ms).
SW-UPGRADE
LED Fast-Triple-Blinking
Firmw are upgrade in progress
Red LED – IX Boot Firmware error LED
IX Boot error
LED State
Description
NO-ERROR
LED-OFF
NO Firmw are error
ERROR
LED-ON
Firmw are error is present.
M ust be repaired w ith new firmw are upgrade.
LOW SUPPLY VCC
LED-FLASHING
Low supply voltage.
Supply voltage must exceed ~7.2 V otherw ise SW start is
blocked w ith the RED-LED-FLASHING
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7.13. Memory
7.13.1. Flash
The main processor in CrossFire IX has 256 Kbyte of internal flash for firmware and application.
The C000 141-70 variant has an additional serial Flash o f 4Mbyte that c an be used for data logging.
7.13.2. RAM
The main processor in CrossFire IX has 32 Kbyte of internal RAM for use by firmware and
application.
7.13.3. FRAM
CrossFire IX has an 8 Kbyte FRAM memory for storage of persistent data. An FRAM memory is
faster than an EEPROM and can handle much more write cycles.
7.14. RTC and back-up battery
The CrossFire I X product C000141-70 contains a real time clock circuit to store time and date
information. The RTC is powered by an internal battery when the external power is not applied.
The battery is a 3 V 100mAh high o perating temperature Poly-carbonmonofluoride Lithium battery.
The expected life time of the battery is approximately 10 years and the battery is not replaceable.
7.15. Diagnostics
The CrossFire IX supports a number o f different supervision functions. It is recommended to use as
many as possible of these and perform appropriate actions. How this is done can be read in
respective programming manual.
Please note that the diagnostics for the regular PWM and the advanced PWM outputs differ due to
differences in the hardware.
7.15.1. Voltage supervision
There are four different supply voltages that are possible to read from software.
External supply voltage
Internal 5V rail
Internal 3.3V rail
The sensor supply output voltage
7.15.2. Temperature supervision
There is a temperature sensor on the board that is possible to read from so ftware. It is
recommended to keep the temperature below 115 degrees Celsius. There is no automatic shut off at
high temperatures. There is also temperature supervision for the advanced PWM outputs that can
be read as part of the port status. It is recommended to shut down outputs if over temperature is
signalled.
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7.15.3. Standard PWM output diagnostics
There are a number o f diagnostics capabilities available for the standard PWM outputs:
Open load detection in off-state.
Open load detection in on-state by reading the output current.
Current sense in on-state.
Short to battery in off-state.
Over current/short to ground/short to battery in on-state.
Note that most errors are signalled through a common error code.
7.15.4. Advanced PWM output diagnostics
There are a number o f diagnostics capabilities available fo r the advanced PWM outputs:
Open load detection in on-state by reading the output current.
Current sense in on-state.
Over current in on-state.
Short to ground in on-state.
Thermal warning/under voltage lockout (UVLO).
7.15.5. 4-20 mA input over current protection
The 4-20mA inputs are shut down individually in c ase the input current exceeds roughly 30 mA. In
case this happens, an error flag is set that c an be read from software. The input is automatically
activated again after a short while.
8. Software overview
The CrossFire I X contains the following software parts.
Application
Purpose
Boot Loader
Makes it possible to upgrade the software ov er CAN
CANopen slav e
application
This application is written by CrossControl to allow the Cr ossFire IX to
act as a CANopen slav e. The application includes all need firmware
to fully control interfaces and IO.
All software parts c an be upgraded. I t is important that all v ersions fit together. Only upgrade to
combinations recommended by CrossControl. For more information about upgrade see supporting
doc ument CrossFire I X – Firmware upgrade instructions.docx.
For details about using the CANopen slave version, read the CrossFire I X - CANopen Slave
Developers Guide.docx.
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9. Specifications
9.1. Environmental specifications
The unit is tested towards the relevant segment tests as defined in:
Earthmoving machines, ISO 13766:2006
Agricultural and forestry machinery, EN ISO 1 4982:2009
Construction Machinery, ISO 13309:2010
Environmental tests are performed at 24 VDC supply voltage unless otherwise required. The
environmental tolerance may be affected by external factors like mounting, omitting the use of
shielded cables etc.
Any changes o r modifications to the device not expressly approved by CrossControl could void the
environmental c lassification, warranty as well as user's authority to operate the equipment.
9.1.1. Electrical test
Environmental Test
Standard
Notes
EMC Transient
ISO 13766: 2006
ISO 7637-2: 2011
+24V system
Pulse1 : -450V C
Pulse2a : +37V A
Pulse2b : +20V C
Pulse3a : -150V A
Pulse3b : +150V A
Pulse4 : -12V A
Pulse5 : +123V, 2Ω A
+12V system Test level III
Pulse1 : -75V C
Pulse2a : +37V A
Pulse2b : +10V C
Pulse3a : -112V A
Pulse3b : +75V A
Pulse4 : -6V C
Pulse5 : +65V, 1Ω A
EMC Immunity, ESD
ISO 13766: 2006
ISO/TR 10605: 2008
Test lev el IV, ±15 kV air, ±8kV contact
EMC RF Immunity, Radiated 1)
ISO 13766: 2006
ISO11452-2: 2004
Radiated
200M-1GHz, 100V/m
EMC RF Immunity, Induced 1)
ISO 11452-4: 2011
BCI 20-200MHz, 100mA
EMC Radiated Emission 1)
ISO 13766: 2006
1 meter Narrowb. Broadb.
MHz dBµV/m dBµV/m
30-75 54-44 64-54
75-400 44-55 64-54
400-1000 55 65
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9.1.2. Climatic test
Environmental Test
Standard
Notes
Dry Heat
IEC 60068-2-2:2007
Functional during and after test,
+85°C, 24 hours
Damp Heat
IEC 60068-2-30:2005
Functional during test, +25°C to
+55°C
>95% RH, 6x24h
Cold
IEC 60068-2-1:2007
Functional during and after test, 40°C, 24 hours
Change of temperature
IEC 60068-2-14:2009
Functional during test, -40°C to
+85°C
5C/min 3h hold time, 20 cycles1
9.1.3. Mechanical test
Environmental Test
Standard
Notes
Vibration
IEC 60068-2-64:2008
IEC 60068-2-6: 2007
0,03 g2/Hz 5-200Hz, 0,01
g2/Hz 200-1000Hz, 3x3h
5g, 5-2000Hz, 1 octav e/min, 20
cycles
Shock
IEC 60068-2-27:2009
30 g / 11ms 3x ±1000 bumps
Enclosure Ingress Protection
IEC 60529:2014
IP65, IP66 and IP67
Chemical compatible
ISO 16750-5: 2010
Window cleaner, Plasticizer, Soda,
Windshield washer fluid, All Purpose
Cleaner, Phosphate wash, Motor
Oil, Gear Oil, Bearing grease,
Hydraulic fluid, Power steering fluid,
Antifreeze, Diesel Oil, Gasoline,
Brake Fluid, Battery acid, Fertilizer
(28% nitrogen with ammonium
nitrate and urea at a pH of 5),
Degreaser
Salt Spray
EN 60068-2-52: 2001
Sev erity level 3 (vehicle)
UV radiation
ISO 4892-3 cycle 6
500h
1
Do not comply w ith requirement in 60950-22 regarding operating mode down to -50°C
9.2. Certifications
CE Marking, (93/68/EEC)
E-marking, (2004/104/EG)
FCC compliance, (FCC/15B)
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9.3. Weight and dimensions
Description
Comments
Dimensions
166 x 137 x 47 mm
(W x H x D)
Weight
0,64 Kg
6,8 (x3)
137
166
47
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26,6
134
106
23
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10. Technical Support
Contact your reseller or supplier for help with possible problems with your device. In order to get
the best help, you should have your device in front o f you and be prepared with the following
information before you contact support.
Part number and serial number of the unit, which you find o n the brand label
Date of purchase, which is found o n the invoice
Installed software versions
The conditions and circumstances under which the problem arises
LED indic ator colors and blink patterns
EMCY object error codes (if possible)
Description of external equipment which is connected to the CrossFire™ IX
Additional so urces of information are available on the CrossControl support site
http://support.crosscontrol.com
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Phone: +46 271 75 76 00
info@crosscontrol.com
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CrossControl
Box 83, SE-822 22 ALFTA
Fax +46 271 75 76 89
Varmv alsvägen 13
SE-721 30 VÄSTERÅS
Fax + 46 21 40 32 10
Fyrisborgsgatan 4
SE-754 50 UPPSALA
Fax + 46 18 12 38 85
11. Trademark, etc.
© 2017 CrossControl
All trademarks sighted in this document are the property of their respective owners.
CrossFire is a trademark which is the property of CrossControl AB.
Freescale is a registered trademark of Freescale Semiconductor I nc. ARM is a registered trademark
of ARM Limited. Linux is a registered trademark of Linus Torvalds. Bluetooth is a trademark of
Bluetooth SIG. CANopen is a registered trademark o f CAN in Automation (CiA).
CrossControl is not responsible for editing errors, technical errors or for material which has been
omitted in this document. CrossControl is not responsible for unintentional damage or for damage
which o ccurs as a result of supplying, handling or using of this material including the devices and
software referred to herein. The information in this handbook is supplied without any guarantees
and can change without prior notification.
For CrossControl licensed software, CrossControl grants you a license, to under CrossControl
intellectual property rights, to use, reproduce, distribute, market and sell the software, o nly as a
part of or integrated within, the devices for which this documentation concerns. Any other usage,
suc h as, but not limited to, reproduction, distribution, marketing, sales and reverse engineer o f this
doc umentation, licensed software source code or any other affiliated material may not be
performed without written consent of CrossControl.
CrossControl respects the intellectual property of others, and we ask our users to do the same.
Where software based o n CrossControl software or products is distributed, the software may only
be distributed in accordance with the terms and conditions provided by the reproduced licensors.
For end-user license agreements (EULAs), copyright notices, conditions, and disclaimers,
regarding certain third-party components used in the device, refer to the copyright notices
doc umentation.
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