Device manual

Mobile controller
CabinetController UK
CR0303
03 / 2015
7390608 / 01
CABINETCONTROLLER CR0303

Contents
1. Safety instructions page 3
2. Functions and features page 4
3. Mounting
3.1 Mounting location page 4
3.2 Fixing page 5
3.3 Cooling page 5
4. Electrical connection
4.1 Connectors page 6
4.2 Fuses page 6
4.3 Laying of supply and signal cables page 7
4.4 Frequency inputs page 7
5. Setup
5.1 Programming page 8
6. Technical data (data sheets 1... 5)
– Dimensions, mechanics, electronics page 9
– Operating and indicating elements page 10
– Rotary switch coding page 10
– Operation display (status LED) page 10
– Characteristics of the inputs page 11
– Characteristics of the outputs page 12
– Test standards and regulations page 12
– Wiring page 13
7. Maintenance, repair and disposal page 14
8. Approvals/standards page 14

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 CABINETCONTROLLER CR0303

1. Safety instructions
This description is part of the device. It contains texts and drawings
concerning the correct correct handling of the device and must be
read before installation or use.
Observe the operating instructions. Non-observance of the notes, operation
which is not in accordance with use as prescribed below, wrong installation or
handling can result in serious harm concerning the safety of persons and plant.
These instructions are intended for ”authorised” persons according to EMC and
the low-voltage directives. The device may only be installed, connected and put
UK
into operation by a qualified electrician.
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-bord system (12/24 V battery oper-
ation), it must be ensured that the external voltage is generated and supplied ac-
cording to the criteria for safety extra-low voltage (SELV) as this voltage is sup-
plied without further measures to supply the connected controller, the sensors
and the actuators.
The wiring of all signals in connection with the SELV circuit of the device must al-
so comply with the SELV criteria (safety extra-low voltage, safe electrical separa-
tion from other electric circuits).
If the supplied SELV voltage has an external connection to ground (SELV becomes
PELV), the responsibility lies with the user and the respective national regulations
for installation must be complied with. All statements in these operating instruc-
tions 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.
The device can be operated within a wide temperature range according to the
technical specification indicated below. Due to the additional internal heating the
housing walls can have high perceptible temperatures when touched in hot envi-
ronments.
In case of malfunctions or uncertainties please contact the manufacturer. Tamper-
ing with the device can lead to serious risks for the safety of persons and plant. It
is not permitted and leads to the exclusion of liability and warranty claims.

Attention
This is a class A installation. It can cause radio interference in domestic areas. In
this case the operator is requested to take appropriate measures.

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CABINETCONTROLLER CR0303

2. Functions and features

The freely programmable controllers of the ”CabinetController” series are rated
for use under difficult conditions (e.g. extended temperature range, strong vibra-
tion, intensive EMC interference). They are suitable for direct installation in mo-
bile vehicles.
By means of the application software, the inputs and outputs can be configured
to adapt to the respective application.
The controllers can be used as CANopen master or intelligent I/O module.

The user is responsible for the safe function of the application programs
which he created himself. If necessary, he must additionally carry out an ap-
proval test by corresponding supervisory and test organisations according
to the national regulations.
The controller is not approved for safety tasks in the field of safety of per-
sons.

3. Mounting
3.1 Mounting location
The controller is to be mounted in a dry and enclosed environment (e.g. control
panel of the driver’s cab, separate control boxes, etc.).
The housing must not be exposed to any torsion forces or mechanical
stress.

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 CABINETCONTROLLER CR0303

3.2 Fixing
Insert the enclosed tubular rivets from the back of the module in the 4 fixing
holes.

UK

Fix the module using 4 washers and screws.

Tighten the screws alternately crosswise.
Torque: 1.5 Nm
Mounting position: any
Hole dimensions: see back of the controller or Technical data, page 9
Screws to be used (M4 x L), e.g.: Standard
Cylinder screws with hexagon socket DIN 912
Cylinder screws with hexagon socket and low head DIN 7984

3.3 Cooling
As the internal heating of the electronics is conducted away via the housing, en-
sure sufficient heat dissipation.

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CABINETCONTROLLER CR0303

4. Electrical connection
4.1 Connectors
The supply cables, interfaces and inputs/outputs are connected via AMP crimp
connectors on the front of the controller.
Plug Connection Number of poles
P/N1 supply, CAN interfaces 6
N2 RS-232, TEST 6
X10 inputs IN08...15 18
X11 inputs A_IN16...23 10
X12 inputs IN00...07 18
X20 outputs OUT08...17 18
X21 outputs OUT00...07 10

X10 X11 X12

X20 X21 N2 P/N1

Pin connection see Technical data (data sheets), page 13.

Close unused connectors with unconnected sockets.
You can find more information about the available connector accessories at:
www.ifm.com ➔ Data sheet direct ➔ CR0303 ➔ Accessories

4.2 Fuses
To protect the whole system (wiring and controller) the individual electric circuits
must be protected.
Designation Potential Plug :pin Fuse
Supply voltage module VBBS P/N1:01 max. 2 A T
Supply voltage OUT00...03 VBBO 01 X21:05 max. 15 A
Supply voltage OUT04...07 VBBO 02 X21:10 max. 15 A
Supply voltage OUT08...11 VBBO 03 X20:13 max. 15 A
Supply voltage OUTxx (10 A) VBBO xx X20:xx max. 15 A
Protect high-current outputs separately !

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 CABINETCONTROLLER CR0303

4.3 Laying of supply and signal cables

Basically all supply and signal cables are to be laid separately.
Connect supply and ground cables to the controller and the sensors/actua-
tors respectively via a common star point
The linking of connections in the plug is not permitted and can impact
safety of persons and machinery.

supply
= not permitted UK
VBB S

GND

P/N1
sensor IN nn OUT 00 load
VBB S OUT OUT 01 load

sensor VBB O 01
IN nn
VBB S OUT
OUT 04 load
OUT 05 load
sensor IN nn
VBB STAB (5/10 V) VBB O 02
controller

4.4 Frequency inputs

Operate frequency inputs with screened cables, so that useful signals are
not affected by external interference.

Explanation of the abbreviations:

VBBO = supply outputs
VBBS = supply controller
VBBS OUT = supply sensors
VBBSTAB = supply sensors stabilised 5/10 V DC

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CABINETCONTROLLER CR0303

5. Setup
5.1 Programming
The user can easily create the application software by means of the IEC 61131-3
compliant programming system CoDeSys 2.3.
Further to the programming systems the following documents are required for
programming the controller:
• System manual R360
• Programming manual CoDeSys V2.3
(alternatively online help CoDeSys)
If the system manual R360 is not available, please contact one of the ifm branch
offices overleaf for your free copy.
Enquiry ➔ System manual R360, English (order no. EC2041)
As download file the documentation and the online help also are available on the
internet.
www.ifm.com ➔ Data sheet direct ➔ CR0303 ➔ Download/Software 1)

6. Technical data
(Data sheets see following pages 9...13)

¹) Downloads with registration

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 CABINETCONTROLLER CR0303

CR0303 226

X10 X11 X12

Mobile controller
CabinetController
24 inputs / 18 outputs
1

133
108
2nd CAN interface 2
for gateway function
according to SAE J 1939
Programming
X20 X21 N2 P/N1
to IEC 61131-3 UK

5,8
198
10...32 V DC 7,8
1) LED 2) rotary switch

Technial data Usable as CANopen master or intelligent I/O module

Housing plastic housing (black)

with transparent hinged cover for operating elements and indicators
Dimensions (L x W x H) 226 x 133 x 39 mm
Mounting fixation via 4 screws M 4 to DIN 912 or DIN 7984
and 4 tubular rivets to DIN 7340 (tubular rivets are enclosed)
Connections AMP crimp connector, to be clipped into place and thus vibration-resistant, protected against reverse polarity
(AMP junior timer contacts)
inputs/outputs 2 x 10-pole, 3 x 18-pole
operating voltage, CAN bus 1 x 6-pole
programming, TEST 1 x 6-pole
Weight 0.68 kg
Operation/storage temperature – 40...85 °C
Protection rating IP 20
Inputs 24
Possible configurations
Quantity Signal Description
8 digital for positive sensor signals, with diagnostic capability BL
4 digital for positive sensor signals, with diagnostic capability BL
or frequency pulse inputs, max. 30 kHz IL
4 digital for positive/negative sensor signals, B L/H
8 analogue 0...10/32 V DC, 0...20 mA or ratiometric A
or digital as binary voltage input BL

Outputs 18
Possible configurations
Quantity Signal Description
8 digital positive switching (high side) BH
or PWM PWM frequency max. 250 Hz PWM
4 digital positive switching (high side), 4 A BH
6 digital positive switching (high side), 10 A BH

Operating voltage UB 10...32 V DC

Nominal voltage 12/24 V DC
overvoltage 36 V for t≤ 10 s
undervoltage detection for UB ≤ 9.5 V
auto save for UB ≤ 9.0 V
Current consumption ≤ 100 mA (without external load 24 V DC)

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CABINETCONTROLLER CR0303

CR0303 Technical data

CAN interface 1 2 x CAN interface 2.0 B, ISO 11898

baud rate 50 Kbits/s...1 Mbit/s (default setting 125 Kbits/s)
(adjustable via rotary switches or CANopen object directory)
communication profile CANopen, CiA DS 301 version 4, CiA DS 401 version 1.4
Programming system CoDeSys (as from version 2.3)
Node ID (default) hex 7F (= dec 127)
(adjustable via 2 rotary switches or CANopen object directory)
CAN interface 2 CAN interface 2.0 A/B, ISO 11898
baud rate 50 kbits/s...1 Mbit/s (default setting 125 kbits/s)
communication profile SAE J 1939 or free protocol
Serial interface RS-232C
baud rate 9.6...57.6 Kbits/s (default setting 57.6 Kbits/s)
topology point-to-point (max. 2 participants); master-slave connection
protocol predefined ifm protocol (INTELHEX) or free protocol
Controller CMOS microcontroller 16 bits C167C, 40 MHz
Memory
program memory 576 Kbytes flash
data memory 80 Kbytes SRAM, 32 Kbytes flash, 2 Kbytes FRAM
data memory (protected in case of power failure) 256 bytes (auto save memory)
Operating elements and indicators
transparent
hinged cover
rotary switch
status LED hex-coded
S1 S2 S3

Rotary switch coding

Switch Position Description
S1 0 1000 Kbit/s
•0•
Baud rate 1 not supported E

2
•C•

•4•6
2 500 Kbit/s
3 250 Kbit/s •8•A

4 125 Kbit/s
5 100 Kbit/s
6 50 Kbit/s
7 not supported
8...E not defined
F setting via application program
S2 0...7 high nibble, e.g. 20 hex (= 32 dec)
Node ID H F setting via application program (S2+S3)
S3 0...E low nibble, e.g. 20 hex (= 32 dec)
Node ID L F setting via application program (S2+S3)

Status indicator RGB LED

Operating states (status indicator)
LED colour State Description
– off no operating voltage
orange 1 x on initialisation or reset checks
green 5 Hz no operating system loaded
green 2.0 Hz run
on stop
red 2.0 Hz run with error
on fatal error or stop with error

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 CABINETCONTROLLER CR0303

CR0303 Characteristics of the inputs

Digital inputs (B L) ■ Digital inputs for positive sensor signals, with diagnostic capability
X12:02, 04, 06, 08, 12, 14, 16, 18 switch-on level > 0.7 UB
IN 00...IN 07 switch-off level < 0.4 UB
can be configured as... input resistance 3.17 kΩ
input frequency 50 Hz
Digital inputs (B L, I L) ■ Digital inputs for positive sensor signals, with diagnostic capability
X10:02, 04, 06, 08 switch-on level > 0.7 UB
IN 08...IN 11 switch-off level < 0.4 UB
can be configured as... input resistance 3.17 kΩ
input frequency 50 Hz
■ Frequency inputs for positive sensor signals, with diagnostic capability
switch-on level
switch-off level
> 0.4...0.7 UB
< 0.2...0.24 UB
UK
input resistance 3.17 kΩ
measuring range max. 30 kHz
Digital inputs (B L/H) ■ Digital inputs for positive sensor signals
X10:12, 14, 16, 18 switch-on level > 0.7 UB
IN 12...IN 15 switch-off level < 0.4 UB
can be configured as... input resistance 3.17 kΩ
input frequency 50 Hz
■ Digital inputs for negative sensor signals
switch-on level < 0.2 UB
switch-off level > 0.5 UB
input resistance 3.17 kΩ
input frequency 50 Hz
Analogue inputs (A) ■ Voltage inputs
X11:01...04, 07...10 input voltage 0...10 V or 0...32 V
A_IN 16...A_IN 23 resolution 10 bits
can be configured as... accuracy ± 1 % FS
input resistance 69.3 kΩ (0...10 V), 46 kΩ (0...32 V)
input frequency 50 Hz
■ Current inputs with diagnostic capabiltiy
input current 0...20 mA
resolution 10 bits
accuracy ± 1 % FS
input resistance 400 Ω
input frequency 50 Hz
At a current of > 23 mA the input is switched to the voltage input!
■ Voltage inputs, 0...32 V, ratiometric
function (UIN ÷ UB) x 1000 ‰
value range 0...1000 ‰
input resistance 46 kΩ
■ Binary voltage inputs for positive sensor signals
switch-on level > 0.7 UB
switch-off level < 0.4 UB
input resistance 3.17 kΩ
input frequency 50 Hz

TEST input For the duration of the test operation (e.g. for programming) the TEST input
N2:05 must be connected to VBBTEST (N2:01).
For the ”RUN” mode the test input may not be connected.
wiring see page 5

Abbreviations
A = analogue
Bh = binary high side
BL = binary low side
I = current-controlled output
IH = pulse high side
IL = pulse low side
PWM = pulse width modulation
%IWx = IEC address for analogue input
%IX0.xx = IEC address for binary input
%QX0.xx = IEC address for binary output

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CABINETCONTROLLER CR0303

CR0303 Characteristics of the outputs

Digital outputs (B H, PWM) ■ Solid state outputs, positive switching (high side), short-circuit and overload protected
X21:01...04, 06...09 switching voltage 10...32 V DC
OUT 00...OUT 07 switching current max. 4 A
total current max. 12 A
■ PWM outputs
PWM frequency max. 250 Hz
setting resolution 0.1 %
switching current max. 4 A
OUT 00...03 are combined with a common VBBO connection.
OUT 04...07 are combined with a common VBBO connection.
Digital outputs (B H) ■ Solid state outputs, positive switching (high side), short-circuit and overload protected
X20:15...18 switching voltage 10...32 V DC
OUT 08...OUT 11 switching current max. 4 A
total current max. 12 A
OUT 08...11 are combined with a common VBBO connection.
Digital outputs(BH) ■ Solid state outputs, positive switching (high side), short-circuit and overload protected
X20:02, 04, 06, 08, 10, 12 switching voltage 10...32 V DC
OUT 12...OUT 17 (10 A) switching current max. 10 A
total current max. 30 A
Value ranges for diagnosis and switch-off
Warning 10...16.5 A (typ. 12 A)
Error (switch-off) 13...21.5 A (typ. 16 A)
OUT 12...OUT 17 each have a power supply connection VBBO
Voltage output (VBBSTAB 5/10 V) ■ Voltage output for the sensor supply
X20:14 voltage 5/10 V DC (can be selected, switched off or read back)
The 10 V output requires at least 13 V supply voltage to work.
current 400 mA
accuracy ±5%

Note free-wheeling diode for the connection of inductive loads is integrated

Overload protection max. 5 minutes (in case of 100 % overload)
(valid for all outputs)
Short-circuit stability max. 5 minutes contact +VBB with GND
(valid for all inputs/outputs)

wiring see page 5

Test standards and regulations

Climatic test damp heat to EN 60068-2-30, test Db
(≤ 95 % rel. air humidity, non-condensing)
protection test to EN 60529
Mechanical resistance vibration to EN 60068-2-6, test Fc
shock to EN 60068-2-27, test Ea
bump to EN 60068-2-29, test Eb
Immunity to to ISO 7637-2, pulses 2, 3a, 3b, severity level 4, function state A
conducted interference to ISO 7637-2, pulse 5, severity level 1, function state A
to ISO 7637-2, pulse 1, severity level 4, function state C
Immunity to interfering fields according to UN/ECE-R10 at 100 V/m (E1 type approval)
and DIN EN 61326 (CE)
Interference emission according to UN/ECE-R10 (E1 type approval)
and DIN EN 61326 (CE)
Tests for the approval for railway applications to BN 411 002 (DIN EN 50155 point 10.2 and DIN EN 50121)

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 CABINETCONTROLLER CR0303

CR0303 Wiring

18 IN 07 BL CAN 2_H 06
17 VBB S OUT CAN 2_L 05
P/ N1
16 IN 06 BL CAN 1_H 04
Power supply
15 VBB S OUT CAN 1_L 03
CAN Bus
14 IN 05 BL GND 02
13 VBB S OUT VBB S 01
12 IN 04 BL
11 GND
X12 10 GND n.c. 06
Inputs 09 GND TEST 05
UK
08 IN 03 BL
N2
RS-232 TxD 04
07 GND
RS-232
RS-232 RxD 03
06 IN 02 BL
Test
GND 02
05 VBB S OUT VBB TEST 01
04 IN 01 BL
03 VBB S OUT 10-32 V
02 IN 00 BL
01 VBB S OUT 5 / 10 V

10 A_IN 23 A VBB O 02 10
09 A_IN 22 A BH / P H OUT07 / PWM 07 09
08 A_IN 21 A BH / P H OUT06 / PWM 06 08
07 A_IN 20 A BH / P H OUT05 / PWM 05 07
X11 06 GND BH / P H OUT04 / PWM 04 06 X21
Inputs 05 VBB S OUT VBB O 01 05 Outputs
04 A_IN 19 A BH / P H OUT03 / PWM 03 04
03 A_IN 18 A BH / P H OUT02 / PWM 02 03
02 A_IN 17 A BH / P H OUT01 / PWM 01 02
01 A_IN 16 A BH / P H OUT00 / PWM 00 01

18 IN 15 BL / B H BH OUT11 18
17 VBB S OUT BH OUT10 17
16 IN 14 BL / B H BH OUT09 16
15 VBB S OUT BH OUT08 15
14 IN 13 BL / B H VBB STAB (5/10 V) 14
13 VBB S OUT VBB O 03 13
12 IN 12 BL / B H BH OUT17 (10 A) 12
11 GND VBB O 17 11
X10 10 GND BH OUT16 (10 A) 10 X20
Inputs 09 GND VBB O 16 09 Outputs
08 IN 11 / FRQ 03 BL / IL BH OUT15 (10 A) 08
07 GND VBB O 15 07
06 IN 10 / FRQ 02 BL / IL BH OUT14 (10 A) 06
05 VBB S OUT VBB O 14 05
04 IN 09 / FRQ 01 BL / IL BH OUT13 (10 A) 04
03 VBB S OUT VBB O 13 03
02 IN 08 / FRQ 00 BL / IL BH OUT12 (10 A) 02
01 VBB S OUT VBB O 12 01

pin connection
(view from the top on the pin side)

5 6
3 4
1 2 PWM = pulse-width modulated signals
RxD = RS-232 data received
Explanation of the abbreviations: TxD = RS-232 data transmitted
A = analogue FRQ/CYL = frequency inputs VBBS = supply controller/sensors
BH = binary (high side) IL = pulse (low side) VBBO = supply outputs
BL = binary (low side) PH = PWM (high side) VBBSTAB = supply sensors stabilised 5/10 V DC

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CABINETCONTROLLER CR0303

7. Maintenance, repair and disposal

As the device does not contain any components which must be maintained by
the user, the housing must not be opened. The maintenance of the device may
only be carried out by the manufacturer.
The disposal must be carried out according to the corresponding national envi-
ronmental regulations.

8. Approvals/standards
For test standards and regulations see Technical data (data sheets), page 12.
The CE-Declaration of Conformity and the e1-approval are available at:
www.ifm.com ➔ Data sheet direct ➔ CR0303 ➔ Approvals

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