CR711S - Industrial Automation IFM - Free user manual and instructions

USER MANUAL CR711S IFM

Original operating instructions ecomat
Controller

CR710S

CR711S

HW version: V1.0.4.x

Contents

1 Preliminary note 3

1.1 Manufacturer's address.... 3
1.2 Symbols used 3
1.3 Warnings.... 3
1.4 Safety symbol on the device 4

2 Safety instructions.... 5

3 Intended use.... 6

3.1 Distinctive features 6
3.2 Predictive incorrect use.... 7

4 Items supplied.... 8

4.1 Scope of delivery ecomat
Controller.... 8
4.2 Download software 8
4.3 Accessories....8

5 Installation.... 9

5.1 Installation location 9
5.2 Mounting surface 9
5.3 Heat dissipation 10
5.4 Installation position 10
5.5 Fastening 10

6 Electrical connection.... 11

6.1 M12 connector 11
6.2 81-pole AMP connector.... 12
6.3 Wiring 12
6.4 Shield connection 16
6.5 Fuses 16
6.6 Laying of the supply and signal cables 17

6.6.1 GND connections 18

6.7 Analogue inputs 18
6.8 Resistor inputs 20
6.9 High-side digital inputs (CSO) 21
6.10 Analogue outputs 21
6.11 Digital / PWM outputs 22
6.12 Digital / PWM outputs, H-bridge 23
6.13 Mixed operation (12 V / 24 V) 23

7 Set-up 25

7.1 Interfaces and system requirements 25
7.2 Required documentation.... 25

8 Maintenance, repair and disposal 26

1 Preliminary note

You will find instructions, technical data, approvals and further information using the QR code on the unit / packaging or at documentation.ifm.com.

1.1 Manufacturer's address

ifm electronic gmbh

Friedrichstraße 1

45128 Essen

Germany

www.ifm.com

[e-mail]

1.2 Symbols used

√ Requirement

Instructions

Reaction, result

[...] Designation of keys, buttons or indications

→ Cross-reference

Important note

Non-compliance may result in malfunction or interference.

Information

Supplementary note

1.3 Warnings

Warnings indicate the possibility of personal injury and damage to property. This enables safe product handling. Warnings are graded as follows:

WARNING

Warning of serious personal injury

▷ If the warning is not observed, fatal and serious injuries are possible.

CAUTION

Warning of minor to moderate personal injury

▷ If the warning is not observed, minor to moderate injuries are possible.

ATTENTION

Warning of damage to property

▷ If the warning is not observed, damage to property is possible.

1.4 Safety symbol on the device

Safety symbol on the device:

▶ Adhere to the operating instructions for the safe operation of the unit.

2 Safety instructions

• The unit described is a subcomponent for integration into a system.
• ▶ The system architect is responsible for the safety of the system.
• The system architect undertakes to perform a risk assessment and to create documentation in accordance with legal and normative requirements to be provided to the operator and user of the system. This documentation must contain all necessary information and safety instructions for the operator, the user and, if applicable, for any service personnel authorised by the architect of the system.
• Read this document before setting up the product and keep it during the entire service life.
• The product must be suitable for the corresponding applications and environmental conditions without any restrictions.
• Only use the product for its intended purpose (→ Intended use).
• If the operating instructions or the technical data are not adhered to, personal injury and/or damage to property may occur.
• The manufacturer assumes no liability or warranty for any consequences caused by tampering with the product or incorrect use by the operator.
  • Installation, electrical connection, set-up, programming, configuration, operation and maintenance of the product must be carried out by personnel qualified and authorised for the respective activity.
• Protect units and cables against damage.
• Replace damaged units, otherwise the technical data and safety will be impaired.
• Observe applicable documents.
• Store the device in its original packaging.
• When the device is to be stored again, preferably use the original packaging.
• Otherwise, provide unused connections with either a mating connector or a protective cap and pack the device in suitable packaging.
• When storing, observe the device's protection rating / pollution degree ( → Technical data).

ATTENTION

Excessive current, weld slag and soiling due to welding

▷ Damage to the device, deterioration of the electrical safety
▶ Welding work on the chassis frame must only be carried out by qualified personnel.
▶ Remove and cover the plus and minus terminals of the batteries.
▶ Disconnect all contacts of the device from the on-board system prior to welding on the vehicle or machine.
▶ Connect the earth terminal of the welding device directly to the part to be welded.
▶ Do not touch the device or electric cables with the welding electrode or the earth terminal of the welding device.
▶ Protect the device incl. all connectors and all connection cables against weld slag and soiling.

3 Intended use

The freely programmable controllers of the "ecomat
Controller" series are rated for use under difficult conditions: This includes an extended temperature range, strong vibration, intensive EMC interferences and wet environments.

Permitted use:

• In mobile machines, with supply from on-board systems (with battery) of 12 V DC or 24 V DC nominal voltage
• In an industrial environment as a permanently installed device with supply from PELV according to the technical data

This is a class A product. This product may cause radio interference in domestic areas.

▶ If required, take appropriate EMC screening measures.

- Two separately programmable PLCs:

– Safety PLC for safety-relevant applications up to SIL 2 with certified software
– Standard PLC for standard applications
- CODESYS V3.5 programming system (in a version approved by ifm) for both controllers.
- The safe controller requires a safety SIL 2 extension for CODESYS.

- For applications operating according to the closed-circuit current principle. The following applies to the safety functions that can be implemented: safe state = power-free state (voltage at the output < 2 V and current at the output < 25 mA).

- For a suitable time interval for the execution of the self-test of the controller, refer to the safety concept or the applicable product standards of the application. If no value can be determined, it is strongly recommended to restart the device after 7 days at the latest (see programming manual).

- The operating mode of the inputs and outputs and their use can be configured via a PLC, for example current, voltage or frequency input; PWM or digital output.

- Sensors and actuators can be connected either as single or dual channel (depending on the required input or output type).

- Connection of sensors or actuators via CAN interfaces. Connection to other controllers via CAN. Implementation of safe communication via CANopen Safety.

- Only use the device within the limits of the technical data: → Technical data.

- Mounting location: → Installation location

By default, the device is not intended for direct connection to IT systems. If this application is required, the user has to implement it (e.g. by using their own additional components).

Please observe the following document: "Operating instructions (supplement) - Cyber Security" via documentation.ifm.com

3.1 Distinctive features

These instructions refer to the derivatives CR710S and CR711S of the "ecomat
Controller" series. The devices differ in the following features:

Feature	CR710S	CR711S
Number of inputs	20	32
Number of outputs	17	28
Number of output groups	2 (supplied via VBB0...1)	3 (supplied via VBB0...2)

3.2 Predictive incorrect use

• Continuous operation 24/7 is not permitted.
- No use in safe applications for which the safe state is not the power-free state.
- Do not carry out safety functions on the standard PLC.
- Do not use the controller in an insufficiently protected network environment together with other network-compatible devices.
- Do no update a safety controller with standard software (firmware).
• No installation on the motor/engine.
• No use in an environment with ionising radiation.

4 Items supplied

4.1 Scope of delivery ecomat
Controller

• 1 ecomat
  Controller
  • 1 screw for the shield connection
  • 4 protective covers
• 1 package insert “Product information and safety instructions” with QR code to the website documentation.ifm.com
  • CE declaration of conformity
  ▶ In the event of incomplete or damaged items supplied, please contact ifm.

4.2 Download software

Documentation and software (device firmware and programming environment) at documentation.ifm.com and in the software package.

▶ Check online for the latest version.

4.3 Accessories

Information about available accessories at www.ifm.com

5 Installation

5.1 Installation location

The system architect is responsible for the stability of the mounting surface and fastening at the installation location. The weight of the device, environmental conditions of the application and local regulations must be taken into account.

The following installation locations are permitted for mobile use:

• Inside of the cabin
• Body
• Vehicle frame

Installation on the motor/engine is not permitted.

The applicable regulations must be complied with, taking into account the specified environmental conditions.

Environmental conditions: → Technical data

▶ Take the protection rating and pollution degree into account.
The system architect is responsible for protecting the device in the application if the required protection rating or pollution degree for the device is not met.

5.2 Mounting surface

The housing must not be exposed to any torsional forces or mechanical stress.

▶ Use suitable compensating elements if there is no flat mounting surface available.

Fig. 1: Mounting surface

▶ During installation and storage, ensure that the pollution degree is 2 or better (IEC 60664-1).

5.3 Heat dissipation

CAUTION

The housing can heat up considerably.

▷ Risk of burns
▶ During installation, ensure sufficient heat dissipation.
▶ Measure maximum device heating in the application. The maximum housing temperature indicated in the data sheet must not be exceeded.
▷ If housing temperatures presenting a danger to people are reached:
▶ Cover housing to prevent unintentional contact.
▶ Apply warning for hot surfaces visibly on the device.

▶ Observe the parameters and specifications for temperature, altitude above sea level and frequency of the outputs specified in the technical data.

5.4 Installation position

In wet environments, install the controller ensuring that no liquid remains on the connectors.

The installation position is defined by the 90° angled cable entry. The cable entries must be oriented vertically downwards to prevent moisture ingress. If this is not possible then an orientation between horizontal and vertically down is allowed.

5.5 Fastening

Fix the controller to a flat surface using 4 zinc-plated M6 screws.

Tightening torque: 10 ±2 Nm

Fig. 2: Installation

Fig. 3: Total height with the attached connector

ATTENTION

Contact corrosion between the mounting screws and the housing

▷ Damage to the device
▶ Do not use stainless steel, copper or nickel-plated materials for the bolting elements.
▶ Use zinc-plated screws.
▶ In very corrosive environments such as extremely salty air, use screws with surface finishing on a zinc/nickel basis with thick-film passivation and sealing.

6 Electrical connection

▶ Disconnect the machine from the mains supply before installation; if necessary, also disconnect any independently supplied input / output load circuits.
▶ Observe the national and international regulations for the installation of electrical equipment.
▶ Observe the requirements according to EN 60204.

The circuit is insulated from device surfaces that could be touched with basic insulation according to IEC 61010-1 (secondary circuit with max. 32 V DC, supplied from the mains circuit up to 300 V of overvoltage category II).

The external wiring has to be carried out in a way that ensures the required separation from other circuits.

GND of the supply is connected via EMC suppression capacitors on the shield connection (metal housing) of the device.

The Ethernet interface is separated from device surfaces that could be touched and from the electric circuit with basic insulation according to EN61010-1 (secondary circuit with max. 32 V DC, supplied from the mains circuit up to 300 V of overvoltage category II).

The connection terminals may only be supplied with the signals indicated in the technical data / on the device label and only the approved accessories from ifm may be connected.

ATTENTION

Absence of reverse polarity protection

▷ Reverse polarity protection is only ensured in case of supply via the on-board system (via a battery), if the polarity of the supply is reversed as a whole (battery connected incorrectly). The basic principle of the reverse polarity protection is that the upstream fuses are quickly switched off in case of excessive current. In case of supply via PELV, reverse polarity protection is not ensured.
▷ Damage to the device
▶ Ensure that the ends of the cables are properly connected to the connector before connecting the latter to the device, also in case of supply via the on-board system.

The device is designed for supply via a mobile on-board system (12/24 V DC nominal voltage) or protective low voltage PELV according to the technical data and national regulations. The supply is directly transferred to the connected sensors/actuators without electrical separation.

Observe all notes on connection technology.

▶ Use twisted-pair cables for CAN connections.
▶ For the Ethernet connection, use a minimum category 5 (Cat 5) cable.

The RS-232 interface serves only as a service interface (e.g. for firmware updates).

▶ Provide all outgoing cables with a strain relief 200 mm behind the cable entry.

6.1 M12 connector

The threaded connections in the device correspond to the M12 standard. To ensure compliance with the specified protection rating, only cables that comply with this standard may be used. In the case of self-assembled cables, the system manufacturer is responsible for the protection rating.

▶ Use connectors with gold-plated contacts.
▶ During installation, place the connectors vertically so that the coupling nut will not damage the thread.
▶ Observe the coding of the connectors during installation.

▶ Tighten the cable plug using 1.3 ± 0.1 Nm.
▶ Cover unused connections with protective covers. Tightening torque: 1.3 ± 0.1 Nm

6.2 81-pole AMP connector

Only connect the 81-pole AMP connectors when the supply voltage is disconnected. "Hot plugging" is not permitted.
Only connect those connector pins of the 81-pole AMP connector that are shown in the pin layout. Unspecified connector pins remain unconnected. The unconnected connector pins need to have sealing of the individual cores.
▶ Use 81-pole AMP connectors with individually sealed cores to ensure protection rating IP67.
The ingress resistance of cables that users have cut to length must be guaranteed.
▶ Consider the requirements of the application when selecting the cable (e.g. current, temperature, mechanical requirements).

6.3 Wiring

Fig. 4: Connectors

CAN0
M12 socket, 5 poles, A-coded
1: not used	1 25 4 3
2: not used
3: GND_COM
4: CAN0_H
5: CAN0_L

CAN1 + RS-232
M12 socket, 5 poles, A-coded
1: RS-232_TxD	1 25 4 3
2: RS-232_RxD
3: GND_COM
4: CAN0_H
5: CAN0_L
ETH0 / ETH1
M12 socket, 4 poles, D-coded
1: TxD+
2: RxD+
3: TxD-
4: RxD-

ST A
AMP connector, 81 poles, A-coded
1-81: see wiring diagram ST A

Fig. 5: Wiring diagram ST A (CR710S)

A:	Analogue	BL :	Binary, low side (CSI)
BH :	Binary, high side (CSO)	BL/H :	Binary, configurable, low side (CSI) / high side (CSO)
FRQL/H :	Frequency/pulse input, configurable, low side (CSI) / high side (CSO)	H:	H-bridge function
PSU:	Voltage supply for the system	PWML :	Pulse width modulation, low side (CSI)
PWMH :	Pulse width modulation, high side (CSO)	PWML/H :	Pulse width modulation, configurable, low side (CSI) / high side (CSO)
PWMI :	Pulse width modulation, current-controlled	R:	Resistor input
VBB0/1 :	Output group supply	VBB30 :	Controller supply

Fig. 6: Wiring diagram ST A (CR711S)

A:	Analogue	BL :	Binary, low side (CSI)
BH :	Binary, high side (CSO)	BL/H :	Binary, configurable, low side (CSI) / high side (CSO)
FRQL/H :	Frequency/pulse input, configurable, low side (CSI) / high side (CSO)	H:	H-bridge function
PSU:	Voltage supply for the system	PWML :	Pulse width modulation, low side (CSI)
PWMH :	Pulse width modulation, high side (CSO)	PWML/H :	Pulse width modulation, configurable, low side (CSI) / high side (CSO)
PWMI :	Pulse width modulation, current-controlled	R:	Resistor input
VBB0...2 :	Output group supply	VBB30 :	Controller supply

6.4 Shield connection

1: Holes for shield connection

To ensure the protection of the device against electrical interference and to ensure the safe function of the device, the housing has to be connected to the body / GND of the supply using the shortest possible route.

Otherwise the safety function is not ensured!

▶ Connect the device to the ground of the vehicle / GND of the supply using the M4 self-tapping screw (included).
▶ Establish an EMC-compliant connection with low connection impedance.

Only use the supplied screw for the shield connection on the device to avoid corrosion. Tightening torque: 3.0 ± 0.2 Nm

To avoid contact corrosion on the shield connection of the device, do not use any stainless steel, copper or nickel-plated materials for the bolting element!

6.5 Fuses

▶ The individual electric circuits must be protected in order to protect the whole system. Automotive spade-type fuses are recommended.

Connection	Nominal value fuse	Required triggering characteristics
VBB15	2 A	Tfuse ≤ 120 s at max. 6.25 A
VBB30	2 A	Tfuse ≤ 120 s at max. 6.25 A
VBB0	15 A	-
VBB1	≤ 15 A	-
VBB2 (only with CR711S)	≤ 15 A	-
Inputs / input groups	2 A	Tfuse ≤ 120 s at max. 6.25 A

All supply lines of the inputs can be protected within the input groups.

6.6 Laying of the supply and signal cables

Fig. 7: Connection of the supply and signal cables (X = not permitted), example CR711S
1: GND star point

Bridging of connections in the connectors is not permitted.

RESET-COM is a service input (see programming manual).

▶ For the operation of the controller, connect RESET-COM to the GND star point ①.

Faulty laying of the supply and signal cables

▷ Deterioration of EMC may occur
▶ Lay supply and signal cables separately, take EMC / application into account
▶ 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.

Provide the unconnected signal inputs with sealing of the individual cores. Unconnected cores or core loops are not permitted.

In case of signal failures, operate inputs with shielded cables. Connect the shields to the shield connection on one side.

WARNING

Overvoltage > 36 V (unprotected)

▷ Risk of personal injuries and/or damage to property.
▷ Uncontrollable and unpredictable dangerous behaviour of the controller, e.g. all outputs activated.
▶ Provide external protection against overvoltage.

WARNING

Load dump and surge

▷ Destruction of the device or deterioration of the safety function
▶ Always connect VBB ₀ .

The CAN bus is internally protected against short circuit to VBB and GND.

For CAN cables ≥ 30 m, ensure appropriate protection against surge (e. g. shielded cables).

6.6.1 GND connections

▶ Connect all required supply lines, GND connections and the shield connection.
▶ Connect the GND connections of the sensors of the high-side digital inputs (CSO) and the actuators (loads) to the common GND star point.

WARNING

Wrong connection of the GND connections

▷ Loss of the safety function, the measurement accuracy and EMC possible
▶ Connect the GND_1...2 and GND_SYS connections individually to the common GND star point.
▶ Do not connect the GND ANA , GND RES , GND _OVA and GND_COM connections to the common GND star point, but to the GND of the signal source or of the connected device.

All GND connections are connected to each other in the device.

6.7 Analogue inputs

Abbreviation	Input / output type
A	Analogue
BH	Binary high side (CSO)
BL	Binary low side (CSI)
FRQL/H	Frequency/pulse inputs configurable low side (CSI) / high side (CSO)
PWMH	Pulse-width modulation high side (CSO)
PWML	Pulse-width modulation low side (CSI)
PWMI	Pulse-width modulation current-controlled
R	Resistor input
VBB0...2	Supply output group
VBB30	Supply controller

Fig. 8: Connection of the analogue inputs (A), example CR711S

▶ Connect GND _ANA to the GND of the signal source.

Do not connect GND_ANA to other GND connections or to the common GND star point.

6.8 Resistor inputs

Fig. 9: Connection of the resistor inputs (R), example CR711S

▶ Connect GND _RES to the GND of the signal source.

Do not connect GND_RES to other GND connections or to the common GND star point.

Do not connect the resistor inputs to a VBB.

6.9 High-side digital inputs (CSO)

Fig. 10: Connection of the high-side inputs ( B_H , FRQ_H ), example CR711S

▶ Connect the GND of the signal source to the common GND star point. Do not connect the GND of the signal source to GND_RES or GND_ANA .

6.10 Analogue outputs

Fig. 11: Connection of the analogue outputs (A), example CR711S

The controller can be connected to the following loads:

- resistive loads

The connected load must not exceed the maximum permissible values of the respective output ( → Technical data).

▶ Connect the GND of the load to GND_OVA .

Do not connect GND of the load to other GND connections or to the common GND star point.

Deviating connections are not permitted.

6.11 Digital / PWM outputs

Fig. 12: Connection of the high-side digital outputs (PWM H , B H ), example CR711S
1: GND star point

WARNING

• Interruption of all GND power supply connections and simultaneously
• loads at the outputs connected to GND

This may cause fault currents to flow through the controller and load which lead to an undefined state of the controller and the system.

▷ Loss of the safety function
▶ Always connect the ground lead of the controller and the loads (actuators) via the common GND star point ① (see image above).
▷ This ensures that in case the line to the battery is interrupted, the loads are no longer connected to GND, either.

The controller can be connected to the following loads:

- resistive loads

• capacitive loads (adapt diagnostic settings to the load, see programming manual)
• inductive loads

The connected load must not exceed the maximum permissible values of the respective output ( → Technical data).

Deviating connections are not permitted.

6.12 Digital / PWM outputs, H-bridge

Fig. 13: Connection of the low-side digital outputs (PWM L , B L ), example CR711S

The controller can be connected to the following loads:

• resistive loads
• capacitive loads (adapt diagnostic settings to the load, see programming manual)
• inductive loads

The connected load must not exceed the maximum permissible values of the respective output ( → Technical data).

▶ Supply low-side outputs ( B_L ) via a high-side output ( B_H ) of the same output group.

Deviating connections are not permitted.

6.13 Mixed operation (12 V / 24 V)

In case of supply via PELV, mixed operation is not permitted.

Mixed operation is only permitted in case of supply via the on-board system.

Fig. 14: Example connection to 24 V and 12 V power supply combined, example CR711S

The operation of the output groups is possible with different supply voltages.

▶ VBB₀ , VBB₃₀ and VBB₁₅ must be connected to the common star point.

7 Set-up

7.1 Interfaces and system requirements

The users are responsible for the safe function of the application programs which they created themselves. If necessary, they must additionally carry out an approval by corresponding supervisory and test organisations according to the national regulations.

The programmer creates the application program with the IEC 61131-3 compliant CODESYS programming system and loads the applications via the Ethernet, RS-232 or CAN interface to the controller. For the required information about installation and set-up, see the programming manual.

Required components:

• Suitable CODESYS version (→ Programming manual)
  • CODESYS plug-ins
  • CODESYS package for the controller
• Firmware (note: check firmware version!)
• Release notes

To program the controller, the persons should be familiar with the CODESYS software and the CODESYS Safety SIL 2 extension.

Moreover, they should be familiar with the following topics:

• Requirements on safety-related programming
  • Required user-specific standards

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 for the firmware version used
• Operating instructions (supplement) - Cyber security

Documentation and software (device firmware and programming environment) at documentation.ifm.com and in the software package.

▶ Check online for the latest version.

CODESYS online help: contained in CODESYS installation (documentation.ifm.com).

8 Maintenance, repair and disposal

The unit is maintenance-free.

▶ Contact ifm in case of malfunction.

It is not possible to repair the device.

Delete all data before disposing of or returning the device:

▶ If necessary, create a data backup before deleting: Backup and restore
▶ Delete all passwords on the device, e.g. by resetting to factory settings (Factory Reset).
▶ Delete all programs and user data on the device, e.g. by resetting to factory settings (Factory Reset).

Disposal:

▶ After use, dispose of the unit in an environmentally friendly way in accordance with the applicable national regulations.

Cleaning the unit:

▶ Disconnect the unit from the voltage supply.
▶ Clean the unit from dirt using a soft, chemically untreated and dry micro-fibre cloth.