Date: Apr 26, 11
MANUAL AND REFERENCE HANDBOOK
Manual and reference handbook
www.crosscontrol.com
CrossFire GX1
CrossFire GX1
Date: Apr 26, 11
Manual and reference handbook
www.crosscontrol.com
Contents
1. Introduction ..................................................................................................................................3
2. Functions and Features ...............................................................................................................4
3. Technical Data Overview............................................................................................................5
3.1. References .................................................................................................................................. 6
3.2. Dimensions .................................................................................................................................. 6
3.3. Identification .............................................................................................................................. 6
3.4. Environmental Tolerance ......................................................................................................... 7
4. Installation .....................................................................................................................................8
4.1. Mounting ..................................................................................................................................... 8
4.2. Cooling ........................................................................................................................................ 8
4.3. Vibration ...................................................................................................................................... 8
4.4. Rain/Moisture ............................................................................................................................. 8
5. Connectors ...................................................................................................................................9
5.1. Connector Overview ................................................................................................................ 9
5.2. Connector Layout ................................................................................................................... 10
6. Electrical Interface Overview ...................................................................................................16
7. Electrical Interface Characteristics .........................................................................................17
7.1. Analog Inputs ........................................................................................................................... 17
7.2. PWM Outputs (Analog Outputs) ........................................................................................... 18
7.3. Digital Inputs ............................................................................................................................. 19
7.4. Digital (On/Off) Outputs ......................................................................................................... 22
7.5. Encoder Inputs ......................................................................................................................... 24
7.6. Pulse Counter Inputs ............................................................................................................... 24
7.7. Power Interface ....................................................................................................................... 25
7.8. CAN Interface (CANin, CANout) ......................................................................................... 26
7.9. ID Interface ............................................................................................................................... 26
7.10. LED Indicators ................................................................................................................... 26
8. Appendix 1 – Environmental Tolerances .................................................................................28
9. Appendix 2 – I/O Interface in Order of Port Number .............................................................29
10. Contact Technical Support .......................................................................................................31
11. Trade Mark, etc. .........................................................................................................................31
Index .................................................................................................................................................32
CrossFire GX1
Date: Apr 26, 11
Manual and reference handbook
www.crosscontrol.com
3
1. Introduction
CrossFire GX1 is a general, flexible I/O module and controller for rough environments. It fits in
distributed and decentralised systems where you want to be able to put electronics close to the I/O
that will be managed. The module is highly configurable, and has its I/O distributed over a number
of M12 connectors.
CrossFire GX1 is a CAN bus node, and by configuring the node properties, the module can be set up
to automatically send and receive I/O to and from the CAN bus network.
CrossFire GX1 supports the CANopen protocol: one of the leading protocols used for CAN bus
networks.
This document describes how CrossFire GX1 should be used.
CrossFire GX1
Date: Apr 26, 11
Manual and reference handbook
www.crosscontrol.com
4
2. Functions and Features
CrossFire GX1 is an I/O (Input/Output) module, designed for automotive products equipped with
hydraulic components. It has 46 ports accessible through 22 I/O connectors which can be
individually configured to provide various types of I/O. CrossFire GX1 can therefore be configured
to have:
Up to 30 Digital ON/OFF Outputs all with diagnostics and Built-In Test
o 26 High-side outputs,
o 4 Low-side outputs
Up to 40 Digital Inputs
o 8 pull up
o 16 pull down
o 6 floating
o 10 software-configurable pull up/down
Up to 12 Analogue Inputs
o 6 current, 0 – 20 mA
o 6 voltage, 0 – 5 V, inputs
Up to 16 PWM (Pulse Width Modulated) Outputs
o 8 dual PWM connectors
o Software controlled ripple frequency and amplitude
CrossFire GX1 also has:
Up to 2 pairs of Encoder Inputs (for quadrature signal decoding)
Up to 2 Pulse Counter Inputs
Support use of sync
Support for both heartbeat and node guarding
Support for EMCY (Emergency) object.
CrossFire GX1
Date: Apr 26, 11
Manual and reference handbook
www.crosscontrol.com
5
3. Technical Data Overview
Kernel
Memory
Infineon C167 20 MHz
Application flash: 8 Mbit Boot flash: 8 Mbit
SRAM: 4 Mbit EEPROM: 1k*8-bit
Physical
Housing
Dimensions
Weight
Metal enclosure filled with silicon compound, metal base plate
L x W x H: 226 x 226 x 41.4 mm
1.5 kg
Environment
Temperature Range
Protection Rating
Protection Class
Vibrations
Shock/Impact
EMC Conformity
Operating: -40 ˚C to +75 ˚C Storage : -40 ˚C to +85 ˚C
IP67 (IEC 60529)
III
Sinus: IEC-60068-2-6 – 4 g Random: IEC-60068-2-34 – 3.7 g
30 g / 6 ms IEC-60068-2-27
ISO 14982 for Emissions, ISO 11452-2 for Immunity
Power Supply
Operating Voltage
Current Consumption
Reverse Polarity Protection
10 to 36 VDC (24 VDC Nominal)
< 200 mA at 24 V without external load
Requires external fuse max rated to 20 A
Indicators
Status, +5V, +24V and 30 red/green diodes for I/O monitoring.
CAN Interface
No. of CAN
Driver
Baud Rate
Node ID
ISO 11898-2 (High Speed CAN)
1 interface with CANin and CANout connectors
NXP TJA1050T
10, 20, 50, 100, 125, 250 kbit/s
1 to 16 hardware set
Connectors
I/O: DIN M12 CAN: DIN M12 Power: 7/8”
Digital Inputs
Input Voltage
0 – 24 V (supply voltage)
Encoder Inputs
Full Quadrature Decoding
Pulse Inputs
Frequency up to 10 kHz
Analog Inputs
Input
Input Impedance
Resolution
Total Unadjusted Error
6 pcs. 0 – 5 V and 6 pcs. 0 – 20 mA
1 MΩ (0 – 5 V)
10 pcs. 10 bits and 2 pcs. 12 bits
±2 LSBs
Digital Outputs
Max Voltage
Max Current
Total Current
Supply voltage
High Side 1.95 A (2.4 A) Low Side 1.6 A
18 A (external fuse not included)
PWM (Analog) Outputs
Max Voltage
Max Current
Resolution
Supply voltage
2.4 A
0.4 %
Protection
Outputs
Inputs
S/C, Overload, Over-current, Thermal S/D, Load dump, ESD
S/C (Short circuit)
Diagnostics (Outputs)
Open Load, Over-temperature / Short circuit supply/ground
Certifications / Compliance
CrossFire GX1
Date: Apr 26, 11
Manual and reference handbook
www.crosscontrol.com
6
3.1. References
CE Marking: http://ec.europa.eu/
International Standards Organisation: http://www.iso.org/
International Electrotechnical Commission http://www.iec.ch/
3.2. Dimensions
The CrossFire GX1 dimensions and placement of the four mounting holes is illustrated below. The
four mounting lugs have clearance for 8 mm bolts. The module weighs 1.5 kg.
3.3. Identification
There is a label on the bottom of CrossFire GX1. On the label there are numbers which identify your
unique module. Take note of them. During service and other contact with the supplier it is
important to be able to provide these numbers.
CrossFire GX1
Date: Apr 26, 11
Manual and reference handbook
www.crosscontrol.com
7
3.4. Environmental Tolerance
CrossFire GX1 has been designed to cope with tough environmental demands. Strict tests have
been conducted on the unit in order to ensure that it fulfils the expectations of a rugged unit. Much
work has been performed to choose and design integral components so that they, in the best
possible way and under all circumstances, provide you with a dependable working instrument. In
Appendix 1, a list of standards can be found according to which CrossFire GX1 has been tested and
approved.
Despite thorough design requirements and testing specifications, it is always best to install and
handle CrossFire GX1 with care. For more information, read further.
CrossFire GX1
Date: Apr 26, 11
Manual and reference handbook
www.crosscontrol.com
8
4. Installation
CrossFire GX1 should be installed in such a way that the module is not exposed to any unnecessary
stress, heat, vibration or moisture. In this section, some recommendations are made regarding
methods for how the unit should be installed.
If the unit is opened by non-authorised personnel, the warranty becomes void.
4.1. Mounting
Ensure that CrossFire GX1 is mounted to a smooth, flat surface.
Fastening the unit to an uneven surface may stress the enclosure, damage the outer flange or
possibly even flex the circuit board inside, leading to a premature failure.
Ensure the mounting bolts are of grade 8.8 or higher, are clean and dry, and apply torque of about
23 N-m (17 ft-lbs). Use lock washers.
Ensure there is adequate clearance to insert/remove all of the connectors.
4.2. Cooling
Although CrossFire GX1 can operate in relatively high temperatures, cooling should still be
considered when installing CrossFire GX1. If the unit becomes too warm, it may not perform to its
full capacity and, with high temperature, cease to function. Common sense should be used to select
an appropriate location where adequate cooling is achievable. It is not recommended to install the
module near a vehicle’s exhaust system, for example.
If the mounting surface is normally cooler than the ambient air, then mount CrossFire GX1 directly
to that surface to improve heat dissipation. If the surface can become much warmer than the
ambient air, then it is recommended to leave a gap between the unit and the surface, using washers,
or standoffs. An insulating material can also be considered to shield the unit from the heat from
the mounting surface.
Inadequate cooling may lead to overheating, causing permanent damage to the unit.
4.3. Vibration
Loose mounting bolts are the most common reason for excessive vibration. Mounting bolts may
become loose due to improper techniques such as missing lock washers, over tightening or under
tightening. Proper tightening requires clean dry bolts, and a torque wrench.
We recommend installing CrossFire GX1 in such a way that it is not unnecessarily exposed to
vibration or other stress.
4.4. Rain/Moisture
CrossFire GX1 shall preferably be placed under a roof in order to prevent direct exposure to water.
CrossFire GX1
Date: Apr 26, 11
Manual and reference handbook
www.crosscontrol.com
9
5. Connectors
Power and communications are found on connectors X1 through X3. These connectors are not
considered to be I/O (Input/Output) connectors.
On the remaining connectors, X4 to X25, I/O pins which share similar functionality are grouped
together. Each connector is therefore designated with a certain interface type. This gives a quick
way to easily identify the types of I/O Interfaces found on a certain connector. The pins found on
connector X6 for example, taken from the table below, are designated as AIN. This is because there
are two Analog Input pins on the connector. Note, however that the characteristic signal type is not
always the one configured by default, and that other configurations are often possible.
5.1. Connector Overview
Connector(s)
Interface
Type
Characteristic Signal Type
Other Configurations
X1
Power
+24 V Power Supply
X2, X3
CAN
CAN Bus connector
X5
ID
Identification Interface
5-V Digital Inputs
X6, X10, X14, X7, X11, X15
AIN
Analog Inputs
Digital Inputs
X20, X21, X22, X24, X25
DIO
Digital Inputs/Outputs
(Pulse Counter Input)
X4, X8, X12, X16
DIOP
PWM Outputs
Digital Outputs, Digital Inputs
X9, X13, X17, X23
EDIO
Encoder Inputs
Low-Side Digital Outputs,
Digital Inputs,
(Pulse Counter Input)
CrossFire GX1
Date: Apr 26, 11
Manual and reference handbook
www.crosscontrol.com
10
5.2. Connector Layout
In order to facilitate the discussion of CrossFire GX1, each I/O pin is assigned with a unique port
number. The ports are accessible through connectors numbered X4 to X25. The port numbering:
acts as an interface between hardware and software
allows easy mapping to the object dictionary’s index/subindex system
distinguishes the electrical independence (i.e. despite identical signal names)
identifies internal I/O so that it can be reflected in the object dictionary
X1 Power Supply Connector
Pin
Port
Default Signal
Comments
DIN 7/8
male, 5-pole
X1.1 - +24 V Power
Supply for I/O (V
batt
)
X1.2 - +24 V Power
X1.3 - GND
Battery ground
X1.4 - GND
X1.5 - +24 V Logic
Supply for logic (V
batt
)
ID
AIN
AIN
AIN
CANout
CANout
AIN
AIN
AIN
DIO
DIO
DIO
DIO
DIO
DIOP
DIOP
DIOP
DIOP
DIOP
DIOP
DIOP
EDIO
EDIO
DIOP
Right Side
Left Side
Power
Loading...