Hirschmann cSCALE Mobile Machinery Modular Controller

Hirschmann cSCALE Mobile Machinery Modular Controller

Product positioning and core application scenarios

Applicable Devices

Non road engineering machinery, agricultural machinery, lifting equipment, material handling vehicles, and special mobile equipment; The equipment is subjected to harsh working conditions such as vibration, dust, water vapor, high and low temperatures, and strong electromagnetic interference for a long time.

Core product advantages

Scalable modular architecture, allowing for free construction of both centralized and distributed control architectures;

Double protection level selection: cabinet IP20, whole machine outdoor IP66/IP67;

Unified wide temperature specifications: Standard -30~+70 ℃, optional -40~+70 ℃; Strong resistance to impact and vibration, with EMC higher than industry standards;

High performance hardware platform, some models integrate hardware FPU floating-point operations;

Multi language programming: CoDeSys2.3/3.5 (IEC61131-3), C/C++;

Rich in vehicle industrial buses: Ethernet, multi-channel CAN/CANopen Safety, J1939, USB;

Complete security solution: T Ü V certified SIL2/PL d Cat.2, supporting redundant systems;

Intelligent IO comes with comprehensive diagnosis and supports hydraulic PWM proportional valve, NAMUR sensor, and 0~100mA pump control dedicated analog output.

Division of Four Core CPU Whole Machine Series

1. cSCALE I2 integrated HMI controller (compact all-in-one machine)

Positioning small mobile devices, PLC+4.3-inch color TFT human-machine interface integrated, no additional HMI required;

Hardware: 532MHz 32-bit CPU, 0.5GB Flash, 256MB memory; 480 × 272 display screen; Built in buzzer;

Interface: M12 10/100 Ethernet, dual CAN (CANopen/J1939), USB;

IP66 protection, power supply of 8-36VDC, supports both embedded and external installations;

Networking: Expand distributed DIO remote IO modules through CANopen;

Programming: CoDeSys 3.5, HMI and control program run on the same device, with no network latency for data exchange.

2. cSCALE S6 Safety Controller (TrueSafety SIL2 Certification)

The product line is divided into IP20 cabinet models and IP66/67 outdoor models, with built-in independent safety CPU and a complete set of T Ü V certification for software and hardware. The safety logic runs on the same machine as ordinary applications.

Core hardware: 500MHz 32-bit CPU, 48MB Flash, 128MB RAM, 2MB battery backup RAM;

Safety qualification: Complies with EN 13849 PL d Cat. 2, IEC 62061 SIL 2, and meets the 2006/42 Machinery Directive;

Standard safety hardware: two series connected safety cut-off relays with self diagnostic safety IO;

Interface configuration differentiation

IP20 model: 2-channel Ethernet, 1-channel CAN, USB, local SYS expansion bus; Basic 16 point IO, expandable local IO;

IP66 standard version: 2 Ethernet, 3 independent CAN, USB, maximum 28 basic IO points;

IP66 expansion version: The local expansion bus can be expanded to 100+IO; the IP20 expansion version has a maximum of 168 points;

IO type: DI with short circuit/disconnection diagnosis, high-speed counting HSC input, 4-20mA/0-10V analog, multi specification PWM current control output, NAMUR dedicated input.

3. cSCALE C8 high-end high-performance controller

Positioning large and complex construction machinery, 1GHz single core CPU, integrated hardware floating-point arithmetic unit FPU;

Storage: 2GB large capacity Flash, 128MB RAM, 512kB FRAM battery free power-off storage;

Interface: Dual Ethernet, multi-channel independent CAN, USB, supporting massive program and log storage;

Programming: CoDeSys3.5 or C/C++, with computational performance that meets complex motion and hydraulic closed-loop algorithms;

No native integrated secure CPU, but the hardware architecture supports PL d secure IO expansion.

4. cSCALE 12 Basic Universal Controller

Basic modular PLC, no integrated HMI, external independent display screen, universal mid to low end mobile device control, basic 32-bit CPU platform, standardized IO base expansion.

Modular hardware system (CPU/power sled/IO expansion module)

1 Power Base Module

The whole machine is powered by DC 8~48V, and the safety model is dedicated to 6~33V; Class III power supply specifications:

Type A: Built in basic power supply only;

Type B: Comes with 8.2V/500mA NAMUR sensor power supply;

Type C: Comes with 12V/500mA CAN bus power supply;

General protection: reverse withstand voltage 100V, short circuit protection, active overvoltage filtering, dual circuit series safety cut-off relay; Panel power/operation/fault/safety status diagnostic LED;

There are two shell specifications: IP20 indoor cabinet and IP66/67 outdoor. The base comes with basic IO.

2 Standardized IO Expansion Modules (IP20/IP66 Dual Series)

All IO supports hardware level fault self diagnosis (ground short circuit, power short circuit, disconnection), and safety IO meets PL and dual channel detection;

Digital input DI

Standard DI; DI-DIAG diagnostic type; DI-HSC high-speed counting; DI-NAMUR explosion-proof sensor dedicated input.

Simulate input AI

4~20mA standard current, switchable between 0~10V voltage, some models support 0~36V wide voltage analog acquisition.

Digital output DO

1A standard switch output; 2A/4A with current closed-loop PWM output, can directly drive hydraulic proportional valve, PWM frequency adjustable from 50~400Hz; All use PROFET high-voltage protection chips, with built-in overcurrent, overheating, and TVS lightning protection.

safe output

Two series safety cut-off relays are used for emergency stop and hydraulic safety circuits. In case of a fault, the hardware forcibly cuts off the load.

Expansion bus SYS Ext

Local high-speed expansion bus, single host can connect multiple IO modules externally, with a maximum IO total of over 300 points per machine.

3 Communication Expansion Modules

CAN expansion card: can expand up to 6 independent CAN channels, supporting CANopen, CANopen Safety, J1939 vehicle protocols, and the safety CAN channel has passed T Ü V SIL2 certification;

Ethernet: Dual 10/100M TCP/IP, supporting SCADA, remote program download, and multi unit network;

USB 2.0: USB flash drive program upgrade, data log storage, local debugging;

The overall interface of the machine adopts M12 industrial aviation plug, which is compatible with the vibration environment of the vehicle.

Core Security Control Solution (cSCALE S6 TrueSafety)

Compliance standards: EN ISO 13849 PL d Category 2, IEC 62061 SIL 2, EU Machinery Directive 2006/42/EC;

Hardware security architecture: The independent security CPU is isolated from the application CPU, and each IO board comes with an independent hardware watchdog. Single point of failure and single channel cutoff do not affect the rest of the machine's control;

3 IO dual channel self-test: Safety DI/DO adopts a dual channel circuit to detect real-time disconnection, short circuit, and single channel failure;

4 Redundancy Support: Hardware supports dual machine hot standby redundancy architecture, automatic fault switching;

5 Supporting Engineering Services: The manufacturer provides SISTEMA security calculation, security function block library, T Ü V whole machine certification assistance, and security program development support;

6. Security program development: CoDeSys standard security programming language (ST/FUP/KOP, etc.), independent scheduling of security tasks, ensuring no delay in execution.

Programming software and storage system

Dual programming system:

CoDeSys 2.3/3.5 (compatible with all series of controllers, unified software platform, program cross machine reuse);

C/C++high-level language, suitable for complex motion and algorithm development;

storage medium

Flash：0.5GB~2GB， Store programs, fault logs, and device parameters;

FRAM battery free storage: permanently saves critical data upon power failure; Battery buffer RAM is used for runtime caching;

3 Program Upgrade: Offline USB flash drive update, Ethernet remote download, no need for professional debugging equipment.

Three mainstream system topology architectures

Centralized single controller architecture

A host paired with local expansion IO is suitable for small and medium-sized devices, with simple wiring and low cost.

Distributed CANopen architecture

Main controller+multiple remote DIO distributed IO modules, sensors/actuators are wired nearby to reduce vehicle long cables and minimize EM interference, making it a mainstream solution for large construction machinery.

Multi machine Ethernet distributed architecture

Multiple cSCALE controllers are interconnected via Ethernet, allowing for independent control of large complete equipment units and coordinated linkage of the entire machine, supporting redundant control systems in multiple areas.

Key environmental, mechanical, and electrical parameters

Temperature range: standard -30 ℃~+70 ℃, wide temperature selection -40 ℃~+70 ℃; Storage -40~+85 ℃;

2 Protection: IP20 (inside the control cabinet), IP66/IP67 (outdoors, waterproof, dustproof, and oil proof);

3. Power supply: General 8-48VDC on-board DC, safe models 6-33VDC;

4. Environmental resistance: Complies with the on-board ISO 7637 power interference and strong vibration impact standards;

5. Mechanical installation: IP66 models support two installation methods: panel embedded/external installation; IP20 standard DIN rail installation.