BERGHOF DC1000 User manual

USER MANUAL 1.10
DC1000 Dialog-Controller
Basic, Prime, Compact, Clean

Copyright © Berghof Automation GmbH
Reproduction and duplication of this document and utilisation and communication of its content is
prohibited, unless with our express permission. All rights reserved. Damages will be payable in case of in-
fringement.
Disclaimer
The content of this publication was checked for compliance with the hardware and software described. How-
ever, discrepancies may arise, therefore no liability is assumed regarding complete compliance. The infor-
mation in this document will be checked regularly and all necessary corrections will be included in subse-
quent editions. Suggestions for improvements are always welcome.
Subject to technical changes.
Trademarks
CANtrol®and CANtrol®- dialog are registered trademarks of Berghof Automation GmbH
Microsoft®, Windows®and the Windows®Logo are registered trademarks of Microsoft Corporation in
the USA and other countries.
EtherCAT®is a registered trademark and patented technology, licensed from Beckhoff Automation
GmbH, Germany.
CiA®and CANopen®are registered community trademarks of CAN in Automation e.V.
All rights reserved by the individual copyright holders.
General Information on this Manual
This equipment manual contains product-specific information valid at the time of publication.
This equipment manual is only complete in conjunction with the product-related hardware and software user
manuals required for the individual application.
You can reach us at:
Berghof Automation GmbH
Harretstr. 1
72800 Eningen
Germany
T +49.7121.894-0
F +49.7121.894-100
e-mail: [email protected]
www.berghof.com
Berghof Automation GmbH works in accordance with DIN EN ISO 9001:2000.
Content
Completeness

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Update
Version
Date
Subject
1.1
22.09.2006
First version
1.2
Inexistent
1.3
31.05.2007
Dimensions updated under “Technical specifications” and in the graphs.
Plug/unplug cycles added to the “USB pin assignment” section of the “Tech-
nical specifications”. Description, “Chemical resistance for touch screens
and I/O-Modules” included.
Notice to “SD-card reader” included. Update under “Power supply - internal
power pack”, “Profibus master card” and “Profibus slave card”.
1.4
23.09.2009
General revision.
New chapter: “Copyright and software licenses”.
1.5
28.10.2009
Supplement of technical data for DC 1005, 1010 and 1012.
Update of “Service Menu” chapter.
1.6
Inexistent
1.7
07.04.2011
Updates of “Declaration of conformity”, “Chemical resistance” and “Notes on
the copyright and software license”. Description of DC1010 Compact (CP)
and DC1012 Compact (CP) incorporated, XR01 and XR02 extension mod-
ules inserted.
“Battery change” diagram corrected.
Corrections of the DC1010 (CP) “Panel cut-out”, DC1012 “Technical data”
(dimensions), new warning for XR01 and XR02 I/O cards (power supply) in-
tegrated.
1.8
08.11.2012
Update in the “Declaration of conformity” section.
Note on terminating resistors, switches S2+S3 with Profibus Master/Slave
card inserted.
Update of chapter “Annex, Standards / Bibliography”.
Update of the trademarks.
Update in the “DC1010 Compact (CP) panel cutout” section.
1.9
04.09.2013
Transition into new CD.
New corporate name “Berghof Automation GmbH”.
Update of chapter “Extension modules”.
1.10
03.05.2016
New EMC directive.
Correction standards.
Update of chapter “Chemical resistance”.
Update of section “Nameplate”.

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Contents
1. GENERAL............................................................................................................................................9
1.1. About this manual..............................................................................................................................9
1.2. Hazard categories and terminology................................................................................................10
1.3. Qualified personnel..........................................................................................................................11
1.4. Due diligence....................................................................................................................................11
1.5. Basic safety measures.....................................................................................................................12
1.6. Use as prescribed ............................................................................................................................13
1.7. Conformity declaration....................................................................................................................14
1.7.1. Extension modules.............................................................................................................................14
1.8. Transport and setup.........................................................................................................................15
2. PRODUCT DESCRIPTION................................................................................................................17
2.1. Identification.....................................................................................................................................19
2.2. The different versions of the Dialog-Controller.............................................................................20
2.2.1. Interfaces ...........................................................................................................................................20
2.2.2. Front foil sheeting...............................................................................................................................20
2.2.3. Overview of types...............................................................................................................................21
2.2.4. Variable thanks to extension cards.....................................................................................................21
2.3. Dialog-Controller DC1005 / DC1010 / DC1012 construction........................................................22
2.3.1. Block circuit diagram..........................................................................................................................22
2.4. Technical data DC1005 ....................................................................................................................23
2.4.1. DC1005 Front view.............................................................................................................................25
2.4.2. DC1005 Rear view.............................................................................................................................25
2.4.3. DC1005 Dimensions ..........................................................................................................................26
2.4.4. DC1005 Panel cutout.........................................................................................................................27
2.4.5. Mounting regulation DC1005..............................................................................................................27
2.5. Technical data DC1010 ....................................................................................................................28
2.5.1. DC1010 Front view.............................................................................................................................30
2.5.2. DC1010 Rear view.............................................................................................................................30
2.5.3. DC1010 Dimensions ..........................................................................................................................31
2.5.4. DC1010 Panel cutout.........................................................................................................................32
2.5.5. Mounting regulation DC1010..............................................................................................................32
2.6. Technical data DC1010 Compact (CP)............................................................................................33
2.6.1. DC1010 Compact (CP) front view......................................................................................................35
2.6.2. DC1010 Compact (CP) rear view.......................................................................................................35
2.6.3. DC1010 Compact (CP) dimensions ...................................................................................................36
2.6.4. DC1010 Compact (CP) panel cutout..................................................................................................37
2.6.5. Mounting regulation DC1010 Compact (CP)......................................................................................37
2.7. Technical data DC1012 ....................................................................................................................38
2.7.1. DC1012 Front view.............................................................................................................................40
2.7.2. DC1012 Rear view.............................................................................................................................40
2.7.3. DC1012 Dimensions ..........................................................................................................................41
2.7.4. DC1012 Panel cutout.........................................................................................................................42

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2.7.5. Mounting regulation DC1012..............................................................................................................42
2.8. Technical data DC1012 Compact (CP)............................................................................................43
2.8.1. DC1012 Compact (CP) front view......................................................................................................45
2.8.2. DC1012 Compact (CP) rear view.......................................................................................................45
2.8.3. DC1012 Compact (CP) dimensions ...................................................................................................46
2.8.4. DC1012 Compact (CP) panel cutout..................................................................................................47
2.8.5. Mounting regulation DC1012 Compact (CP)......................................................................................47
2.9. Mounting and connection................................................................................................................48
2.9.1. Mounting ............................................................................................................................................48
2.9.2. Connections .......................................................................................................................................48
2.10. Pin assignment.................................................................................................................................49
2.10.1. Pin overview.......................................................................................................................................49
2.10.2. Power supply......................................................................................................................................49
2.10.3. 10/100 Base-T Network Connection (Ethernet)..................................................................................49
2.10.4. USB....................................................................................................................................................50
2.10.5. CAN bus.............................................................................................................................................51
2.10.6. Serial ports.........................................................................................................................................52
2.10.7. E-bus..................................................................................................................................................55
2.10.8. Connections for expansion ports........................................................................................................55
2.11. SD card..............................................................................................................................................56
3. DIALOG-CONTROLLER OPERATION.............................................................................................57
3.1. Commissioning ................................................................................................................................57
3.2. Function selection, indicators, diagnostics...................................................................................57
3.2.1. Status indicators.................................................................................................................................57
3.3. Service menu....................................................................................................................................59
3.3.1. Using the service menu......................................................................................................................60
3.3.2. Parameter window..............................................................................................................................60
“Config” service menu ........................................................................................................................61
“PLC” service menu............................................................................................................................64
“INFO” service menu ..........................................................................................................................65
“Display” service menu.......................................................................................................................66
3.3.3. PLC window .......................................................................................................................................67
3.4. Decommissioning ............................................................................................................................70
3.4.1. Disposal .............................................................................................................................................70
3.5. Maintenance......................................................................................................................................71
3.6. Help in case of problems.................................................................................................................71
4. EXTENSION MODULES....................................................................................................................73
4.1. I/O card with SC-CAN interface.......................................................................................................74
4.1.1. Technical data ....................................................................................................................................75
4.1.2. Pin assignment...................................................................................................................................77
4.1.3. Analog inputs .....................................................................................................................................81
4.1.4. Digital inputs/outputs 12/4/8-0.5.........................................................................................................82
4.1.5. Digital inputs, positive switched..........................................................................................................83
4.1.6. Digital outputs, positive switched........................................................................................................86
4.1.7. Digital input/output pin assignments...................................................................................................89

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4.2. PROFIBUS-MASTER card................................................................................................................91
4.2.1. Technical data ....................................................................................................................................92
4.2.2. Front view and pin assignment...........................................................................................................93
4.3. PROFIBUS-SLAVE card ...................................................................................................................96
4.3.1. Technical data ....................................................................................................................................97
4.3.2. Front view and pin assignment...........................................................................................................98
4.4. PROFIBUS card (Master/Slave functionality)...............................................................................101
4.4.1. Technical data ..................................................................................................................................102
4.4.2. Front view and pin assignment.........................................................................................................103
4.5. I/O XR01 and XR02 cards with analog and digital I/O .................................................................106
4.5.1. Technical data..................................................................................................................................107
4.5.2. Pin assignment.................................................................................................................................108
4.5.3. Power supply....................................................................................................................................108
4.5.4. Plug-in connectors............................................................................................................................109
4.5.5. Installation........................................................................................................................................110
4.5.6. 8/8-0.5 digital inputs/outputs ............................................................................................................110
4.5.7. Terminal assignment of digital inputs/outputs...................................................................................116
4.5.8. Analog inputs/outputs.......................................................................................................................117
5. MAINTENANCE...............................................................................................................................127
5.1. Real-time clock with backup battery ............................................................................................128
5.1.1. Battery replacement.........................................................................................................................129
6. CHEMICAL RESISTANCE ..............................................................................................................131
6.1. Resistance of the touch screen ....................................................................................................131
6.2. Resistance of the AUTOTEX front foil sheeting to chemicals....................................................132
6.2.1. General resistance of the foil sheeting material ...............................................................................132
6.2.2. Resistance to household chemicals.................................................................................................133
6.2.3. Environmental values.......................................................................................................................133
6.3. Resistance of the AUTOFLEX- front foil sheeting to chemicals.................................................134
6.3.1. General resistance of the foil sheeting material ...............................................................................134
6.3.2. Resistance to household chemicals.................................................................................................135
6.3.3. Outdoor use .....................................................................................................................................135
7. COPYRIGHT AND SOFTWARE LICENSES...................................................................................137
8. ANNEX.............................................................................................................................................139
8.1. Environmental Protection..............................................................................................................139
8.1.1. Emission...........................................................................................................................................139
8.1.2. Disposal ...........................................................................................................................................139
8.2. Maintenance/Upkeep......................................................................................................................139
8.3. Repairs/Service ..............................................................................................................................139
8.3.1. Warranty...........................................................................................................................................139
8.4. Nameplate.......................................................................................................................................140
Nameplate descriptions (example)...................................................................................................140
8.5. Addresses and Bibliography.........................................................................................................141
8.5.1. Addresses ........................................................................................................................................141

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8.5.2. Standards/Bibliography....................................................................................................................142

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1. General
Documentation
This equipment manual is intended for qualified personnel and contains information regarding the moun-
ting, installation, commissioning and maintenance of the Dialog Controller. The information contained in
this manual is subject to change without prior notice.
1.1. About this manual
This equipment manual is an integral part of the product. Make sure the equipment manual is always avail-
able near the product’s point-of-employment. The manual contains information about the following topics
Areas of application
Safety
Mechanical construction
Electrical construction
Connections
Commissioning
Care and maintenance
Decommissioning
Disposal

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1.2. Hazard categories and terminology
DANGER
Immediate danger
Failure to observe the information indicated by this warning will result in death,
serious injury or extensive property damage.
WARNING
Potential danger
Failure to observe the information indicated by this warning may result in
death, serious injury or extensive property damage.
CAUTION
Danger
Failure to observe the information indicated by this warning may result in injury
or property damage.
NOTICE
No hazard
Information indicated in this manner provides additional notes concerning the
product.

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1.3. Qualified personnel
Only qualified personnel may install, operate and maintain the Dialog Controller.
Within the context of this documentation and the safety information it contains, qualified personnel consti-
tutes trained specialists who have the authority to mount, install, commission, ground and identify equip-
ment, systems and power circuits in accordance with the standards of safety technology, and who are familiar
with the safety concepts of automation technology.
1.4. Due diligence
The operator or original equipment manufacturer (OEM) must ensure …
that the Dialog Controller is only employed for its intended use.
that the Dialog Controller is only employed in a fault-free, operational state.
that the equipment manual is always maintained in a complete and legible condition and is available at
the point-of-employment of the Dialog Controller.
that only properly qualified and authorized personnel mount, install, commission and maintain the
Dialog Controller.
that these specialists receive regular and ongoing instruction in all pertinent questions related to work
safety and environmental protection and that they are familiar with the contents of the equipment
manual, in particular, with the safety information it contains.
that the equipment identifiers as well as safety and warning information applied to the Dialog Control-
ler are not removed and that they are maintained in a legible condition.
that all international, federal, state and local ordinances governing the control of machinery and
equipment applicable at the location at which the Dialog Controller is employed are complied with.
that the users always have available all relevant information they require with regard to the Dialog
Controller and its employment.

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1.5. Basic safety measures
WARNING
If damage can be seen on the faceplate of the dialog controller, the device
must not be operated any more! It must be disconnected from the supply
voltage immediately!
Besides the danger of injury owing to the visibly sharp edges, there is also the
risk of touching parts under high voltage. Contact with high voltage can still
occur even some time after the supply voltage has been shut off.
HAZARDOUS
VOLTAGE
Working on the DC
Before beginning work on the Dialog Controller you must always
first ensure that the equipment is in a safe state,
then first switch the DC off, followed by the equipment, and
only then disconnect the DC from the equipment.
WARNING
Hazards due to unforeseeable functional and processing movements
when the Industrial PC is disconnected.
These can result in death, serious injury or extensive property damage.
All equipment components must be disconnected from the Dialog Controller
whenever the Dialog Controller is not being used for operational or control pur-
poses, e.g., during maintenance or during functional checks after repairs.
Lock out and tag out all equipment components after they have been
switched off!
HAZARDOUS
PROCESSES
Opening the DC
First, please note all the tasks steps outlined in the above section “Working on the DC”. The supply voltage
must be switched off before opening the housing or when components are being installed or removed.
To do this, switch the power supply to the Dialog Controller off. Then remove the plug from the power supply
socket on the Dialog Controller.
WARNING
Do not open the housing cover with the power switched on!
Hazard due to contact with live components.
This can result in death, serious injury or extensive property damage.
Only open the housing cover once the Dialog Controller has been safely dis-
connected from the power supply.
HAZARDOUS
VOLTAGE

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1.6. Use as prescribed
This is a modular automation system based on the CANbus, intended for industrial control applications
within the medium to high performance range.
The automation system is designed for use within Overvoltage Category I (IEC 364-4-443) for the controlling
and regulating of machinery and industrial processes in low-voltage installations in accordance with the fol-
lowing general parameters:
maximum rated supply voltage of 1,000 VAC (50/60 Hz) or 1,500 VDC;
for use in maximum category 2 pollution environment (EN 60950);
for use up to a maximum altitude of 2,000 m above msn;
for indoor use only in areas not exposed to direct UV radiation;
max. ambient temperature inside and outside the control cabinet is within the technical specifications
(see section “Technical data”)
Qualified project planning and design, proper transport, storage, installation, use and careful maintenance
are essential to the flawless and safe operation of the automation system.
The automation system may only be used within the scope of the data and applications specified in the
present documentation and associated user manuals.
The automation system is to be used only as follows:
as prescribed
in technically flawless condition
without arbitrary or unauthorized changes
exclusively by qualified users
The regulations of the German professional and trade associations, the German technical supervisory board
(TÜV), the VDE (Association of German electricians) or other corresponding national bodies are to be ob-
served.
Safety-oriented (fail-safe) systems
Particular measures are required in connection with the use of SPC in safety-oriented systems. If an SPC is to
be used in a safety-oriented system, the user ought to seek the full advice of the SPC manufacturer in
addition to observing any standards or guidelines on safety installations which may be available.
WARNING
As with any electronic control system, the failure of particular compo-
nents may result in uncontrolled and/or unpredictable operation.
All types of failure and the associated fuse systems are to be taken into ac-
count at system level. The advice of the SPC manufacturer should be sought if
necessary.

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1.7. Conformity declaration
Both the standard version of the Dialog Controller and with the extension modules mentioned below comply
with and make allowance for the following directives and standards:
EMC Directive 2014/30/EU
EN 61131-2:2007 Programmable logic controllers
Part 2: Equipment requirements and tests
Class B, connector cable of the I/O, max 30 m
EN 61000-6-2:2005/AC:2005 Electromagnetic compatibility (EMC)
Part 6-2: Generic standard –immunity for industrial environments
EN 61000-6-4:2007/A1:2011 Electromagnetic compatibility (EMC)
Part 6-4: Generic standard –electrostatic discharge for industrial environments
1.7.1. Extension modules
Conformity is declared to the above-stated directives for the extension modules given below, built into the
Dialog-Controller:
PROFIBUS-MASTER card
PROFIBUS-SLAVE card
PROFIBUS card (Master/Slave functionality)
I/O cards XR01 and XR02 with analog and digital I/O
No general conformity can be declared for extensions with contact line system, built into the Dialog-
Controller:
I/O card with SC-CAN interface
With connected contact line system the compliance of the EMC requirements on the complete system must
be checked and ensured („fixed installation“ for the purpose of the EMC directive).

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1.8. Transport and setup
NOTICE
Please note the specified storage conditions in the section “Technical
specifications”.
Transport
Protect the Dialog Controller against extreme mechanical stress during transport. Always transport the
Dialog Controller in its original packaging. The built-in components are extremely sensitive to jarring and
strong vibrations.
CAUTION
Condensation hazard resulting from climatic fluctuations
Risk of damage as a result of moisture forming on or in the Dialog Controller
(condensation). This can result in destruction of the device or consequential
damages.
After storage or transport in cold weather or under conditions of strongly fluctu-
ating temperatures, the Dialog Controller must be allowed to slowly adjust to
the ambient temperature at its point of use before it can be taken into
service.
In case of condensation, the unit may not be taken into service for at least
12 hours (temperature compensation).
CONDENSATION
Unpacking
Proceed as follows:
Inspect the packaging for any external damage. If the packaging is severely damaged or if damage to
the contents can be detected, do not open the packaging any further. Immediately contact your shipper
and your supplier.
Remove the packaging. Do not discard the original packaging! The packaging can be used for sub-
sequent transport.
Inspect the contents for visible shipping damage.
Check the contents against the order for completeness. Save all included documentation. This docu-
mentation contains important information concerning the Dialog Controller and is an integral part of
the product.
If shipping damage is detected or if the received contents do not agree with the order, please contact
your supplier immediately.
Setup
This Dialog Controller is designed for installation in fully enclosed circuit cabinets of industrial machinery
and equipment. When installing the Dialog Controller, take particular care to ensure that the included seal
profiles are not damaged. Also ensure compliance with the ambient conditions specified under “Technical
specifications”.

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2. Product description
The Dialog-Controller is a real-time control module with a display and a broad spectrum of data interfaces.
The module can be programmed in 'C' or in accordance with IEC 61131-3 (CODESYS 2.3).
Installation
The Dialog-Controllers are intended for front panel or switch cabinet installation in harsh industrial environ-
ments. Maintenance is minimal, thanks to their fan-free design and flash memory.
Processors
The Dialog-Controller is equipped with either a 266 MHz or 400 MHz POWERPCTM processor from Free-
scale.
Display
The great differences in the appearance of the Dialog-Controller are based on the selection of the employed
display technology and a common display diagonal size. 5.7” units with a monochrome (STN), color (CSTN)
or TFT display are available. Above a diagonal screen size of 10.4” only TFT displays are employed. Unit
housing dimensions and protective method (IP65 on the front) do not depend on whether the version in
question has a touch screen or matrix keypad.
Ethernet
A 10/100 MBit/s Ethernet interface is included. TCP/IP and UDP/IP protocols offer highly flexible connec-
tions to visualization software, higher order control units or an IT infrastructure.
USB ports
The two USB host ports provide interfaces for widely dispersed peripheral devices. For example, one USB
stick can be used to quickly and easily perform application updates or data extraction. Please contact our
Technical Support if no driver support is available for a specific USB device.
CAN ports
The Dialog-Controller is equipped with two standard CAN interfaces, both of which can be operated at
1 MBit/s.
Serial ports
A total of three serial ports can be used on the Dialog-Controller. The RS232 programming interface is sup-
plemented by an additional RS232 and an RS485 port.
E-bus extension
The Dialog-Controller’s I/O level can be expanded via the E-bus socket to include up to seven E-bus sub-
scribers.
Short description

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Expansion slots
The device is equipped with three expansion slots for expansion cards (e.g., I/O cards) with the associated
SPI interface. Alternately, one of the slots can be used for an “Anybus®” embedded bus module (e.g., Profibus
DP) manufactured by HMS.
Real-time clock
A software interface can be used to set or reset a real-time clock equipped with a backup battery.
SD card reader
Data can be written to or read from memory cards using the conventional MMC/SD card interfaces.
NOTICE
If the SD card reader is activated, then the second RS232 interface (X5) is not
longer available.
Performance feature overview
Freescale POWERPCTM CPU 266 (400) MHz
Application program and data memory (RAM): 64 (128) MB onboard / 32 (96) MB for the application
Application program memory (Flash): 16 (32) MB onboard / 8 (24) MB for the application
Retain memory 16 KB
1 Ethernet 10/100 port
1 (3) USB host ports
1 (2) CAN ports
1 RS232 serial port for programming tools and applications
1 (2) serial data ports RS232 / RS485
I/O level locally expandable via an internal E-bus for up to seven subscribers (digital / analog)
Up to 3 onboard expansion slots for I/Os and a bus module
Real-time clock
MMC/SD card slot
The scope of supply of the controller module consists of:
Dialog-Controller DC10xx
incl. 2-pin plug-in connector for power supply
Scope of supply

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2.1. Identification
Product: Dialog-Controller, Type DC10xx
Identification code
The features of the Dialog-Controller (see nameplate) can be itemised according to the identification code.
2VF100227DG04.cdr
D C 1 0 0 5M T M P 66
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 ... ...
S C AP B A CIS
Screen size
(diagonal)
Activation method
Processor type
Display technology
Resolution
Extension-Modules
05
10
12
15
=
= 10,4”
= 12,1”
= 5,0”1
5,7”
M=
= Color (CSTN)
= Color TFT
C
T
Monochrome (STN)
V= VGA640 x 480
T
K
A
= Touchpanel
= Keyboard
= Touch + Keyboard
BASIC
CLEAN
= DC1000 with
basic equipment
= Continuous of the
front foil sheeting
= compact modelCP
MP266
MP400 = Power PC 266 MHz = Power PC 400 MHz
SC
PS = I/O card = Profibus Slave
= Profibus Master
= Profibus Master/Slave
= XR I/O card
PM
PA
IO
Model

USER MANUAL 1.10 | DC1000 DIALOG-CONTROLLER
Berghof Automation GmbH | Harretstrasse 1 | 72800 Eningen | www.berghof.com
DC1000_HB_en_2D0982010ZD00.docx | 2VF100107FE10.docx
20
2.2. The different versions of the Dialog-Controller
2.2.1. Interfaces
Communication is the forte of the DC1000. Its spectrum of interfaces and exten-
sion options makes is the reason for this. The DC1000 with a Prime interface is
extremely adaptable.
The maximum scope of the interfaces can be supplemented with further commu-
nication an I/O extension cards. So it is easy to always find the rigth automation
solution.
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The DC1000 with the Basic Interface is optimal for standard applications.
With high processor power and equipped minimally with interfaces, it is the right
solution for a price sensitive market.
2VF100398DG00.cdr
2.2.2. Front foil sheeting
If cleanliness is a priority, the Clean Front is the right choice. Dust and dirt do not
stand a chance here; and what's more, it is easy to clean.
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Machine parameters or data records can be exchanged simply and fast by means
of a USB stick. It is very convenient to have a USB port available at the front.
The Connect front is distinguished by the USB port at the front with IP65 cover.
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Touch screen or membrane key pad: this is not merely a philosophical operational
issue. Gloves are often needed on site. If this is the case, keys are simple and safe
to use.
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Prime Interface
Basic Interface
Clean Touch
Connect Touch
Connect Key