Installation instructions UK

ClassicController
CR0505
ClassicController CR0505

Contents
1 Preliminary note 3 11 Symbols used
3
12 Warning signs used 3
2 Safety instructions 4 21 General
4
22 Target group 4
23 Electrical connection 4
24 Housing temperature 4
25 Tampering with the device 5
26 Electromagnetic compatibility 5
27 Electrical welding on vehicles and plants 5
3 Functions and features 5
4 Installation 6 41 Fastening
6
42 Installation position 6
43 Mounting surface 7
44 Heat dissipation 7
5 Electrical connection 9 51 Wiring
9
52 Ground connection 9
53 Fuses 9
54 Interaction between the inputs and outputs within one group of
connections
9 55 Laying the supply and signal
cables 10
56 Frequency and analogue inputs 11
6 Set-up 11
61 Documentation 11
7 Technical data 12 71 Mechanical and electric
data 12

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 ClassicController CR0505
72 Test standards and regulations 14
73 Input characteristics 15
74 Output characteristics 16
75 Wiring 17
8 Maintenance, repair and disposal 18
9 Approvals/standards 18

UK
This document is the original instructions
All trademarks and company names are subject to the copyright of the respective companies
1 Preliminary note
This document applies to devices of the type "ClassicController" (art no:
CR0505)
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
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ClassicController CR0505
CAUTION
Warning of personal
injury reversible injuries may result
Slight
NOTE
Warning of damage to property
2 Safety instructions
2.1 General
These instructions are an integral 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 may be connected

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 ClassicController CR0505
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
2.5 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 UK
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 "ClassicController" series are rated
for use under difficult conditions (eg 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
safety
"ClassicController"
of series is not approved for safety tasks in the field of
persons
TheWARNING
user is responsible for the safe function of the application programs which

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ClassicController CR0505
If necessary, he must additionally carry out an approval test
by
he corresponding
createdsupervisory and test organisations according to the national
himself
regulations
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
► Connect the housing to GND (→ 5.2 Ground connection)

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

4.2 Installation position

► Align the controller in such a way that the cable entry of the connector faces
downwards

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 ClassicController CR0505

UK

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

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

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ClassicController CR0505

Heat dissipation and sandwich mounting

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 ClassicController CR0505
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 supply cables and GND terminals
5.2 Ground connection
UK
To ensure the protection of the device against electrical interference and
the safe function of the device, the housing must be connected to the
ground of the vehicle

1: Drill hole 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 S 23 ≤2AT

Supply voltage outputs VBB O 05 ≤ 15 A

Supply voltage via relay VBB R 34 ≤ 15 A

5.4 Interaction between the inputs and outputs within one group of
connections
In the applications the following must be observed as regards the use of the
terminals as input and output:

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ClassicController CR0505
Within one output group inputs and outputs should not be mixed One output
group is marked by a common VBBX potential
The background is a possible internal cross-connection of the outputs from the
externally supplied inputs This may occur unexpectedly if the supply to the
outputs is switched off externally Should a mixture still be carried out for
reasons of optimising the terminals, please inform yourself in detail about the
situations described in the system manual and the restrictions resulting from this
Follow these instructions for your application and keep records of this

5.5 Laying the supply and signal cables

► Basically all supply and signal cables must be laid separately
► Screen signal cables in EMC critical applications
► Connect supply and ground cables to the controller and the
sensors/actuators via the respective common star point
WARNING
The linking of connections in the plug is not permitted and can affect the
operators and safety of
machinery

X = not permissible
If a prewired connection cable is used, remove the cores with unused
signal inputs and outputs
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 ClassicController CR0505
Unused cores, in particular core loops, lead to interference coupling that
can influence the connected controller

5.6 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

UK
6 Set-up
6.1 Documentation
The user can easily create the application program by means of the IEC 61131-
3 compliant programming system CODESYS 23 In addition to the programming
system CODESYS, the following documents are required for programming and
commissioning of the controller:
● System manual CR0505
(alternatively CODESYS 23 online help)
● Manual on PLC programming with CODESYS 23
(alternatively CODESYS 23 online help)
The system manual CR0505 is available for download on the internet:
www.ifm.com → Data sheet search → CR0505 → Operating instructions
The manual on PLC programming with CODESYS 23 and the online help are
automatically installed on the PC upon installation of the CODESYS package
from the ecomatmobile DVD
As an alternative, the CODESYS package can be downloaded from the internet:
www.ifm.com → Service → Download → Systems for mobile machines*
*) Download area with registration

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ClassicController CR0505
7 Technical data 7.1
Mechanical and electric data

Technical data Controller as black box system

for the implementation of a central or decentralised system design

Housing closed, screened metal housing with flange fastening

Dimensions (H x W x D) 153 x 226 x 43 mm
Mounting screw connection by means of 4 M5xL screws according to DIN 7500 or DIN 7984 mounting
position horizontal or vertical to the mounting wall
Connection 55-pin connector, latched, protected against reverse polarity, type AMP or Framatome
AMP junior timer contacts, crimp connection 0.5/2.5 mm²
Weight 1.2 kg
Housing / storage temperature –40...85 °C (depending on the load) / –40...85 °C
Protection IP 67 (for inserted plug with individually sealed cores e.g. EC2084)

Input/output channels total max. 24 (the total number which is available depends on
the wiring and configuration of the controller)
Inputs max. 24 (corr. to 0 outputs)
possible configurations

Number Signal Version

8 digital for positive sensor signals, with diagnostic capability BL
or analogue 0...10/32 V DC, 0/4...20 mA or ratiometric A
8 digital for positive sensor signals BL
4 digital for positive sensor signals, with diagnostic BL
*) only positive sensor signals with or frequency capability max. 50 kHz IL
diagnostic capability 4 digital for positive/negative sensor signals, with diagnostic B
or frequency capability * max. 1 kHz L/H I
L

Outputs max. 8 (corr. to 16 inputs)

possible configurations

Number Signal Version

8 digital positive switching (High Side), with diagnostic BH
capability
or PWM PWM frequency 20...250 Hz PWM

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 ClassicController CR0505
or current- 0,1...4 A PWM I
controlled
Abbreviations
A = analogue
B H = binary High Side
BL = binary Low Side
FRQ/CYL = frequency inputs
IH = pulse High Side
IL = pulse Low Side
PWM = pulse width modulation
PWM I = current-controlled output %IWx = IEC
address for analogue input
%IX0.xx = IEC address for binary input
%QX0.xx = IEC address for binary output
CR0505 Technical data

Operating voltage UB 10...32 V DC UK

overvoltage 36 V for t ≤ 10 s
undervoltage detection for UB ≤ 10 V
switching-off in case of undervoltage for UB ≤ 8 V
Current consumption ≤ 160 mA (without external load at 24 V DC)
CAN interface 1 CAN interface 2.0 B, ISO 11898
Baud rate 50 kbits/s...1 Mbits/s (default setting 125 kbits/s)
Communication profile CANopen, CiA DS 301 version 4, CiA DS 401 version 1.4
Node-ID (CANopen) hex 7F (= dec. 127)
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-232 C
Baud rate 9.6 / 19.2 / 28.8 / 38.4 / 57.6 kBit/s (default setting 57.6 kbits/s)
Topology point-to-point (max. 2 participants); master-slave connection
Protocol predefined ifm protocol (INTELHEX)
Processor CMOS microcontroller 16 bits C167CS cycle
frequency 20/40 MHz
Device monitoring undervoltage monitoring watchdog
function
check sum test for program and system excess
temperature monitoring
Process monitoring concept Two relays according to EN 954 monitor
two groups of 4 outputs each
Physical memory Flash: 2 MByte
RAM: 256 kByte
Remanent memory: 32 kByte
Memory allocation See system manual www.ifm.com → Data sheet search → CR0505 →
More information
Status indication three-colour LED (R/G/B)
Operating states (Status-LED)
LED colour Status Description
– off no operating voltage
yellow 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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ClassicController CR0505
7.2 Test standards and regulations

Test standards and regulations

Climatic test Damp heat to EN 60068-2-30, test Db

(≤ 95% rel. humidity, non-condensing)
Salt mist test to EN 60068-2-52, test Kb, severity level 3 Degree
of protection to EN 60529
Mechanical resistance Vibration to EN 60068-2-6, test Fc Shock
to EN 60068-2-27, test Ea
Immunity to conducted interference to ISO 7637-2, pulses 2, 3a, 3b, severity level 4, function state A 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
EN 61000-6-2 (CE)
Interference emission according to UN/ECE-R10 (E1 type approval) and
EN 61000-6-3 (CE)
Tests for the approval to BN 411 002 (DIN EN 50155 clause 10.2)
for railway applications

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 ClassicController CR0505
7.3 Input characteristics

UK

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ClassicController CR0505
7.4 Output characteristics

Ω
■

Ω
Ω

≥
≤

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 ClassicController CR0505
7.5 Wiring
ANSCHLUSSBELEGUNG / wiring / branchement
Pin Potential Bezeichnung / description Bemerkung / note

23 VBB S (10...32 V DC) Versorgung Sensoren und Modul / supply sensors and module

05 VBB O (10...32 V DC) Versorgung Ausgänge / supply outputs relaisgeschaltet / relay switched (1)
34 VBB R (10...32 V DC) Versorgung über Relais / supply via relay relaisgeschaltet / relay switched (2)
01 GND S Masse Sensoren und Modul / ground sensors and module

15 GNDO Masse Ausgänge / ground outputs UK

12 GNDA Masse Analogeingänge / ground analogue outputs

CAN, RS-232, ERROR, TEST

14 CAN1 H CAN-Interface 1 (High)

32 CAN1 L CAN-Interface 1 (Low)

26 CAN2 H CAN-Interface 2 (High) SAE J 1939

25 CAN2 L CAN-Interface 2 (Low) SAE J 1939
33 GND Masse / ground (RS-232/CAN)

06 RxD RS-232 Interface (Programmierung / programming) Pin 03, PC D-Sub (9 pin)

07 TxD RS-232 Interface (Programmierung / programming) Pin 02, PC D-Sub (9 pin)
13 ERROR Fehlerausgang B H / error output BH

Pin Potential Bezeichnung / description Bemerkung / note

24 TEST TEST-Eingang / test input

EIN-/AUSGÄNGE / inputs/outputs / entrées/sorties
Pin EINGÄNGE Konfiguration AUSGÄNGE Konfiguration diagnosefähig* relaisgeschaltet pin INPUTS configuration OUTPUTS configuration diagnostic
capability* relay switched
INPUT / OUTPUT

08 %IX0.00 / %IW03 BL A – – • / –

27 %IX0.01 / %IW04 BL A – – • / –

09 %IX0.02 / %IW05 BL A – – • / –

28 %IX0.03 / %IW06 BL A – – • / –

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ClassicController CR0505
10 %IX0.04 / %IW07 BL A – – • / –

29 %IX0.05 / %IW08 BL A – – • / –

11 %IX0.06 / %IW09 BL A – – • / –

30 %IX0.07 / %IW10 BL A – – • / –

44 %IX0.08 BL %QX0.00 BH PWM PWM I – / • VBB O (1)

45 %IX0.09 BL %QX0.01 BH PWM PWM I – / • VBB O (1)

46 %IX0.10 BL %QX0.02 BH PWM PWM I – / • VBB O (1)

47 %IX0.11 BL %QX0.03 BH PWM PWM I – / • VBB O (1)

20 %IX0.12 BL I (FRQ0) – – • / –
L

02 %IX0.13 BL I (FRQ1) – – • / –
L

21 %IX0.14 BL I (FRQ2) – – • / –
L

38 %IX0.15 BL I (FRQ3) – – • / –
L

36 %IX1.00 BL %QX0.04 BH PWM PWM I – / • VBB R (2)

54 %IX1.01 BL %QX0.05 BH PWM PWM I – / • VBB R (2)

17 %IX1.02 BL %QX0.06 BH PWM PWM I – / • VBB R (2)

53 %IX1.03 BL %QX0.07 BH PWM PWM I – / • VBB R (2)

19 %IX1.04 B L/H I L (CYL0) – – • / –

55 %IX1.05 B L/H I L (CYL1) – – • / –

18 %IX1.06 B L/H I L (CYL2) – – • / –

37 %IX1.07 B L/H I L (CYL3) – – • / –

Note the double pin connection of inputs/outputs. *) only positive sensor signals with diagnostic capability

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8 Maintenance, repair and disposal
The device 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 → CR0505 → More information

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