IFM Electronic CR0401, CR0411, CR0403 Installation Instructions Manual

Page 1
Installation instructions
BasicController
and
BasicController
plus
CR0401 CR0403
80010113 / 00 10 / 2014
UK
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BasicController / BasicController
plus
2
Contents
1 Preliminary note � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4
1�1 Symbols used� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4 1�2 Warning signs used � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4
2 Safety instructions � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 5
2�1 General� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 5 2�2 Target group � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 5 2�3 Electrical connection � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 5 2�4 Tampering with the device � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 5
3 Functions and features � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 6
3�1 Overview of the common characteristics � � � � � � � � � � � � � � � � � � � � � � � � � � 6 3�2 Application example � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 6 3�3 Devices of the Basic series (examples) � � � � � � � � � � � � � � � � � � � � � � � � � � � 7
4 Installation� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 8
4�1 General installation instructions � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 8
4�1�1 Protection� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 8
4�1�2 Mounting surface � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 8 4�2 Fastening � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 8 4�3 Cover and cable seal � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 10
4�3�1 Installation of the cable seal� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 10
4�3�2 Removal of the cable seal � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 10
4�3�3 Installation of the cover � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �11
4�3�4 Removing the cover � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �11
5 Electrical connection� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 12
5�1 General electrical connection � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 12 5�2 Connection accessories � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 13
5�2�1 Example accessories � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 13 5�3 Frequency inputs � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 13 5�4 Fuses � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 13
6 Indicators � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 14
7 Set-up � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 15
7�1 Programming � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 15 7�2 Required documentation � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 15 7�3 Required hardware� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 15
8 Technical data� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 16
8�1 CR0401 � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 16 8�2 CR0403 � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 21 8�3 CR0411 � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 27
9 Maintenance, repair and disposal� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 33
9�1 Maintenance� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 33 9�2 Cleaning the housing surface� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 33 9�3 Repair� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 33
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This document is the original instructions� Valid as from device status CR0401AC, CR0403AD und CR0411AA
All trademarks and company names are subject to the copyright of the respective companies�
9�4 Disposal � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 33
10 Approvals/standards � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 33
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1 Preliminary note
This document applies to devices of the type "BasicController" (art� no�: CR0401, CR0403) and "BasicController
plus
" (art� no�: CR0411)�
These instructions are an integral part of the device�
This document is intended for specialists� These specialists are people who are qualified by their appropriate training and their experience to see risks and to avoid possible hazards that may be caused during operation or maintenance of the device� The document contains information about the correct handling of the device�
Read this document before use to familiarise yourself with operating conditions, installation and operation� Keep this document during the entire duration of use of the device�
Adhere to the safety instructions�
1.1 Symbols used
Instruction > Reaction, result […] Designation of keys, buttons or indications Cross-reference
Important note
Non-compliance can result in malfunction or interference�
Information
Supplementary note
1.2 Warning signs used
WARNING
Warning of serious personal injury� Death or serious irreversible injuries may result�
CAUTION
Warning of personal injury� Slight reversible injuries may result�
NOTE
Warning of damage to property�
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2 Safety instructions
2.1 General
These instructions contain texts and figures concerning the correct handling of the device and must be read before installation or use�
Observe the operating instructions� Non-observance of the instructions, operation which is not in accordance with use as prescribed below, wrong installation or incorrect handling can seriously affect the safety of operators and machinery�
2.2 Target group
These instructions are intended for authorised persons according to the EMC and low-voltage directives� The device must only be installed, connected and put into operation by a qualified electrician�
2.3 Electrical connection
Disconnect the device externally before handling it� If necessary, also disconnect any independently supplied output load circuits�
If the device is not supplied by the mobile on-board system (12/24 V battery operation), it must be ensured that the external voltage is generated and supplied according to the criteria for safety extra-low voltage (SELV) as this voltage is supplied without further measures to the connected controller, the sensors and the actuators�
The wiring of all signals in connection with the SELV circuit of the device must also comply with the SELV criteria (safety extra-low voltage, safe electrical isolation from other electric circuits)�
If the supplied SELV voltage is externally grounded (SELV becomes PELV), the responsibility lies with the user and the respective national installation regulations must be complied with� All statements in this document refer to the device the SELV voltage of which is not grounded�
The connections may only be supplied with the signals indicated in the technical data and/or on the device label and only the approved accessories of ifm electronic gmbh may be connected�
2.4 Tampering with the device
In case of malfunctions or uncertainties please contact the manufacturer� Any tampering with the device can seriously affect the safety of operators and machinery� This is not permitted and leads to the exclusion of any liability and warranty claims�
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3 Functions and features
The freely programmable controllers of the "BasicController" and "BasicController
plus
" series are rated for use under difficult conditions (e�g� extended temperature range, strong vibration, intensive EMC interference)� They are suitable for direct installation in mobile vehicles�
By means of the application software the user can configure the inputs and outputs to adapt to the respective application� The controllers can be used as CAN
controller, CANopen master or intelligent I/O module. (→ 8 Technical data).
Application-specific extensions and adaptations are possible in conjunction with additional products of the modular Basic series�
WARNING
The "BasicController" and "BasicController
plus
" series are not approved for safety
tasks in the field of safety of persons�
NOTE
"BasicController" and "BasicController
plus
" are intended for installation in vehicle
bodies, not in engines�
3.1 Overview of the common characteristics
Freely programmable to IEC 61131-3
2 CAN interfaces (incl� interface for BasicDisplay CR0451 or CR0452)
Configurable inputs/outputs
Protection IP 20 (with cover and cable seal IP 54)
Status LED
3.2 Application example
Use with cover and BasicDisplay
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3.3 Devices of the Basic series (examples)
BasicDisplay (art� no�: CR0451) programmable 2�8 inch colour display with graphic capabilities 5 freely programmable backlit function keys 1 rocker switch for cursor function
BasicDisplay XL ( art� no�: CR0452) programmable 4�3 inch colour display with graphic capabilities 6 freely programmable backlit function keys 1 rocker switch for cursor function
BasicRelay (art� no�: CR0421) freely wirable relay and fuse carrier for 6 automotive relays and 10 automotive fuses
Cover (art� no�: EC0401)
Cover with built-in display recess (art� no�: EC0402) incl� cable seal to obtain protection rating IP 54
For information about the available Basic products see: www.ifm.com → Products → Control systems or directly
www.ifm.com → Data sheet search → e.g. CR0451
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4 Installation
4.1 General installation instructions
4.1.1 Protection
The achievable protection rating of the device depends on the accessories used and the mounting position�
Protection Accessories Installation position Art. no.
IP 20 freely selectable
IP 54 cover with cable seal cable connection from the
bottom
e�g� EC0401
4.1.2 Mounting surface
NOTE
The housing must not be exposed to any torsional forces or mechanical stress�
► Mount the device on a flat surface� ► Use compensating elements if there is no flat mounting surface available�
Mounting surface
4.2 Fastening
► Insert the enclosed tubular rivets from the back of the module in the 4 fixing
holes�
► Fix the module using 4 washers and M4 screws�
Tighten the screws alternately crosswise�
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Use of the tubular rivets
Tightening torque: 1�5 Nm
Hole dimensions (→ 8 Technical data)
Screws to be used (examples): Standard
Cylinder screws with hexagon socket (M4 x L) DIN 912
Cylinder screws with hexagon socket and low head (M4 x L) DIN 7984
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4.3 Cover and cable seal
NOTE
Protection IP 54 can only be guaranteed if the cover is used together with the cable seal�
NOTE
When a cover is installed, the device temperature can increase�
4.3.1 Installation of the cable seal
► Insert the cable seal into the locator from below�
> The locking of the cable seal audibly clips into place�
1� Locator for cable seal 2� Locking
Mounted cable seal
The cable seal cannot be used as strain relief of the cables�
(→ 5.1 General electrical connection)
4.3.2 Removal of the cable seal
► Press the locking at the bottom of the device and remove the cable seal from
the device by pulling downwards�
1� Cable seal 2� Locking
Bottom of the device
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4.3.3 Installation of the cover
The covers of the Basic series feature a single-lever locking� Installation is done without tools�
1: locking lever 2: cover guides
3: insertion slots for cover guides
► Pull out the locking lever and rotate it towards you� ► Place the cover diagonally onto the device�
Insert the 2 cover guides, found at the bottom of the cover, into the slots�
► Close the cover onto the lower part�
The 2 guides and slots provide a pivot point�
► Move the locking lever back into its initial position�
> The cover is locked�
1: BasicController 2: cover
4.3.4 Removing the cover
► Pull out the locking lever and rotate it towards you�
> The cover is unlocked and can be removed�
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5 Electrical connection
5.1 General electrical connection
The supply cables, CAN interfaces and input/outputs are connected via 6�3 x 0�8 mm blade male terminals on the front of the device�
Wiring (→ 8 Technical data)
A B C D E F
N2
P/N1
1: Inputs 2: Outputs 3: Supply and CAN interfaces
Connector area (here e�g� CR0403)
Connector Connection CR0401 CR0403 CR0411 Number of
poles
A Inputs IN0���3 IN0���3 IN0���3 8
B IN4���7 IN4���7 IN4���7
C IN8���11 IN8���11
D Outputs OUT0���3 OUT0���3
E OUT0���3 OUT4���7 OUT4���7
F OUT4���7 OUT8���11
P/N1 CAN interface 1 and supply 6
N2 CAN interface 2 (e�g� for BasicDisplay CR0451 or CR0452) 4
– = not connected
NOTE
Wrong connection may cause damage to the device�
► Observe the safety instructions (→ 2.3 Electrical connection).
► Basically all supply and signal cables must be laid separately� ► Lay supply and signal cables away from the device using the shortest possible
route�
► All connected cables must be provided with a strain relief at least 100 mm
behind the cable entry�
► Protect unused terminals with unpopulated sockets if no cover is used�
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5.2 Connection accessories
You can find more information about the available accessories at:
www.ifm.com → Data sheet search → e.g. CR0401 → Accessories
5.2.1 Example accessories
BasicDisplay CR0451 cover with EC0402 built-in display recess EC0452 connection cable
Accessories and example connection
5.3 Frequency inputs
► Operate frequency inputs with screened cables, so that useful signals are not
affected by external interference�
5.4 Fuses
► The individual electric circuits must be protected in order to protect the whole
system�
Description Potential Connector: pin Fuse
VBB
S
Supply sensors/module 8…32 V DC P/N1: 1 ≤ 2 A T
VBB
1
Supply outputs
CR0401: OUT0���3 CR0403: OUT0���7 CR0411: OUT0���3
8…32 V DC P/N1: 2 15 A
VBB
2
Supply outputs
CR0401: OUT4���7 CR0403: OUT8���11 CR0411: OUT4���7
8…32 V DC P/N1: 3 15 A
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6 Indicators
1: Status LED 2: LED lighting in the cover (e�g� EC0401)
Operating states (→ 8 Technical data)
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7 Set-up
7.1 Programming
The user can easily create the application software by means of the IEC 61131-3 compliant programming system CODESYS 2�3�
WARNING
The user is responsible for the safe function of the application programs which he created himself� If necessary, he must additionally carry out an approval test by corresponding supervisory and test organisations according to the national regulations�
7.2 Required documentation
In addition to the CODESYS programming system, the following documents are required for programming and set-up of the device:
Programming manual CODESYS V2�3 (alternatively as online help)
BasicController system manual (alternatively as online help)
The manuals can be downloaded from the internet:
www.ifm.com → Data sheet search → e.g. CR0401 → Additional data
CODESYS and BasicController online help
www.ifm.com → Service → Download → Control systems*
*) Download area with registration
7.3 Required hardware
A CAN interface for the connection to a PC or a notebook is required to load the application program to the device�
Example:
CAN/RS232 USB interface CANfox (art� no�: EC2112)
Adapter cable for CANfox (art� no�: EC2113)
You can find more information about the available accessories at: www.ifm.com → Data sheet search → CR0451 → Accessories or directly
www.ifm.com → Data sheet search → EC2112
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8 Technical data
8.1 CR0401
Control systems
CR0401
18
ABCD E F
N2
P/N1
25,5
127
163
145
12,5
8,5
6,5
10,5
79,7
112
LED
8,5
Mobile controller
BasicController
12 inputs 8 outputs
2 CAN interfaces
Programming
to IEC 61131-3
8...32 V DC
Technical data Modular control system
Usable as CANopen controller or intelligent I/O module
Mechanical data
Housing plastic housing (black)
Dimensions (H x W x D) without cover with EC0401 cover with EC0402 cover and BasicDisplay CR0451
163 x 112 x 25.5 mm
163 x 112 x 68 mm
163 x 112 x 73.4 mm
Installation  xing by means of 4 M4 screws to DIN 912 or DIN 7984 and 4 tubular rivets to
DIN 7340 (tubular rivets are supplied)
Connection AMP blade male terminals 6.3 mm, to be clipped into place and thus vibration-
resistant, protected against reverse polarity
contacts AMP timer, CuZn pre-tin-plated
core cross-section 0.5...2.5 mm²
Inputs Outputs Operating voltage , CAN bus
3 x 8-pole 2 x 8-pole
1 x 6-pole, 1 x 4-pole
Protection rating IP 20 (with cover and cable seal IP 54)
Operating/storage temperature -40...85° C / -40...85° C
Weight 0.30 kg
Electrical data
Operating voltage 8...32 V DC
Current consumption 45 mA (at 24 V DC)
Overvoltage Undervoltage detection Undervoltage shutdown
36 V for t 10 s
at U
B
7.8 V
at U
B
7.0 V
Processor Freescale PowerPC, 50 MHz
Memory (total) 208 Kbytes RAM / 1536 Kbytes Flash / 1 Kbyte FRAM
Memory allocation see BasicController system manual
www.ifm.com data sheet search e.g. CR0401 Additional data
Device monitoring undervoltage monitoring
watchdog function
checksum test for program and system
excess temperature monitoring
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ifm electronic gmbh • Friedrichstraße 1 • 45128 Essen
We reserve the right to make technical alterations without prior notice! 24.10.2014CR0401 / page 2
CR0401 Technical data
Control systems
CAN interfaces 1/2 Baud rate Communication pro le
CAN interface 2.0 A/B, ISO 11898
20 kBit/s...1 MBit/s (default CAN1: 250 kBit/s, CAN2: 250 kBit/s)
CANopen, CiA DS 301 version 4, CiA DS 401 version 1.4
or SAE J 1939 or free protocol
Software/programming
Programming system CODESYS version 2.3 (IEC 61131-3)
Inputs 12 (con gurable),
Con gurations
Number Version
4 digital for positive / negative sensor signals
analogue (0…10/32 V DC, 0..20 mA, ratiometric) frequency ( 30 kHz)
B
L/BH
A
FRQ
4 digital for positive sensor signals
resistance measurement (0,016...3.6 kΩ)
B
L
4 digital for positive sensor signals B
L
positive sensor signals have diagnostic capabilities
Outputs 8 (con gurable),
Con gurations
Number Version
2 positive switching (high side)
PWM output (20…250 Hz), 2 A, diagnosis
B
H
PWM
4 positive switching (high side)
PWM output (20…250 Hz), 1 A
B
H
PWM
2 positive switching (high side)
PWM output (20…250 Hz), 4 A, diagnosis
B
H
PWM
Status LED two-colour LED (red/green)
Operating states (preset)
Colour Status Description
permanently off no operating voltage orange 1 x on initialisation or reset checks green 5 Hz no operating system loaded
2 Hz application is running (RUN) permanently on application stopped (STOP)
red 10 Hz application stopped (STOP with error)
5 Hz application stopped due to undervoltage permanently on system fault (fatal error)
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CR0401 Technical data
Control systems
Characteristics of the inputs
Analogue inputs (A) Connection A: 02, 03, 06, 07 IN0...IN3 can be con gured as:
● Voltage inputs Input voltage 0...10 V or 0...32 V Resolution 12 bits Accuracy ± 1% FS Input resistance 65.6 kΩ (0...10 V), 50.7 kΩ (0...32 V) Input frequency 500 Hz
● Current inputs, with diagnostic capability Input current 0...20 mA Resolution 12 bits Accuracy ± 1% FS Input resistance 400 Ω Input frequency 500 Hz At a current of > 23 mA the input is switched to the voltage input!
● Voltage inputs, 0...32 V, ratiometric Function (U
IN
÷ UB) x 1000 ‰ Value range 0...1000 ‰ Input resistance 50.7 kΩ
● Binary voltage inputs for positive sensor signals
Switch-on level > 0.7 U
B
Switch-off level < 0.3 U
B
Input resistance 3.2 kΩ Input frequency 50 Hz Diagnosis wire break > 0.95 U
B
Diagnosis short circuit < 1 V
● Binary voltage inputs for negative sensor signals Switch-on level > 0.7 UB Switch-off level < 0.3 UB Input resistance 3.2 kΩ Input frequency 50 Hz
● Frequency inputs Input resistance 3.2 kΩ Input frequency 30 kHz Switch-on level > 0.35...0.48 U
B
Switch-off level < 0.29 U
B
Digital input (BL) Connection B: 02, 03, 06, 07 IN4…IN7 can be con gured as...
● Binary voltage inputs for positive sensor signals Switch-on level > 0.7 U
B
Switch-off level < 0.3 U
B
Input resistance 3.2 kΩ Input frequency 50 Hz Diagnosis wire break > 0.95 U
B
Diagnosis short circuit < 1 V
● Resistor input Measuring range 16…3.6 kΩ Accuracy ± 3 %
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CR0401 Technical data
Control systems
Digital input (BL) Connection C: 02, 03, 06, 07 IN8…IN11 can be con gured as...
● Binary voltage inputs for positive sensor signals Switch-on level > 0.7 U
B
Switch-off level < 0.3 U
B
Input resistance 3.2 kΩ Input frequency 50 Hz Diagnosis wire break > 0.95 U
B
Diagnosis short circuit < 1 V
Characteristics of the outputs
Digital outputs (B
H
, PWM) Connection F: 01, 03, OUT4…OUT5
● Semiconductor outputs, positive switching (high side), short-circuit and overload protected. Diagnosis via voltage feedback, pullup resistance can be deactivated (wire break/ short circuit)
Switching voltage 8...32 V DC Switching current 2A
● PWM outputs
Output frequency 20...250 Hz Pulse/pause ratio 1…1000 ‰ Switching current 2A
If only one output of the output pair is active, the switching current is 2.5 A.
Max. switch-on current 11 A
Digital outputs (B
H
, PWM) Connection E: 01, 03, 05, 07 OUT0…OUT3
● Semiconductor outputs, positive switching (high side), short-circuit and over- load protected
Switching voltage 8...32 V DC Switching current 1 A
● PWM outputs
Output frequency 20...250 Hz Pulse/pause ratio 1…1000 ‰ Switching current 1 A
Max. switch-on current 11 A
Digital outputs (B
H
, PWM) Connection F: 05, 07 OUT6…OUT7
● Semiconductor outputs, positive switching (high side), short-circuit and overload protected. Diagnosis via voltage feedback, pullup resistance can be deactivated (wire break/ short circuit)
Switching voltage 8...32 V DC Switching current 4 A
● PWM outputs
Output frequency 20...250 Hz Pulse/pause ratio 1…1000 ‰ Switching current 4 A
Max. switch-on current 30 A
Free wheel diodes free wheel diodes for the deactivation of inductive loads are integrated
Overload protection (valid for all outputs)
5 minutes (at 100% overload)
Short-circuit strength (valid for all inputs and outputs)
5 minutes (contact +VBB with GND)
Max. total current of the output supplies VBB
1
/VBB2 (Continuous current load)
permanently 50 % of the nominal current
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CR0401 Technical data
Control systems
Test standards and regulations
CE marking EN 61000-6-2 Electromagnetic compatibility (EMC)
Noise immunity
EN 61000-6-4 Electromagnetic compatibility (EMC)
Emission standard
EN 61010-1 Safety requirements for electrical equipment for
measurement, control and laboratory use
E1 marking UN/ECE-R10 Emission standard
Immunity with 100 V/m
Electrical tests ISO 7637-2 Pulse 1, severity level: IV; function state C
Pulse 2a, severity level: IV; function state A Pulse 2b, severity level: IV; function state C Pulse 3a, severity level: IV; function state A Pulse 3b, severity level: IV; function state A Pulse 4, severity level: IV; function state A Pulse 5, severity level: III; function state C (data valid for the 24 V system) Pulse 4, severity level: III; function state C (data valid for the 12 V system)
Climatic tests EN 60068-2-30 Damp heat, cyclic
Upper temperature 55°C, number of cycles: 6
EN 60068-2-78 Damp heat, steady state
Test temperature 40°C / 93% RH, Test duration: 21 days
EN 60068-2-52 Salt spray test
Severity level 3 (motor vehicle) only with installed EC0401 or EC0402 cover
Mechanical tests ISO 16750-3 Test VII; Vibration, random
Mounting location: vehicle body
EN 60068-2-6 Vibration, sinusoidal
10...500 Hz; 0.72 mm/10 g; 10 cycles/axis
ISO 16750-3 Bumps
30 g/6 ms; 24,000 shocks
Note The EC declaration of conformity and approvals can be found at:
www.ifm.com data sheet search CR0401 More information
Wiring
A B C D E F N2 P/N1
8 poles 4 poles 6 poles
VBB
S
IN0 IN1 GND GND IN2 IN3 VBB
S
VBB
S
IN4 IN5 GND GND IN6 IN7 VBB
S
VBB
S
IN8 IN9 GND GND IN10 IN11 VBB
S
OUT0 GND OUT1 GND OUT2 GND OUT3 GND
OUT4 GND OUT5 GND OUT6 GND OUT7 GND
VBB
S
GND CAN2_H CAN2_L
VBB
S
VBB
1
VBB
2
GND CAN1_H CAN1_L
D = not used
Abbreviations A = analogue
B
H
= binary high side
B
L
= binary low side FRQ = frequency/pulse inputs PWM = pulse width modulation VBB
S
= supply sensors/module
VBB
1
= supply OUT 0...3
VBB
2
= supply OUT 4...7
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8.2 CR0403
Control systems
ifm electronic gmbh • Friedrichstraße 1 • 45128 Essen
We reserve the right to make technical alterations without prior notice! 24.10.2014CR0403 / page 1
CR0403
18
A B C D E F
N2
P/N1
25,5
127
163
145
12,5
8,5
6,5
10,5
79,7 112
LED
8,5
Mobile controller
BasicController
12 inputs
12 outputs
2 CAN interfaces
Programming
to IEC 61131-3
8...32 V DC
Technical data Modular control system
Usable as CANopen master or intelligent I/O module
Mechanical data
Housing plastic housing (black)
Dimensions (H x W x D) without cover with EC0401 cover with EC0402 cover and BasicDisplay CR0451
163 x 112 x 25.5 mm
163 x 112 x 68 mm
163 x 112 x 73.4 mm
Installation  xing by means of 4 M4 screws to DIN 912 or DIN 7984 and 4 tubular rivets to
DIN 7340 (tubular rivets are supplied)
Connection AMP blade male terminals 6.3 mm, to be clipped into place and thus vibration-
resistant, protected against reverse polarity
contacts AMP timer, CuZn pre-tin-plated
core cross-section 0.5...2.5 mm²
Inputs Outputs Operating voltage, CAN bus
3 x 8-pole 3 x 8-pole
1 x 6-pole, 1 x 4-pole
Protection rating IP 20 (with cover and cable seal IP 54)
Operating/storage temperature -40...85° C / -40...85° C
Weight 0.30 kg
Electrical data
Operating voltage 8...32 V DC
Current consumption 45 mA (at 24 V DC)
Overvoltage Undervoltage detection Undervoltage shutdown
36 V for t 10 s
at U
B
7.8 V
at U
B
7.0 V
Processor Freescale PowerPC, 50 MHz
Memory (total) 592 Kbytes RAM / 1536 Kbytes Flash / 1 Kbyte FRAM
Memory allocation see BasicController system manual
www.ifm.com data sheet search e.g. CR0403 Additional data
Device monitoring undervoltage monitoring
watchdog function
checksum test for program and system
excess temperature monitoring
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CR0403 Technical data
Control systems
CAN interfaces 1/2 Baud rate Communication pro le
CAN interface 2.0 A/B, ISO 11898
20 kBit/s...1 MBit/s (Default CAN1: 250 kBit/s, CAN2: 250 kBit/s)
CANopen, CiA DS 301 version 4, CiA DS 401 version 1.4
or SAE J 1939 or free protocol
Software/programming
Programming system CODESYS version 2.3 (IEC 61131-3)
Inputs 12 (con gurable)
Con gurations
Number Version
4 digital for positive / negative sensor signals
analogue (0…10/32 V DC, 0..20 mA, ratiometric) frequency ( 30 kHz)
B
L/BH
A
FRQ
4 digital for positive sensor signals
resistance measurement (0,016...3.6 kΩ)
B
L
4 digital for positive sensor signals B
L
positive sensor signals have diagnostic capabilities
Outputs 12 (con gurable)
Con gurations
Number Version
2 positive switching (high side)
PWM output (20…250 Hz), 2A, current-controlled 0.02…2 A, diagnosis
B
H
PWM PWM-I
4 positive switching (high side)
PWM output (20…250 Hz), 2 A, diagnosis
B
H
PWM
4 positive switching (high side)
PWM output (20…250 Hz), 1 A
B
H
PWM
2 positive switching (high side)
PWM output (20…250 Hz), 4 A, diagnosis
B
H
PWM
Status LED two-colour LED (red/green)
Operating states (preset)
Colour Status Description
permanently off no operating voltage orange 1 x on initialisation or reset checks green 5 Hz no operating system loaded
2 Hz application is running (RUN) permanently on application stopped (STOP)
red 10 Hz application stopped (STOP with error)
5 Hz application stopped due to undervoltage permanently on system fault (fatal error)
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CR0403 Technical data
Control systems
Characteristics of the inputs
Analogue inputs (A) Connection A: 02, 03, 06, 07 IN0...IN3 can be con gured as:
● Voltage inputs Input voltage 0...10 V or 0...32 V Resolution 12 bits Accuracy ± 1% FS Input resistance 65.6 kΩ (0...10 V), 50.7 kΩ (0...32 V) Input frequency 500 Hz
● Current inputs, with diagnostic capability Input current 0...20 mA Resolution 12 bits Accuracy ± 1% FS Input resistance 400 Ω Input frequency 500 Hz At a current of > 23 mA the input is switched to the voltage input!
● Voltage inputs, 0...32 V, ratiometric Function (U
IN
÷ UB) x 1000 ‰ Value range 0...1000 ‰ Input resistance 50.7 kΩ
● Binary voltage inputs for positive sensor signals
Switch-on level > 0.7 U
B
Switch-off level < 0.3 U
B
Input resistance 3.2 kΩ Input frequency 50 Hz Diagnosis wire break > 0.95 U
B
Diagnosis short circuit < 1 V
● Binary voltage inputs for negative sensor signals Switch-on level > 0.7 UB Switch-off level < 0.3 UB Input resistance 3.2 kΩ Input frequency 50 Hz
● Frequency inputs Input resistance 3.2 kΩ Input frequency < 30 kHz Switch-on level > 0.35...0.48 U
B
Switch-off level < 0.29 U
B
Digital input (BL) Connection B: 02, 03, 06, 07 IN4…IN7 can be con gured as...
● Binary voltage inputs for positive sensor signals Switch-on level > 0.7 U
B
Switch-off level < 0.3 U
B
Input resistance 3.2 kΩ Input frequency 50 Hz Diagnosis wire break > 0.95 U
B
Diagnosis short circuit < 1 V
● Resistor input Measuring range 16…3.6 kΩ Accuracy ± 3 %
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CR0403 Technical data
Control systems
Digital input (BL) Connection C: 02, 03, 06, 07 IN8…IN11 can be con gured as...
● Binary voltage inputs for positive sensor signals Switch-on level > 0.7 U
B
Switch-off level < 0.3 U
B
Input resistance 3.2 kΩ Input frequency 50 Hz Diagnosis wire break > 0.95 U
B
Diagnosis short circuit < 1 V
Characteristics of the outputs
Digital outputs (B
H
, PWM, PWM-I) Connection D: 01, 03 OUT0…OUT1
● Semiconductor outputs, positive switching (high side), short-circuit and over- load protected
Diagnosis via current feedback (wire break / overload) Diagnosis via voltage feedback, pullup resistance can be deactivated (wire break/ short circuit)
Switching voltage 8...32 V DC Switching current 2A Load resistance 6 Ω (at 12 V DC)
12 Ω (at 24 V DC)
● PWM outputs
Output frequency 20...250 Hz Pulse/pause ratio 1…1000 ‰ Switching current 2A
● Current-controlled output
Output frequency 20...250 Hz Control range 0.02…2 A Setting resolution 1 mA Control resolution 2 mA
If only one output is active, the switching current is 2.5 A.
Max. switch-on current 11 A
Digital outputs (B
H
, PWM) Connection D: 05, 07 OUT2…OUT3 Connection F: 01, 03, OUT8…OUT9
● Semiconductor outputs, positive switching (high side), short-circuit and over- load protected
Diagnosis via voltage feedback, pullup resistance can be deactivated (wire break/ short circuit)
Switching voltage 8...32 V DC Switching current 2A
● PWM outputs
Output frequency 20...250 Hz Pulse/pause ratio 1…1000 ‰ Switching current 2 A
If only one output of the output pair is active, the switching current is 2.5 A.
Max. switch-on current 11 A
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CR0403 Technical data
Control systems
Digital outputs (BH) Connection E: 01, 03, 05, 07 OUT4…OUT7
● Semiconductor outputs, positive switching (high side), short-circuit and over- load protected
Switching voltage 8...32 V DC Switching current 1 A
● PWM outputs
Output frequency 20...250 Hz Pulse/pause ratio 1…1000 ‰ Switching current 1 A
Max. switch-on current 11 A
Digital outputs (B
H
, PWM) Connection F: 05, 07 OUT10…OUT11
● Semiconductor outputs, positive switching (high side), short-circuit and over- load protected
Diagnosis via voltage feedback, pullup resistance can be deactivated (wire break/ short circuit)
Switching voltage 8...32 V DC Switching current 4 A
● PWM outputs
Output frequency 20...250 Hz Pulse/pause ratio 1…1000 ‰ Switching current 4 A
Max. switch-on current 30 A
Free wheel diodes free wheel diodes for the deactivation of inductive loads are integrated
Overload protection (valid for all outputs)
5 minutes (at 100% overload)
Short-circuit strength (valid for all inputs and outputs)
5 minutes (contact +VBB with GND)
Max. total current of the output supplies VBB
1
/VBB
2
(continuous current load)
permanently 50 % of the nominal current
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CR0403 Technical data
Control systems
Test standards and regulations
CE marking EN 61000-6-2 Electromagnetic compatibility (EMC)
Noise immunity
EN 61000-6-4 Electromagnetic compatibility (EMC)
Emission standard
EN 61010-1 Safety requirements for electrical equipment for
measurement, control and laboratory use
E1 marking UN/ECE-R10 Emission standard
Immunity with 100 V/m
Electrical tests ISO 7637-2 Pulse 1, severity level: IV; function state C
Pulse 2a, severity level: IV; function state A Pulse 2b, severity level: IV; function state C Pulse 3a, severity level: IV; function state A Pulse 3b, severity level: IV; function state A Pulse 4, severity level: IV; function state A Pulse 5, severity level: III; function state C (data valid for the 24 V system) Pulse 4, severity level: III; function state C (data valid for the 12 V system)
Climatic tests EN 60068-2-30 Damp heat, cyclic
Upper temperature 55°C, number of cycles: 6
EN 60068-2-78 Damp heat, steady state
Test temperature 40°C / 93% RH, Test duration: 21 days
EN 60068-2-52 Salt spray test
Severity level 3 (motor vehicle) only with installed EC0401 or EC0402 cover
Mechanical tests ISO 16750-3 Test VII; vibration, random
Mounting location: vehicle body
EN 60068-2-6 Vibration, sinusoidal
10...500 Hz; 0.72 mm/10 g; 10 cycles/axis
ISO 16750-3 Bumps
30 g/6 ms; 24,000 shocks
Note The EC declaration of conformity and approvals can be found at:
www.ifm.com data sheet search CR0403 More information
Wiring
A B C D E F N2 P/N1
8 poles 4 poles 6 poles
VBB
S
IN0 IN1 GND GND IN2 IN3 VBB
S
VBB
S
IN4 IN5 GND GND IN6 IN7 VBB
S
VBB
S
IN8 IN9 GND GND IN10 IN11 VBB
S
OUT0 GND OUT1 GND OUT2 GND OUT3 GND
OUT4 GND OUT5 GND OUT6 GND OUT7 GND
OUT8 GND OUT9 GND OUT10 GND OUT11 GND
VBB
S
GND CAN2_H CAN2_L
VBB
S
VBB
1
VBB
2
GND CAN1_H CAN1_L
Abbreviations A = analogue
B
H
= binary high side
B
L
= binary low side FRQ = frequency/pulse inputs PWM = pulse width modulation VBB
S
= supply sensors/module
VBB
1
= supply OUT 0...7
VBB
2
= supply OUT 8...11
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8.3 CR0411
Control systems
ifm electronic gmbh • Friedrichstraße 1 • 45128 Essen
We reserve the right to make technical alterations without prior notice! 24.10.2014CR0411 / page 1
CR0411
18
A B C D E F
N2
P/N1
25,5
127
163
145
12,5
8,5
6,5
10,5
79,7 112
LED
8,5
Mobile controller
BasicController
plus
8 inputs
8 outputs
2 CAN interfaces
Programming
to IEC 61131-3
8...32 V DC
Technical data Modular control system
Usable as CANopen master or intelligent I/O module
Mechanical data
Housing plastic housing (black)
Dimensions (H x W x D) without cover with EC0401 cover with EC0402 cover and BasicDisplay CR0451
163 x 112 x 25.5 mm
163 x 112 x 68 mm
163 x 112 x 73.4 mm
Installation  xing by means of 4 M4 screws to DIN 912 or DIN 7984 and 4 tubular rivets to
DIN 7340 (tubular rivets are supplied)
Connection AMP blade male terminals 6.3 mm, to be clipped into place and thus vibration-
resistant, protected against reverse polarity
contacts AMP timer, CuZn pre-tin-plated
core cross-section 0.5...2.5 mm²
Inputs Outputs Operating voltage , CAN bus
2 x 8-pole 2 x 8-pole
1 x 6-pole, 1 x 4-pole
Protection IP 20 (with cover and cable seal IP 54)
Operating/storage temperature -40...85° C / -40...85° C
Weight 0.30 kg
Electrical data
Operating voltage 8...32 V DC
Current consumption 45 mA (at 24 V DC)
Overvoltage Undervoltage detection Undervoltage shutdown
36 V for t 10 s
if U
B
7.8 V
if U
B
7.0 V
Processor Freescale PowerPC, 50 MHz
Memory (total) 592 Kbytes RAM / 1536 Kbytes Flash / 1 Kbyte FRAM
Memory allocation see BasicController
plus
system manual
www.ifm.com Data sheet search e.g. CR0411 Additional data
Device monitoring Undervoltage monitoring
Watchdog function
Checksum test for program and system
Excess temperature monitoring
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CR0411 Technical data
Control systems
CAN interfaces 1/2 Baud rate Communication pro le
CAN interface 2.0 A/B, ISO 11898
20 Kbits/s...1 Mbit/s (default CAN1: 250 Kbits/s, CAN2: 250 Kbits/s)
CANopen, CiA DS 301 version 4, CiA DS 401 version 1.4
or SAE J 1939 or free protocol
Software/programming
Programming system CODESYS version 2.3 (IEC 61131-3)
Inputs 8 (con gurable)
Con gurations
Number Description
4 digital for positive/negative sensor signals
analogue (0...10/32 V DC, 0...20 mA, ratiometric) frequency ( 30 kHz)
B
L/BH
A
FRQ
4 digital for positive sensor signals
resistance measurement (0.016...30 kΩ)
B
L
R
positive sensor signals have diagnostic capabilities
Outputs 8 (con gurable)
Con gurations
Number Description
4 positive switching (high side)
PWM output (20…250 Hz), 2.5 A, current-controlled, 0.02…2.5 A, diagnosis
B
H
PWM PWM-I
4 positive switching (high side)
negative switching (low side), 4 A PWM output (20…250 Hz), 4 A, diagnosis current-controlled, 0.02…4 A, diagnosis H-bridge function
B
H
B
L
PWM PWM-I H bridge
Status LED two-colour LED (red/green)
Operating states (preset)
Colour Status Description
permanently off no operating voltage orange 1 x on initialisation or reset checks green 5 Hz no operating system loaded
2 Hz application running (RUN) permanently on application stopped (STOP)
Red 10 Hz application stopped (STOP with error)
5 Hz application stopped due to undervoltage permanently on system error (fatal error)
Abbreviations A
B
H
B
L
FRQ H PWM PWM-I
R
VBB
S
VBB
1
VBB
2
Analogue Binary high side Binary low side Frequency/pulse inputs H-bridge function Pulse width modulation Pulse width modulation, current-controlled Resistor input Supply sensors/module supply OUT 0...3 supply OUT 4...7
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CR0411 Technical data
Control systems
Input characteristics
Analogue inputs (A, B
L/BH
, FRQ) Connection A: 02, 03, 06, 07 IN0...IN3 can be con gured as...
● Voltage inputs Input voltage 0...10 V or 0...32 V Resolution 12 bits Accuracy ± 1% FS Input resistance 65.6 kΩ (0...10 V), 50.7 kΩ (0...32 V) Input frequency 500 Hz
● current inputs, with diagnostic capability Input current 0...20 mA Resolution 12 bits Accuracy ± 1% FS Input resistance 400 Ω Input frequency 500 Hz At a current of > 23 mA the input is switched to the voltage input!
● Voltage inputs, 0...32 V, ratiometric Function (U
IN
÷ UB) x 1000 ‰ Value range 0...1000 ‰ Input resistance 50.7 kΩ
● Binary voltage inputs for positive sensor signals
Switch-on level > 0.7 U
B
Switch-off level < 0.3 U
B
Input resistance 3.2 kΩ Input frequency 50 Hz Diagnosis wire break > 0.95 U
B
Diagnosis short circuit < 1 V
● Binary voltage inputs for negative sensor signals Switch-on level > 0.7 UB Switch-off level < 0.3 UB Input resistance 3.2 kΩ Input frequency 50 Hz
● Frequency inputs Input resistance 3.2 kΩ Input frequency 30 kHz Switch-on level > 0.35...0.48 U
B
Switch-off level < 0.29 U
B
Digital/resistor inputs (BL, R) Connection B: 02, 03, 06, 07 IN4…IN7 can be con gured as…
● Binary voltage inputs for positive sensor signals Switch-on level > 0.7 U
B
Switch-off level < 0.3 U
B
Input resistance 3.2 kΩ Input frequency 50 Hz Diagnosis wire break > 0.95 U
B
Diagnosis short circuit < 1 V
● Resistor input Measuring current < 2.0 mA Input frequency 50 Hz Measuring range 0.016…30 kΩ Accuracy ± 2 % FS: 16 Ω...3 kΩ
± 5 % FS: 3...15 kΩ
± 10 % FS: 15...30 kΩ Diagnosis > 31 kΩ Diagnosis short circuit to VBB
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CR0411 Technical data
Control systems
Output characteristics
Digital outputs
(B
H
, PWM, PWM-I)
Connection D: 01, 03, 05, 07 OUT0…OUT3
● Semiconductor outputs, positive-switching (high side)
Short-circuit proof and overload protected Diagnosis via current feedback (wire break / overload) Diagnosis via voltage feedback, pullup resistance can be deactivated (wire break/ short circuit)
Switching voltage 5.5...32 V DC Switching current 2.5 A Load resistance 4.8 Ω (at 12 V DC)
9.6 Ω (at 24 V DC)
● PWM outputs
Output frequency 20...250 Hz Pulse/pause ratio 1…1000 ‰ Switching current 2.5 A
● Current-controlled output
Output frequency 20...250 Hz Control range 0.02…2.5 A Setting resolution 1 mA Control resolution 2 mA
Max. ambient temperature in PWM mode: 70 °C
Max. switch-on current 24 A
Digital outputs
(B
H/L
, PWM, PWM-I, H)
Connection E: 01, 03, 05, 07 OUT4…OUT7
● Semiconductor outputs, positive-switching (high side),
negative switching (low side), short-circuit and overload protection Diagnosis via current feedback (wire break / overload) Diagnosis via voltage feedback, pullup resistance can be deactivated (wire break/ short circuit)
Switching voltage 5.5...32 V DC Switching current 4 A Max. clamp energy < 3 J (at 25°C) Load resistance 3 Ω (at 12 V DC)
6 Ω (at 24 V DC)
● PWM outputs
Output frequency 20...250 Hz Pulse/pause ratio 1…1000 ‰ Switching current 4 A
● current-controlled output
Output frequency 20...250 Hz Control range 0.02…4 A Setting resolution 1 mA Control resolution 2 mA
Max. ambient temperature in PWM mode: 70 °C
Max. switch-on current 24 A (high side)
16 A (low side)
Free wheel diodes Free wheel diodes for the deactivation of inductive loads are integrated
Overload protection (valid for all outputs)
5 minutes (at 100% overload)
Short-circuit strength (valid for all inputs and outputs)
5 minutes (contacts +VBB/GND)
Total current per output supply VBB
1
or
VBB
2
8 A
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ifm electronic gmbh • Friedrichstraße 1 • 45128 Essen
We reserve the right to make technical alterations without prior notice! 24.10.2014CR0411 / page 5
CR0411 Technical data
Control systems
Total summation current of the output supply VBB
1
and VBB
2
(continuous current load)
12 A
Test standards and regulations
CE marking EN 61000-6-2 Electromagnetic compatibility (EMC)
Noise immunity
EN 61000-6-4 Electromagnetic compatibility (EMC)
Emission standard
E1 marking UN/ECE-R10 Emission standard
Immunity with 100 V/m
Electrical tests ISO 7637-2 Pulse 1, severity level: IV; function state C
Pulse 2a, severity level: IV; function state A Pulse 2b, severity level: IV; function state C Pulse 3a, severity level: IV; function state A Pulse 3b, severity level: IV; function state A Pulse 4, severity level: IV; function state B Pulse 5, severity level: III; function state C (data valid for the 24 V system) Pulse 4, severity level: III; function state C (data valid for the 12 V system)
Climatic tests EN 60068-2-30 Damp heat, cyclic
Upper temperature 55°C, number of cycles: 6
EN 60068-2-78 Damp heat, steady state
Test temperature 40°C / 93% RH, Test duration: 21 days
EN 60068-2-52 Salt spray test
Severity level 3 (vehicle) Only with installed EC0401 or EC0402 cover
Mechanical tests ISO 16750-3 Test VII; Vibration, random
Mounting location: vehicle body
EN 60068-2-6 Vibration, sinusoidal
10...500 Hz; 0.72 mm/10 g; 10 cycles/axis
ISO 16750-3 Bumps
30 g/6 ms; 24,000 shocks
Tests for railway applications EN 50121-3-2 Electromagnetic compatibility (EMC)
EN 50155 clause 12.2 Electronic equipment used on rolling stock
Note The EC declaration of conformity and approvals can be found at:
www.ifm.com Data sheet search CR0411 More information
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ifm electronic gmbh • Friedrichstraße 1 • 45128 Essen
We reserve the right to make technical alterations without prior notice! 24.10.2014CR0411 / page 6
CR0411 Technical data
Control systems
Wiring
A B C D E F N2 P/N1
8 poles 4 poles 6 poles
VBB
S
IN0 IN1 GND GND IN2 IN3
VBB
S
VBB
S
IN4 IN5 GND GND IN6 IN7
VBB
S
OUT0 GND OUT1 GND OUT2 GND OUT3 GND
OUT4 GND OUT5 GND OUT6 GND OUT7 GND
VBB
S
GND CAN2_H CAN2_L
VBB
S
VBB
1
VBB
2
GND CAN1_H CAN1_L
C/F = not used
Abbreviations A
B
H
B
L
FRQ H PWM PWM-I
R VBB
S
VBB
1
VBB
2
Analogue Binary high side Binary low side Frequency/pulse inputs H-bridge function Pulse width modulation Pulse width modulation, current-controlled Resistor input Supply sensors/module Supply OUT 0...3 Supply OUT 4...7
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9 Maintenance, repair and disposal
9.1 Maintenance
The device does not contain any components that need to be maintained by the user�
9.2 Cleaning the housing surface
► Disconnect the device� ► Clean the device from dirt using a soft, chemically untreated and dry cloth� ► In case of heavy dirt, use a damp cloth�
The following agents are not suited for cleaning the device: chemicals dissolving plastics such as methylated spirit, benzine, thinner, alcohol, acetone or ammonia�
Micro-fibre cloths without chemical additives are recommended�
9.3 Repair
The device must only be repaired by the manufacturer�
Observe the safety instructions (→ 2.4 Tampering with the device)
9.4 Disposal
► Dispose of the device in accordance with the national environmental
regulations�
10 Approvals/standards
Test standards and regulations (→ 8 Technical data)
The EC declaration of conformity and approvals can be found at:
www.ifm.com → Data sheet search → e.g. CR0401 → Approvals
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