BERGHOF B-Fortis CC-Prime Series User manual

USER MANUAL 1.2
B-Fortis CC-Prime Series

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®// is a registered trademark 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 NXP Semiconductors.
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 user manual
This equipment manual 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
Arbachtalstrasse 26
72800 Eningen
Germany
T [phone]
F [phone]
E-mail: [e-mail]
https://www.berghof-automation.com
Berghof Automation GmbH is certified according to DIN EN ISO 9001:2015.

USER MANUAL 1.2 | B-FORTIS CC-PRIME SERIES
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Change log
Version
Date
Description
0.1
03.01.2020
First draft regarding new catalog numbers and options , Rabold bis
page 21
0.9
11.05.2020
Updates
1.0
18.06.2020
Formatting of the document and change of address
1.2
05.03.2021
Dual Core Versions added

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Contents
1. GENERAL INFORMATION...................................................................................................7
1.1. Notes on the manual ...........................................................................................................7
1.2. Symbols and visual depictions ..........................................................................................8
Design of warnings: ...............................................................................................................8
1.3. Hazard categories and indications ....................................................................................8
1.4. Qualified personnel .............................................................................................................9
1.5. Duty of care ........................................................................................................................10
1.5.1. General ................................................................................................................................10
1.6. Intended use.......................................................................................................................10
1.7. Transport and storage.......................................................................................................11
Transport and storage .........................................................................................................11
Devices with batteries/rechargeable batteries.....................................................................11
Operation.............................................................................................................................11
1.8. Unpacking...........................................................................................................................11
2. SAFETY...............................................................................................................................13
Safety related systems ........................................................................................................13
2.1. Safety instructions.............................................................................................................13
Working on the device .........................................................................................................13
3. PRODUCT DESCRIPTION .................................................................................................14
3.1. Overview B-Fortis CC-Prime.............................................................................................14
3.2. Scope of delivery and accessories..................................................................................15
Scope of delivery .................................................................................................................15
Accessories..........................................................................................................................15
3.2.1. CC-Prime Connector set as order option ............................................................................15
3.2.2. CC-Prime Connector set as order-number..........................................................................15
3.3. Product features ................................................................................................................16
Assembly .............................................................................................................................16
Processor.............................................................................................................................16
Ethernet ...............................................................................................................................16
USB......................................................................................................................................16
CAN interfaces (S02-S08) ...................................................................................................16
Serial interfaces (S04-S08...................................................................................................16
Additional interfaces ............................................................................................................16
Real Time Clock...................................................................................................................16
microSD card (optional).......................................................................................................16
Onboard inputs / outputs .....................................................................................................16
Visualisation.........................................................................................................................16
Summary of features............................................................................................................17

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4. INSTALLATION ..................................................................................................................18
Requirements: .....................................................................................................................18
5. CONNECTION ....................................................................................................................19
5.1. Power supply .....................................................................................................................19
Internal power supply ..........................................................................................................19
Installation ...........................................................................................................................19
5.1.1. Connecting the power supply..............................................................................................20
5.2. Earth....................................................................................................................................21
Earthing the B-Fortis CC-Prime...........................................................................................21
5.3. Data connections...............................................................................................................22
5.3.1. Digital outputs (O)................................................................................................................23
5.3.2. Digital inputs (I)....................................................................................................................26
5.3.3. Counter inputs .....................................................................................................................29
Available options for the counter inputs: .............................................................................29
Examples for counters: up/down; pulse/direction; encoder (A/B) .......................................29
Example for counter: capture input or Z input.....................................................................30
Data of the counter inputs ...................................................................................................30
Installation information.........................................................................................................30
5.3.4. Analogue inputs and outputs (AIO)(not for S06).................................................................31
Analogue channel wiring .....................................................................................................32
Data of the analogue inputs ................................................................................................32
Operating modes for the analogue inputs...........................................................................33
Data of the analogue outputs ..............................................................................................37
Operating modes for the analogue outputs.........................................................................38
5.3.5. Example connections of analogue inputs and outputs........................................................39
Voltage input AI (U) .............................................................................................................39
Power input AI (I).................................................................................................................40
Temperature measurement AI (T).......................................................................................41
2-wire measurement............................................................................................................41
3-wire measurement............................................................................................................41
Voltage output AO (U).........................................................................................................42
5.3.6. CAN interface (only S02 and higher)...................................................................................43
5.3.7. RS 485 / RS 232 interface...................................................................................................44
Special feature S08.............................................................................................................45
5.3.8. RS 485 interface..................................................................................................................46
Special feature S08.............................................................................................................47
5.3.9. Ethernet (switch) interface...................................................................................................48
5.3.10. EtherCAT interface ........................................................................................................49
5.3.11. USB interface.................................................................................................................50
6. OPERATION .......................................................................................................................51
6.1. Switching on and off .........................................................................................................51
Switching on ........................................................................................................................51
Switching off ........................................................................................................................51

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6.2. Network start-up ................................................................................................................52
6.3. Operation............................................................................................................................54
6.3.1. Status displays.....................................................................................................................54
Location of the operating status LEDs.................................................................................54
Meaning of the LED displays...............................................................................................55
6.3.2. Start/Stop.............................................................................................................................57
6.3.3. Real-time clock with buffer battery.......................................................................................57
Setting the time....................................................................................................................57
Changing the battery ...........................................................................................................57
6.3.4. microSD card.......................................................................................................................58
Inserting a microSD card .....................................................................................................58
6.4. Troubleshooting.................................................................................................................59
6.4.1. In error stop mode................................................................................................................59
6.4.2. Unknown IP address............................................................................................................59
7. MAINTENANCE/UPKEEP ..................................................................................................60
7.1. Maintenance .......................................................................................................................60
7.2. Cleaning..............................................................................................................................60
8. UNINSTALLATION .............................................................................................................61
9. DISPOSAL...........................................................................................................................62
Disposal via manufacturer ...................................................................................................62
Dispose of the device according to regional specifications.................................................62
10. TECHNICAL DATA .............................................................................................................63
10.1. B-Fortis CC-Prime..............................................................................................................63
10.2. Identification plate .............................................................................................................66
10.3. Device variants and identification....................................................................................67
10.4. Options and extensions....................................................................................................67
Extensions for tooling and debugging..................................................................................68
11. STANDARDS AND CERTIFICATES..................................................................................69
11.1. Standards ...........................................................................................................................69
11.2. Declaration of conformity .................................................................................................70
12. CUSTOMER SERVICES / ADDRESSES ...........................................................................71
12.1. Customer services.............................................................................................................71
12.2. Addresses...........................................................................................................................71
13. APPENDIX...........................................................................................................................72
13.1. Hinweise zu Copyright und Lizenz der Software...........Fehler! Textmarke nicht definiert.
13.2. Table of figures ..................................................................................................................72

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1. General information
This user manual is intended for use by qualified professionals and contains information on the
as-sembly, installation, start-up and maintenance of the device.
1.1. Notes on the manual
This user manual is part of the product.
The manual 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.

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1.2. Symbols and visual depictions
The following symbols and visual depictions will be used in this manual:
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
Design of warnings:
WARNING
Optional:
Other
Symbols
Hazard type and source
Short description and consequences
Preventive measures
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.

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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.
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 who are familiar with safety concepts in automation
engineering and who are authorized to assemble, install, start up, earth and identify devices,
systems and electrical circuits in accordance with standards set in safety engineering.

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1.5. Duty of care
1.5.1. General
The user (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.
→These authorised personnel must receive regular training on all relevant occupational health
and safety and environmental protection issues and must be fully familiar with the contents
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.
The user takes direct responsibility for agreeing with the competent authorities the use of safety-
related control components, and for compliance with their instructions
1.6. Intended use
The device is part of a modular automation system for industrial control applications within the
medium to high performance range. It extends the communications capabilities to include
EtherCAT, Profinet, Modbus and others.
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
→Environment with maximum category 2 pollution (EN 61010-1)
→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 in accordance with the
technical data (see “Chapter 10“)
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:

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→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 into a suitable cut-out on 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 "Chapter 10").
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 "Chapter 10”).
Protect the device against condensation and damp.
Devices with batteries/rechargeable batteries
Lithium metal batteries are hazardous items. The manufacturer’s information specifies that they
are subject to UN 3091 (must be permanently installed within the device).
The ADR 188 special regulations can be applied for transport.
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
On receipt of the device, a check must be made that it is complete and undamaged.
Check the packaging for external damage.

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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.
Remove the packaging and keep it safe for subsequent transport.
Check the contents for evidence of damage in transport.
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.
If you discover damage in transport, or if the equipment delivered does not match the order:
Inform the supplier immediately.

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2. Safety
Safety related systems
The use of PLCs in safety-related systems requires specific measures. Wherever a PLC 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 to 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. Exposed sharp edges pose an
injury risk.
If you discover damage to the front glass of the device, do not continue to operate the
device. Immediately disconnect it from the power supply.
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.
Bring the system into a safe condition.
Switch the system and the device off.
Secure the system against being switched on again.
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
"Chapter 12").

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3. Product description
The compact PLC controller family B-Fortis CC-Prime are CODESYS PLCs for control and
regulating of automation and industrial processes in low-voltage installations, e.g. for compact
machinery or building automation. The programming language CODESYS 3.5 (IEC 61131-3) is
used for programming the device. The CODESYS SoftMotion packet permits complex multi-axis
drive applications.
The device can be connected via different interfaces and has additional digital and analogue
inputs and outputs.
3.1. Overview B-Fortis CC-Prime
Fig. 1: Overview B-Fortis CC-Prime
Item
Description
Item
Description
X1
Electrical connection (power)
X13
EtherCAT [ETH1]
X2
Digital outputs
X14
USB 2.0
X3
Digital inputs
X15
(reserved)
X4
Analogue inputs and outputs
X16
Debug interface
X5
Analogue inputs and outputs
X20
Functional earth
X6
Analogue inputs and outputs
S1
Function key (Reset and Run/Stop)
X7
CAN Bus [CAN0]1
S2
Terminal resistance CAN-Bus
ON/OFF
X8
RS 232 [COM1] / RS 485 [COM2]
S3
Terminal resistance RS 485 ON/OFF
X9
RS 485 [COM3]
S4
Terminal resistance RS 485 ON/OFF
X10
Ethernet Switch PORT 1 [ETH0]
LED
LEDs for power and system status
1
Designations in [ ]: CODESYS-designations of the connections

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Item
Description
Item
Description
X11
Ethernet Switch PORT 2 [ETH0]
µSD
microSD card connection (optional)
X12
Ethernet Switch PORT 3 [ETH0]
3.2. Scope of delivery and accessories
Scope of delivery
B-Fortis CC-Prime
Accessories
The following accessories can be ordered directly via the option or separately via order number:
3.2.1. CC-Prime Connector set as order option
order option: H001
note: the plug set suitable for the respective device is supplied
3.2.2. CC-Prime Connector set as order-number
Connector set via order-number
S-02020102-0100
CC-Prime S06 connector set:
1 x 6 pin connector for power supply, 2 x 16 pin connector for digital
In/Out
S-02020102-0200
CC-Prime S01/S02/S03/S07 connector set:
1 x 6 pin connector for power supply, 2 x 16 pin connector for digital
In/Out und 1 x 14 pin connector for analog In/Out
S-02020102-0300
CC-Prime S04 connector set:
1 x 6 pin connector for power supply, 2 x 16 pin connector for digital
In/Out und 2 x 14 pin connector for analog inputs
S-02020102-0400
CC-Pprime S05/S08 connector set:
1 x 6 pin connector for power supply, 2 x 16 pin connector for digital
In/Out und 3 x 14 pin connector for analog inputs

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3.3. Product features
Assembly
The device is designed for installation on a DIN rail (35 mm) in a control cabinet in an industrial
environment with a category 2 pollution environment.
Processor
In its the basic configuration the device is equipped with an 800 MHz ARM®CPU with a Cortex™-
A9 core.
Ethernet
The device has two 10/100 Mbit/s Ethernet interfaces. TCP/IP and UDP/IP protocols permit
flexible connections to visualisation software, higher-level control units and to the IT infrastructure.
One Ethernet interface can be equipped with an optional 3-switch (3 ports for the user) connected
directly to the CPU.
The second Ethernet interface is connected to the controller via a PCIe.
Additional protocols are available: PROFINET, BACnet, Ethernet IP and Modbus.
USB
Thanks to the USB host interface, a wide range of peripherals can be connected to the device.
Examples are a USB stick for updating the application or for downloading data directly.
CAN interfaces (S02-S08)
The device has one standard CAN interface which can be used at a speed of up to 1 Mbit/s.
Serial interfaces (S04-S08
The B-Fortis CC-Prime has up to three potential-free serial interfaces (2x RS485; 1x RS232).
Additional interfaces
There is also a debugging interface located on the modulw which can be used in conjunction with
a special cable to be connected to the jack plug (for additional information, please contact our
customer services team).
Real Time Clock
A battery-buffered, maintenance-free real-time clock can be used within the CODESYS
application via a software interface.
microSD card (optional)
The standard commercial microSD card interface (SDHC up to max. 32 GB) allows data to be
written to memory cards or read from memory cards.
Onboard inputs / outputs
The device provides digital inputs, digital outputs and analogue inputs.
Visualisation
CODESYS target visualisation is included in the scope of delivery. The Berghof Ethernet
terminals B-Primis ET series provide a simple, user-friendly display.
The B-Fortis-CC-Prime also supports web visualisation.

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Summary of features
→ARM® CPU with CortexTM-A9 single-core (800 MHz; optional dual or quad core)
→Program memory and data memory (RAM): up to 1024 MB
→Program memory (flash): up to 1024 MB onboard/ 896MB user memory
→1 x USB host interfaces (USB 2.0, type A)
→Retain memory 100 kB
→2 x Ethernet 10/100 Base T interfaces (2nd Interface: EtherCAT master interface)
→Up to 2 CAN interfaces (SXX dependent)
→Up to 3 serial interfaces (2 x RS-485; 1 x RS-232)
→1 µSD card slot
→Onboard I/O, up to 16 digital inputs, up to 16 x digital outputs, up to 12 x analogue inputs,
up to 6 x analogue outputs
→Real Time Clock (RTC)

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4. Installation
The B-Fortis CC-Compact devices are designed to be mounted on DIN rails (according to EN
60715:2001, 35 x 7.5 mm).
CAUTION
Hot surfaces
The surface of the device can become hot.
Ensure that there is sufficient convectional cooling for heat to dissipate
Ensure that there is also a minimum of 50 mm free space both above and below the
device.
Fig. 2: mounting the device
Requirements:
at least 1 cm free space must be left between the device and the adjacent module.
1. Insert the device into the support rail according to the image above so that the plastic snap-
in hooks between the mounting surface and the rail are pressed in.
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 an external 24 V DC supply.
Before plugging in the device, ensure it meets the specifications for external power supplies
(type K according to 61131-2).
External PLC power supply (24 V DC: L+; L1+; L2+; L3+; L4+)
Supply voltage
+24 V DC SELV (–15% / +20%)
Alternating current
proportion
Max. 5%
The direct voltage level must not fall below 20.4 V.
Energy buffering
Power fail 10 ms
Internal power supply
A power supply for the system electronics for an input voltage of 24 V DC (–15% / +20%) is
integrated into the device. The power supply has integrated protection against reverse polarity
and surge current protection (1.2 A).
Fuse the supply lines for the IO lines (L1+ to L4+) externally so that the value (approx. 5 A)
for the power-limited electrical circuits (150/U) are not exceeded (U = value of the voltage
applied).
Installation
All connections and cables must be laid out 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 the power supply
CAUTION
Live parts!
Before starting any work on the device, switch off all power feeds, including peripherals.
Connect the power supply to plug X1 according to the following table.
Fig. 3: power supply plug X1
Power supply plug X1
Pin
Label
Assignment
1
L+
external 24 V DC (–15% / +20%) power supply (internal PLC) max. 1 A
2
M
external GND power supply
3
L1+
Digital output DO1–4 supply, 24 V DC (–20% / +25%) max. 2 A1
4
L2+
Digital output DO5–8 supply, 24 V DC (–20% / +25%) max. 2 A1
5
L3+
Digital output DO9–12 supply, 24 V DC (–20% / +25%) max. 2 A1
6
L4+
Digital output DO13–16 supply, 24 V DC (–20% / +25%) max. 2 A1
1
Nominal current 2 A at peak load; in case of overload, up to 3 A might flow.