BERGHOF ECC DIO 16/16 Instruction Manual

USER HANDBOOK 1.2
ECC DIO / ECC AIO
I/O expansion

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.
Infringements will result in compensation for damages.
Legal disclaimer
The content of this document has been verified for conformity with the hardware and software described
therein. It is, however, impossible to rule out all variations. As a result, we cannot be held responsible if the
content is not fully compliant. The information given in this document is updated regularly and any
corrections will be reflected in future versions. We are always willing to receive suggestions for
improvements. Subject to technical modifications.
Trademarks
CANtrol®and CANtrol®-dialog are trademarks belonging to Berghof Automation GmbH.
Microsoft®, Windows®and the Windows®logo are registered trademarks belonging to the Microsoft
Corp. in the USA and in other countries.
EtherCAT®is a registered trademark and patented technology licensed from Beckhoff Automation
GmbH, Germany.
CiA®and CANopen®are registered trademarks belonging to CAN in Automation e. V.
ARM ® and Cortex ® are registered trademarks belonging to ARM Limited.
PROFINET® is a registered trademark belonging to PROFIBUS Nutzerorganisation e.V.
Modbus® is a registered trademark belonging to the Modbus-IDA Organisation.
i.MX6 is a registered trademark belonging to Freescale.
The rights of all companies and company names as well as products and product names mentioned in this
website belong to the respective companies.
Notes on this handbook
This device handbook contains information which is specific to the product and which is valid at the time of
printing.
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: [e-mail]
www.berghof.com
Berghof Automation GmbH is certified to DIN EN ISO 9001:2000.

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Change log
Version Date Description
0.8
13/03/2015
Preliminary version
1.0
20/05/2015
First version
1.1
27/07/2016
Addition ECC AIO 12/6, corrections, update certificates
1.2
02/12/2016
Corrections scope of delivery and accessories 3.1.3

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Table of contents
1. GENERAL INFORMATION .................................................................................................................6
1.1. Notes on the handbook .....................................................................................................................6
1.2. Symbols and visual depictions.........................................................................................................6
1.3. Hazard categories and indications...................................................................................................7
1.4. Qualified personnel............................................................................................................................7
1.5. Duty of care.........................................................................................................................................8
1.6. Intended use.......................................................................................................................................8
1.7. Transport and storage .......................................................................................................................9
1.8. Unpacking...........................................................................................................................................9
2. SAFETY.............................................................................................................................................10
2.1. Safety instructions...........................................................................................................................10
3. PRODUCT DESCRIPTION................................................................................................................11
3.1. Overview ...........................................................................................................................................11
3.1.1. Overview ECC DIO 16/16 ..................................................................................................................11
3.1.2. Overview ECC AIO 12/6.....................................................................................................................12
3.1.3. Scope of delivery and accessories.....................................................................................................13
3.2. Product features...............................................................................................................................13
4. INSTALLATION.................................................................................................................................14
4.1. Installing the device.........................................................................................................................14
5. CONNECTION...................................................................................................................................15
5.1. Power supply....................................................................................................................................15
5.1.1. Connecting power supply...................................................................................................................16
5.2. Earth..................................................................................................................................................17
5.3. Data connections .............................................................................................................................18
5.3.1. Block diagram of the ECC DIO 16/16.................................................................................................18
5.3.2. Block diagram ECCAIO 12/6.............................................................................................................19
5.3.3. Digital inputs of the ECC DIO 16/16...................................................................................................20
5.3.4. Digital outputs ECC DIO 16/16...........................................................................................................24
5.3.5. Analogue inputs and outputs ECC AIO 12/6 ......................................................................................27
Analogue channel wiring....................................................................................................................28
Data from analogue inputs.................................................................................................................28
Operating modes for the analogue inputs ..........................................................................................29
Data from analogue outputs...............................................................................................................32
Operating modes for the analogue outputs........................................................................................33
5.3.6. Example connections of analogue inputs and outputs.......................................................................34
Voltage input AI (U) ............................................................................................................................34
Current inputAI (I)..............................................................................................................................35
Temperature measurement AI (T).......................................................................................................36
Voltage output AO (U) ........................................................................................................................37

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5.3.7. EtherCAT output.................................................................................................................................38
5.3.8. EtherCAT input...................................................................................................................................39
6. OPERATION......................................................................................................................................40
6.1. Switching on and off........................................................................................................................40
6.2. Initial start-up ECC DIO 16/16..........................................................................................................41
6.3. Initial start-up ECC AIO 12/6............................................................................................................43
6.3.1. Configuration......................................................................................................................................43
6.3.2. I/O mapping........................................................................................................................................44
Coding of the status bytes..................................................................................................................44
6.4. Operation ..........................................................................................................................................45
6.4.1. Status displays...................................................................................................................................45
Location of the operating status LEDs................................................................................................45
7. MAINTENANCE/UPKEEP.................................................................................................................46
7.1. Maintenance......................................................................................................................................46
7.2. Cleaning............................................................................................................................................46
8. UNINSTALLATION............................................................................................................................47
9. DISPOSAL.........................................................................................................................................48
10. TECHNICAL DATA............................................................................................................................49
10.1. ECC DIO 16/16 P/N ...........................................................................................................................49
10.2. ECC AIO 12/6 ....................................................................................................................................51
10.3. Identification plate............................................................................................................................53
11. STANDARDS AND CERTIFICATES.................................................................................................54
11.1. Standards..........................................................................................................................................54
11.2. UL certificate.....................................................................................................................................55
11.3. Declaration of conformity................................................................................................................56
12. CUSTOMER SERVICES / ADDRESSES ..........................................................................................58
12.1. Customer services...........................................................................................................................58
12.2.Addresses.........................................................................................................................................58
13. APPENDIX.........................................................................................................................................59
13.1. List of figures....................................................................................................................................59

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1. General information
This user handbook is intended for use by qualified professionals and contains information on the assembly,
installation, start-up and maintenance of the device.
1.1. Notes on the handbook
This user handbook is a component of the product and applies to the following devices:
ECC DIO 16/16 positive switching
ECC DIO 16/16 negative switching
ECC AIO 12/6
It contains information on the following topics:
Applications
Safety
Mechanical design
Electrical design
Connections
Start-up
Upkeep and maintenance
Decommissioning
Disposal
Always keep this user handbook available alongside the product.
1.2. Symbols and visual depictions
The following symbols and visual depictions will be used in this handbook:
Symbol Meaning
… List entry
… Individual instruction or list of instructions which can be carried out in any
order.
1. …
2. …
List of instructions which must be carried out in the order given.
Additional product information

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Design of warnings:
WARNING Danger type and source
Short description and possible consequences
Preventive measures
Optional:
additional
symbols
1.3. Hazard categories and indications
The following indications are used in the case of warning messages so as to ensure your personal safety and
avoid any damage to property.
The indications have the following meanings:
DANGER
Serious injury or death
Non-compliance with the safety features will result in death or serious injury.
Take preventive measures.
WARNING
Possible serious injury or death
Non-compliance with the safety features may result in death or serious injury.
Take preventive measures.
CAUTION Possible minor injuries
Non-compliance with the safety features may result in minor injuries.
Take preventive measures.
NOTE
Possible damage to property
Non-compliance with the safety features may result in damage to property.
Take preventive measures.
Further information
1.4. Qualified personnel
The installation, start-up and maintenance of the device must be carried out by qualified personnel.
For the purposes of this documentation and the safety instructions contained therein, “qualified personnel”
means trained staff with the authorisation to assemble, install, start up, earth and identify devices, systems
and electrical circuits in accordance with standards set in safety engineering and who are familiar with safety
concepts in automation engineering.

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1.5. Duty of care
The user or processor (OEM) must ensure the following:
The device must only be used according to regulations.
The device must only be used in good working order.
The user handbook must always be kept legible and fully available.
Only sufficiently qualified and authorised personnel may carry out the assembly, installation, start-up
and maintenance of the device.
This authorised personnel must receive regular training on all relevant occupational health and safety
and environmental protection issues and must be fully familiar with the content of this user handbook,
particularly the sections regarding safety features.
Any markings or identification labels and safety and warning signs on the device must not be removed
and must be kept legible at all times.
The national and international regulations regarding the operating of machinery and facilities where
the device is being used must be observed at all times.
The user must always be kept abreast of any current relevant information regarding the device and its
use or operation.
1.6. Intended use
The devices are intended for use in modular automation systems for industrial control applications within
the medium to high performance range. They expand the control system (e. g. ECC22XX) by addition of
further digital or analogue inputs and outputs, and are connected by means of EtherCAT.
The automation system is designed for use within overvoltage category I (IEC 364-4-443) systems for
controlling and regulating machinery and industrial processes in low-voltage installations in accordance with
the following general parameters:
maximum rated supply voltage of 1,000 V AC (50/60 Hz) or 1,500 V DC
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
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 this
documentation and associated user manuals.
The automation system must only be used:
as intended
in a technically perfect condition
without any unauthorised modifications
by qualified users
Observe the rules of the employer’s liability insurance association, the technical inspectorate, and the
VDE (Association of German Electrical Engineers) or corresponding country regulations.
The device is intended for installation within enclosed control cabinets of industrial machines and systems in
indoor areas.
When installing the device, check that the seal profiles are undamaged.
For operation, refer to the applicable statement of ambient conditions (see “Technical data”).

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1.7. Transport and storage
The device is susceptible to impacts, heavy vibration, moisture and extreme temperatures.
Transport and storage
Protect the device against major mechanical stresses during transport.
Always pack the device in its original packaging for transport.
For storage, refer to the applicable statement of ambient conditions (see “Technical data”).
Protect the device against condensation and damp.
Operation
If the device has been stored or transported in cold weather or under conditions or large fluctuations
in temperature, do not start to operate it until it has acclimatised to room temperature for the place it
is used.
If condensation is present, wait at least 12 hours before starting to operate the device.
1.8. Unpacking
Or receipt of the device, a check must be made that it is complete and undamaged.
1. Check the packaging for external damage.
2. If the packaging is seriously damaged or if damage to the contents is evident: Do not proceed further
with opening the packaging, instead immediately inform the transport company and your supplier.
3. Remove the packaging and keep it safe for subsequent transport.
4. Check the contents for evidence of damage in transport.
5. Check the contents for completeness against the order documentation and keep all the delivery
documentation for future reference. The delivery documentation contains important information
about the device and is part of the product.
6. If you discover damage in transport or the contents do not match the order: Inform the supplier
immediately.

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2. Safety
Safety-related systems
The use of PLCs and additional devices in safety-related systems requires specific measures. Wherever the
device is to be used in a safety-related system, the user must be given comprehensive advice by the PLC
manufacturer in addition to information on any available standards or regulations regarding safety
installations.
Before starting any work on devices, switch off all power feeds, including peripherals.
Keep all ventilation holes unobstructed.
Failure in certain components in an electronic control system may result in uncontrolled and/or
unpredictable operational behaviour.
All types of failure must be considered at the system level and the associated preventative measures
identified.
If necessary, request information from your automation system provider.
2.1. Safety instructions
The device may be operated only when it is in good working order.
Working on the device
Do not start work on the device until all necessary safety precautions have been taken. Take precautions to
avoid unforeseeable functional events and movements of the system.
1. Bring the system into a safe condition.
2. Switch the system and the device off.
3. Secure the system against being switched on again.
4. Disconnect the device from the system.
The casing of the device must not be opened.
If work on the internal parts of the device is necessary, contact the manufacturer (see “Addresses”).

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3. Product description
Each ECC DIO 16/16 module expands an automation system by 16 digital inputs and 16 digital outputs. The
device is connected to a suitable controller by means of EtherCAT.
The connection ports are all the plug-in type and are located on the front face of the device. The ECC DIO
16/16 is intended for installation on a mounting rail in the control cabinet.
3.1. Overview
3.1.1. Overview ECC DIO 16/16
Fig. 1: Overview ECC DIO 16/16
Item Designation Item Designation
X1 Power supply X5 EtherCAT input
X2 Digital inputs 1 Functional earth (FE)
X3 Digital outputs 2 LEDs: EtherCAT Run, +24 V, +24 V I/O
X4 EtherCAT output

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3.1.2. Overview ECC AIO 12/6
Fig. 2: Overview ECC AIO 12/6
Item Designation Item Designation
X1 Power supply X5 Analogue inputs / outputs
X2 Analogue inputs / outputs X6 Analogue inputs / outputs
X3 EtherCAT output 1 Functional earth (FE)
X4 EtherCAT input 2 LEDs: EtherCAT Run, +24 V

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3.1.3. Scope of delivery and accessories
Scope of delivery
ECC DIO 16/16:
Device
ECC AIO 12/6:
Device
Accessories
ECC DIO 16/16:
Connector Set FK ECC DIO (Best.-Nr. Berghof 201607600)
E-I/O plug 16-P. black (order no. Weidmüller 1972070000)
E-I/O plug, 4-pin, black (order no. Weidmüller 1971590000)
ECC AIO 12/6:
Connector Set FK ECC AIO (Best.-Nr. Berghof 201607900)
E-I/O plug 14-P. black (order no. Weidmüller 1972000000)
E-I/O plug, 4-pin, black (order no. Weidmüller 1971590000)
3.2. Product features
Installation
The device is designed for installation on a DIN rail (35 mm) in a control cabinet in an industrial
environment with a category 2 level of pollution.
EtherCAT
The device has two EtherCAT interfaces. The first EtherCAT interface is used as an input, the second
interface as an output.
Summary of features
ECC DIO 16/16:
2 EtherCAT RJ-45 interfaces (1 input, 1 output)
16 digital inputs
16 digital outputs
ECC AIO 12/6:
2 EtherCAT RJ-45 interfaces (1 input, 1 output)
12 analogue inputs
6 analogue outputs

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4. Installation
4.1. Installing the device
Fig. 3: Installing the device
1. Insert the device into the support rail according to the image above so that the spring hooks in between
the mounting surface and the rail.
2. Push the device at the top in towards the mounting surface.
3. Push the device down so that the profile is aligned with the upper part of the rail mounting.
The device should now be fixed in place.

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5. Connection
WARNING Uncontrolled and unpredictable operational behaviour!
Failure of certain components in electronic control systems may result in
uncontrolled and unpredictable operational behaviour.
All types of failure and the associated protection systems must be taken
into account at system level.
Comply with all automation system manufacturer instructions.
5.1. Power supply
The device is powered by a 24 V DC external power supply. It is not designed to be connected to a DC mains
supply.
Before plugging in the device, ensure that the external power supply meets the required specifications
(type K to 61131-2).
External power supply (24 V DC)
Supply voltage +24 V DC SELV (–15% / +20%)
Ripple current
proportion
Max. 5%
The direct voltage level must not fall below 20.4 V.
Power consumption Total max. 0.25 A at +24 V DC (typ. 0.05 A electronic)
Energy buffering 10 ms
Internal power supply
The power supply unit that supplies the system electronics is specified for an input voltage of 24 V DC (–15%
/ +20%) and is incorporated within the device. The power supply has integrated protection against reverse
polarity and surge current protection (0.5 A).
Installation
All connections and cables must be laid so as to prevent inductive and capacitive interference causing
any damage to the device.
Ensure that the infeed lines provide adequate current and voltage carrying capacity.

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5.1.1. Connecting power supply
WARNING Uncontrolled and unpredictable operational behaviour!
If the device is operated without both the ground
terminals connected,
uncontrolled and unpredictable operational behaviour may occur at both the
inputs and outputs.
Make sure that both the ground terminals – GND and GND IO – are
connected to the common GND of the machine/system.
CAUTION Live parts!
Before starting any work on the device, switch off all power feeds,
including the feeds to peripherals.
Connect the power supply to plug X1 according to the following table.
Fig. 4: Power supply at plug X1 with Power LEDs
Power supply plug X1
Pin
ECC DIO 16/16
ECC AIO 12/6
Des.
Assignment
Des.
Assignment
1
GND IO
Digital inputs / outputs ground
GND
Device ground
2
+24 V IO
Supply 24 V DC to digital I/O
+24 V
Supply 24 V DC to device
3
GND
Device ground
GND
Device ground
4
+24 V
Supply 24 V DC to device
+24 V
Supply 24 V DC to device
–
L+
Device power supply LED
L+
Device power supply LED
–
L1+
Digital outputs power supply LED
–
–
The following counterparts have been tested with the SC-SMT 3.81 (Weidmüller) plug-in connector and are
approved for use with the device:
Weidmüller BCZ 3.81/04/180 (F, LH)
Weidmüller BCF 3.81/04/180 (F, LH)
ECC DIO 16/16: L+ and GND, and L1+ and GND IO are two separate circuits, which are not
connected internally. Both circuits must be connected or externally bridged.

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5.2. Earth
The functional earth dissipates HF currents and increases the electromagnetic immunity of the device.
HF interference is transferred internally from the electronic circuit board to the metal housing. The metal
housing requires its own suitable connection to a functional earth.
Earthing the device
Requirements:
The support rail has a conductive contact with the control cabinet.
The control cabinet itself must be earthed.
Make sure that the device housing has a conductive contact with the support rail.
If specifically required in certain installations, additional PE conductors may be connected to protect
all metallic parts from high voltages on the underside of the device (PE connection).
The device is now earthed.
Where necessary, the functional earth (FE) of the device can also be connected directly to the
earth.
Fig. 5: Functional earth (FE) on the device

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5.3. Data connections
5.3.1. Block diagram of the ECC DIO 16/16
Fig. 6: Blockdiagram of the ECC DIO 16/16

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5.3.2. Block diagram ECC AIO 12/6
Fig. 7: Block diagram ECC AIO 12/6

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5.3.3. Digital inputs of the ECC DIO 16/16
NOTE
Damage to the inputs or to the device!
Voltages over ±32 V can damage the inputs or the device.
No voltage in excess of ±32 V may be present at the inputs.
Depending on the version of the device, the digital inputs are positive or negative switching inputs of type 1
(IEC 61131-2). They are designed for nominal input voltages of 24 V. The input signals are transmitted
internally on a cyclical basis for process data processing. An open input is always interpreted in the
programming system as logical 0 (LOW) (level: 0 V for P, +24 V for N). The inputs also have a common
reference potential (GND).
The following counterparts have been tested with the SC-SMT 3.81 (Weidmüller) plug-in connector and are
approved for use with the device:
Weidmüller BCZ 3.81/16/180 (F, LH)
Weidmüller BCF 3.81/16/180 (F, LH)
Fig. 8: Digital inputs of the ECC DIO 16/16 plug X2 with LEDs 1 to 16
Digital inputs plug X2
Pin Desig-
nation
Assignment n-switching Assignment p-switching
logical 0
logical 1
logical 0
logical 1
1
I 1
+24 V DC
0 V DC
0 V DC
+24 V DC
2
I 2
+24 V DC
0 V DC
0 V DC
+24 V DC
3
I 3
+24 V DC
0 V DC
0 V DC
+24 V DC
4
I 4
+24 V DC
0 V DC
0 V DC
+24 V DC
5
I 5
+24 V DC
0 V DC
0 V DC
+24 V DC
6
I 6
+24 V DC
0 V DC
0 V DC
+24 V DC
7
I 7
+24 V DC
0 V DC
0 V DC
+24 V DC
8
I 8
+24 V DC
0 V DC
0 V DC
+24 V DC