IFM Electronic ECOMAT100 CR2500 User manual

Installation instructions
SmartController
CR2500
7390282 / 03 05 / 2014
UK

SmartController CR2500
2
Contents
1 Preliminary note � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 3
1�1 Symbols used� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 3
1�2 Warning signs used � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 3
2 Safety instructions � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4
2�1 General� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4
2�2 Target group � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4
2�3 Electrical connection � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4
2�4 Housing temperature � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 4
2�5 Tampering with the device � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 5
2�6 Electromagnetic compatibility� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 5
2�7 Electrical welding on vehicles and plants � � � � � � � � � � � � � � � � � � � � � � � � � � 5
3 Functions and features � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 5
4 Installation� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 6
4�1 Fastening � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 6
4�2 Installation position� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 6
4�3 Mounting surface � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 7
4�4 Heat dissipation � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 7
5 Electrical connection� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 8
5�1 Wiring � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 8
5�2 Ground connection � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 8
5�3 Fuses � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 8
5�4 Laying the supply and signal cables� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 8
5�5 Frequency and analogue inputs � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 9
6 Set-up � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 9
6�1 Programming � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 9
6�2 Required documentation � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 9
7 Technical data� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 10
7�1 Mechanical and electric data � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 10
7�2 Characteristics of the inputs/outputs � � � � � � � � � � � � � � � � � � � � � � � � � � � � 12
7�3 Test standards and regulations � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 13
7�4 Wiring � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 14
8 Maintenance, repair and disposal� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 15
9 Approvals/standards � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � 15
This document is the original instructions�
Licences and trademarks
All trademarks and company names are subject to the copyright of the respective companies�

UK
SmartController CR2500
3
1 Preliminary note
This document applies to devices of the type "SmartController" (art� no�: CR2500)�
These instructions are 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
►Instructions
> Reaction, result
[…] Designation of pushbuttons, 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�

SmartController CR2500
4
2 Safety instructions
2.1 General
These instructions are part of the device� They 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 connection terminals 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 Housing temperature
As described in the technical specifications below the device can be operated
in a wide ambient temperature range� Because of the additional internal heating
the housing walls can have high perceptible temperatures when touched in hot
environments�

UK
SmartController CR2500
5
2.5 Tampering with the device
In case of malfunctions or uncertainties please contact the manufacturer�
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�
2.6 Electromagnetic compatibility
This is a class A product� It can cause radio interference in domestic areas� In this
case the operator is requested to take appropriate measures�
2.7 Electrical welding on vehicles and plants
Welding work on the chassis frame must only be carried out by qualified persons�
Remove and cover the plus and minus terminals of the batteries�
Disconnect all contacts of the controller from the on-board system prior to welding
on the vehicle or plant� Connect the earth terminal of the welding device directly to
the part to be welded�
Do not touch the controller or electric cables with the welding electrode or the
earth terminal of the welding device�
Protect the controller against weld slag�
3 Functions and features
The freely programmable controllers of the "SmartController" series are rated for
use under difficult conditions (e�g� extended temperature range, strong vibration,
intensive EMC interference)�
They are suited for direct installation in machines in mobile and robust
applications� Integrated hardware and software functions (operating system) offer
high protection for the machine�
The controllers can be used as CANopen master�
WARNING
The SmartController series is not approved for safety tasks in the field of safety
of persons�
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�

SmartController CR2500
6
4 Installation
4.1 Fastening
►Fix the controller to a flat surface using 4 M5 screws�
Screw material: steel or stainless steel
Tightening torque: 8 ±2 Nm
NOTE
Use screws with a low head to avoid that the connector is damaged when placed
and locked�
Screws to be used (examples) Standard
Button head hexagon socket screws (M5 x L) ISO 7380
Cylinder screws with hexagon socket and low head (M5 x L) DIN 7984
Cutting screws for metric ISO thread with low head DIN 7500
Example button head hexagon socket screw
4.2 Installation position
►Align the controller so that the cable entries of the connectors face downwards�
Preferred installation position

UK
SmartController CR2500
7
4.3 Mounting surface
NOTE
The housing must not be exposed to any torsional forces or mechanical stress�
►Use compensating elements if there is no flat mounting surface available�
Mounting surface
4.4 Heat dissipation
►Ensure sufficient heat dissipation as the internal heating of the electronics is
conducted away via the housing�
►In case of sandwich mounting of controllers use spacers�
Heat dissipation and sandwich mounting

SmartController CR2500
8
5 Electrical connection
5.1 Wiring
Wiring (→ 7 Technical data)
Only connect the connector pins as shown in the pin layout�
Unspecified connector pins remain unconnected�
►Connect all indicated supply cables and GND terminals�
5.2 Ground connection
To ensure the protection of the device against electrical interference, the
housing must be connected to GND (e�g� to the ground of the vehicle)�
1: Drill holes for ground connection
►Establish a connection between the device and the ground of the vehicle using
M5 screws�
Screws to be used (→ 4.1 Fastening)
5.3 Fuses
►The individual electric circuits must be protected in order to protect the whole
system�
Description Potential Pin no. Fuse
Supply voltage sensors/module VBB S23 ≤ 2 A time-lag
Supply voltage outputs VBB O05 ≤ 15 A
5.4 Laying the supply and signal cables
WARNING
The linking of connections in the plug is not permitted and can affect the safety of
operators and machinery�
►Basically all supply and signal cables must be laid separately�

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SmartController CR2500
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►Connect supply and ground cables to the controller and the sensors/actuators
via the respective common star point�
If a prewired connection cable is used, remove the cores with unused signal
inputs and outputs�
Unused cores, in particular core loops, lead to interference coupling that
can influence the connected controller�
5.5 Frequency and analogue inputs
►Operate inputs with screened cables, so that useful signals are not affected by
external interference�
►Connect screens to ground on one side�
6 Set-up
6.1 Programming
The user can easily create the application software by means of the IEC 61131-3
compliant programming system CODESYS 2�3�
6.2 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)
●SmartController system manual
(alternatively as online help)
The manuals can be downloaded from the internet:
www.ifm.com → Data sheet search → CR2500 → More information
CODESYS and SmartController online help:
www.ifm.com → Service → Download → Systems for mobile machines*
*) Download area with registration

SmartController CR2500
10
7 Technical data
7.1 Mechanical and electric data
132
5,5
26
80
15
45°
153
LED
43
±0,5
±1
106,5 ±1
Control systems
ifm electronic gmbh • Friedrichstraße 1 • 45128 Essen
21.05.2014
CR2500
Mobile controller
SmartController
2nd CAN interface
for gateway function
according to SAE J 1939
Programming to
IEC 61131-3
Supply voltage
10...32 V DC
We reserve the right to make technical alterations without prior notice. CR2500 / page 1
Technical data
Housing
Dimensions (H x W x D)
Mounting
Connection
Weight
Inputs
can be configured as
Outputs
can be configured as
Switching current per output
Total current of all outputs
Operating voltage UB
Overvoltage
Reset in case of undervoltage
Auto save
Current consumption
Housing temperature
Storage temperature
Protection
CAN interface 1
Baud rate
Communication profile
CAN interface 2
Baud rate
Communication profile
Serial interface
Baud rate
Topology
Protocol
Node ID (default)
can be used as CANopen master or intelligent I/O module
8 inputs (4 digital/4 analog) and 4 outputs (digital/PWM/current-controlled)
closed screened metal housing
with flange fastening
153 x 132 x 43 mm
by means of 4 M5 x L screws to DIN 7500 or DIN 7984
mounting position horizontal or vertical to the mounting wall
55-pin connector, latched, protected against reverse polarity
type AMP housing or Framatome
AMP junior timer contacts, crimp connection 0.5/2.5 mm2
0.95 kg
8
4 digital; for positive sensor signals (Low Side); NAMUR; with diagnostic capability
incl. 2 pulse inputs (max. 30 kHz)
4 analog; 0...10/32 V DC or 0/4...20 mA
4
digital, positive switching (High Side)
PWM (PWM frequency 20...250 Hz)
current-controlled (0.1...4 A)
max. 4 A
max. 12 A
10...32 V DC
36 V for t ≤10 s
at UB≤9.5 V
at UB≤9.0 V
≤160 mA (without external load)
– 40...85 °C (depending on the load)
– 40...85 °C
IP 67 (for inserted plug with individually sealed cores e.g. EC2084)
CAN interface 2.0 B, ISO 11898
50 Kbits/s...1 Mbits/s (default setting 125 kBits/s)
CANopen, CiA DS 301 version 3.0, CiA DS 401 version 1.4
CAN interface 2.0 A/B, ISO 11898
50 Kbits/s...500 Kbits/s (default setting 125 kBits/s)
SAE J 1939
RS 232 C
9.6 Kbits/s, 19.2 Kbits/s, 28.8 Kbits/s, 57.6 Kbits/s
point-to-point (max. 2 participants); master/slave connection
predefined ifm protocol (INTELHEX)
hex 20 (= dec. 32)

UK
SmartController CR2500
11
CR2500
Processor
Device monitoring
Program memory
Data memory
Data memory
(protected in case of power failure)
Memory allocation
Status LED
Operating status (status LED)
Electrical connection
Control systems
ifm electronic gmbh • Friedrichstraße 1 • 45128 Essen 21.05.2014We reserve the right to make technical alterations without prior notice. CR2500 / page 2
Technical data
CMOS microcontroller 16 bits C167C, pulse frequency 20 MHz
undervoltage monitoring
watchdog function
check sum test for program and system
monitoring of too high a temperature
192 Kbytes flash, can be used by the user
64 Kbytes SRAM, 32 Kbytes flash, 3 Kbytes EEPROM
256 bytes
(auto save memory)
see system manual
www.ifm.com →Data sheet search →CR2500 →More information
two-colour LED (red/green)
During the start-up or reset of the controller
the green and red LEDs light simultaneously.
This appears orange.
LED colour Flashing frequency Description
– constantly off no supply voltage
orange for a short time on initialisation or reset checks
green 5 Hz no operating system loaded
green 2.0 Hz Run
constantly on Stop
red 2.0 Hz Run with error
constantly on Fatal error or stop with error
Designation Pin no. Potential
supply voltage 23 10...32 V DC (VBBS)
supply voltage outputs 05 10...32 V DC (VBB0)
ground 01 GNDS
CAN interface 1 14 / 51 CAN_H
32 / 50 CAN_L
33 / 15 CAN_GND
CAn interface 2 42 / 43 CAN_H
44 / 45 CAN_L
26 / 31 CAN_GND
RS 232 interface 07 (TxD) pin 02, PC D-Sub (9 pins)
(programming) 06 (RxD) pin 03, PC D-Sub (9 pins)
13 (GND) pin 05, PC D-Sub (9 pins)
"TEST" input
programming mode 24 10...32 V DC (VBBS)
operating mode 24 open
To guarantee the electrical interference
protection of the controller, the housing
must be connected to the ground of the
vehicle!

SmartController CR2500
12
7.2 Characteristics of the inputs/outputs
CR2500
Digital inputs
(%IX0.0 / 0.8 / 1.0 / 1.8)
can be configured as ...
Analog inputs
(%IW6...%IW9)
can be configured as ...
Outputs
(%QX0.0 / 0.8 / 1.0 / 1.8)
can be configured as ...
Input "TEST"
Control systems
ifm electronic gmbh • Friedrichstraße 1 • 45128 Essen
21.05.2014We reserve the right to make technical alterations without prior notice. CR2500 / page 3
Characteristics of the inputs/outputs
■Digital inputs for positive switching sensor signals
switch-on level 0.7 UB
switch-off level 0.4 UB
input resistance 2.86 kΩ
input frequency 50 Hz
■NAMUR inputs; digital inputs with diagnostic capability when used with ifm NAMUR
sensors, supply voltage 5...25 V, e.g. NT5001...NN5002
input resistance 2.86 kΩ
input frequency 50 Hz
■Diagnostic inputs (analog evaluation), digital inputs with diagnostic capability when
an external resistor connection is used, corresponds to the NAMUR input
input resistance 2.86 kΩ
input frequency 50 Hz
■Frequency inputs; with diagnostic capability, evaluation with integrated comparator
input frequency 1 100 Hz...30 kHz (IN 0)
input frequency 2 100 Hz...30 kHz (IN 1)
input resistance 2.86 kΩ
■Voltage inputs
input voltage 0...10/32 V
resolution 10 bit
input resistance 50 kΩ
input frequency 50 Hz
■Current inputs
input current 0/4...20 mA
resolution 10 bit
input resistance 400 Ω
input frequency 50 Hz
■Semi conductor outputs,
positive switching (high side), short-circuit and overload protected
switching voltage 10...32 V DC
switching current max. 4 A; total current max. 12 A
■PWM outputs; with diagnostic capability
PWM frequency max. 250 Hz
PWM pulse ratio 1...99 %
resolution depending on the PWM frequency
switching current max. 4 A; total current max. 12 A
integrated pull-down resistor (4.7 kΩ) to trigger Danfoss valves
■Current-controlled outputs; with diagnostic capability
switching current 0.1...4 A; total current max. 12 A
setting resolution 1 mA
control resolution 5 mA
accuracy ± 2% FS
During the test mode (e.g. programming) the "TEST" connection
must be connected to UB. For the "RUN" mode the input must not be connected.
input resistance 12 kΩ

UK
SmartController CR2500
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7.3 Test standards and regulations
CR2500
Humidity test
Mechanical resistance
Immunity to
conducted interference
EC declaration of conformity
E1 marking
Railway specification
Steuerungssysteme
ifm electronic gmbh • Friedrichstraße 1 • 45128 Essen 21.05.2014We reserve the right to make technical alterations without prior notice. CR2500 / page 4
Test standards and regulations
to IEC 68-2-30
≤90 % rel. humidity, non-condensing
vibration to IEC 68-2-6
shock to IEC 68-2-27
bump to IEC 68-2-29
to ISO 7637: 2004
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 / 24V function state A
Pulse 5a, severity level III, function state A
according to directive RL 2004/108/EG
to EN 61000-6-2: 2005
to EN 61000-6-3: 2007
according to UN/ECE-R10
(immunity with 100 V/m)
to BN 411 002 (DIN EN 50155 part 12.2: issue 03/2008)

SmartController CR2500
14
7.4 Wiring
Control systems
ifm electronic gmbh • Friedrichstraße 1 • 45128 Essen
21.05.2014We reserve the right to make technical alterations without prior notice. CR2500 / page 5
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


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
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


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

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
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 

 
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

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
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CR2500 Wiring with configuration examples
Explanation of the abbreviations:
A = analog
BH = binary high side
BL = binary low side
CANH= CAN interface
CANL= CAN interface
CYL = inputs for time period measurement
FRQ = frequency inputs
PWM = pulse-width-modulated signals
RxD = serial interface (data received)
TxD = serial interface (data transmitted)
VBBO= supply voltage outputs
VBBS= supply voltage sensors/module
%IWx = IEC address for analog input
%IX0.xx = IEC address for binary input
%QX0.xx = IEC address for binary output
digital
e.g. two-way valves
PWM, current-controlled
e.g. proportional valve
PWM
e.g. Danfoss proportional valve
(pull-down resistor integrated)
For safety reasons the valve is
supplied with voltage via a
binary output.

UK
SmartController CR2500
15
8 Maintenance, repair and disposal
The unit is maintenance-free�
►Do not open the housing as the device does not contain any components
which can be repaired by the user� The device must only be repaired by the
manufacturer�
►Dispose of the device in accordance with the national environmental
regulations�
9 Approvals/standards
Test standards and regulations (→ 7 Technical data)
The EC declaration of conformity and approvals can be found at:
www.ifm.com → Data sheet search → CR2500 → Approvals