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The CCC TIOC-555HD is a high-density, Ethernet-enabled remote digital I/O controller developed by Control Concepts Corporation (CCC) for industrial automation applications requiring cost-effective, reliable field signal interfacing. Combining 32 sinking/sourcing digital inputs and 32 solid-state digital outputs in a compact DIN-rail housing, the CCC TIOC-555HD delivers robust performance for machine control, conveyor systems, packaging lines, and process skids—particularly where space, wiring, and integration simplicity are critical.
Designed as a drop-in alternative or expansion to mainstream PLC I/O systems, the CCC TIOC-555HD supports open industrial protocols including EtherNet/IP™, Modbus TCP, and native TCP/UDP socket communication, enabling seamless interoperability with Rockwell Automation, Siemens, Schneider Electric, and other major control platforms. Its dual Ethernet ports allow linear daisy-chaining of up to 16 units without external switches, significantly reducing network infrastructure costs. The CCC TIOC-555HD also features an embedded web server for real-time diagnostics, configuration, and firmware updates—eliminating the need for proprietary software during commissioning or troubleshooting.
Technical Specifications
| Parameter Name | Parameter Value |
|---|---|
| Product Model | TIOC-555HD |
| Manufacturer | Control Concepts Corporation (CCC) |
| Product Type | High-Density Ethernet Remote Digital I/O Module |
| Digital Inputs | 32 channels, 24 VDC nominal, sink/source configurable, 3.5 mA @ 24 V |
| Digital Outputs | 32 channels, 24 VDC, 0.5 A per channel, short-circuit protected MOSFETs |
| Communication Interfaces | 2 × 10/100BASE-T Ethernet (RJ45), auto-MDI/MDIX |
| Supported Protocols | EtherNet/IP™ (Adapter mode), Modbus TCP, TCP/UDP Raw Sockets |
| Operating Voltage | 24 VDC ±10% (via terminal block or DIN rail power bus) |
| Operating Temperature | -20°C to +60°C |
| Protection Rating | IP20 (for use in control cabinets) |
| Mounting | 35 mm DIN rail (EN 60715 compliant) |
| Dimensions (W × H × D) | 120 mm × 110 mm × 80 mm |
| Certifications | CE, UL 508, RoHS |
| Diagnostics | Per-channel LEDs, module status LEDs, web-based diagnostics |
Main Features and Advantages
High channel density with flexible wiring:
The CCC TIOC-555HD packs 64 discrete I/O points into a single 120 mm-wide module—equivalent to multiple traditional I/O blocks—reducing panel space, power distribution complexity, and termination labor. Each input can be configured via wiring to operate in either sink or source mode, accommodating NPN or PNP sensor types without hardware changes. Outputs use ruggedized MOSFET switches with individual short-circuit and thermal overload protection, ensuring safe operation even during field faults like grounded solenoid coils.
Open protocol support for multi-vendor integration:
Unlike proprietary I/O systems, the CCC TIOC-555HD natively supports EtherNet/IP™ as a Class 1 Adapter device, allowing direct integration into Allen-Bradley Logix platforms using standard Add-On Instructions (AOIs). Simultaneously, its Modbus TCP server enables easy connection to Siemens S7-1200/1500, Schneider M580, or Wonderware SCADA systems. For custom applications, raw TCP/UDP sockets allow direct data exchange with HMIs, robots, or edge gateways—making the CCC TIOC-555HD exceptionally versatile in hybrid or legacy modernization projects.
Simplified networking with daisy-chain topology:
Equipped with two Ethernet ports, the CCC TIOC-555HD supports linear topologies where units are connected end-to-end—ideal for long conveyor lines or assembly cells. This eliminates the need for managed switches in basic deployments, cutting both cost and potential failure points. All units share the same subnet, and automatic IP assignment (via DHCP or CCC’s proprietary discovery tool) accelerates setup. The built-in web interface provides real-time I/O status, error logs, and protocol configuration—accessible from any browser on the network.
Robust industrial design with intelligent diagnostics:
Housed in a flame-retardant polycarbonate enclosure rated for UL 508, the CCC TIOC-555HD withstands electrical noise, humidity, and mechanical vibration typical of factory floors. Comprehensive LED indicators show power, link/activity, and per-channel status—critical for rapid troubleshooting. Advanced features include watchdog timers, auto-recovery after communication loss, and output state retention on power cycle (configurable). These capabilities ensure the CCC TIOC-555HD maintains deterministic behavior even in unstable network conditions.
Application Field
In food and beverage packaging lines, the CCC TIOC-555HD interfaces with photoelectric sensors, fill-level detectors, reject gates, and capping actuators across multiple stations—all controlled by a central CompactLogix PLC over a single EtherNet/IP cable. Its high channel count reduces the number of remote drops needed, while daisy-chaining simplifies installation along curved conveyors. Similarly, in automotive sub-assembly cells, the CCC TIOC-555HD aggregates signals from safety light curtains, part presence sensors, and pneumatic clamps, communicating directly with a Siemens S7-1500 via Modbus TCP.
Within warehouse automation, the CCC TIOC-555HD is deployed at sortation diverter points to monitor package detection and control solenoid valves—often integrated with third-party WCS (Warehouse Control Systems) using raw TCP sockets for low-latency response. In water/wastewater pump stations, it replaces aging relay panels by digitizing dry contacts from float switches and motor starters, transmitting status to a central SCADA system over Modbus TCP without requiring a local PLC. Even in renewable energy applications like solar tracker arrays, the CCC TIOC-555HD’s wide temperature range and surge-resistant inputs make it suitable for outdoor enclosures. Across all these scenarios, the CCC TIOC-555HD delivers industrial-grade reliability at a fraction of the cost of branded alternatives.
Related Products
TIOC-555: Base model with 16 inputs / 16 outputs; TIOC-555HD is the high-density 32/32 variant.
TIOC-555A: Analog version supporting 8 universal analog inputs (voltage/current/RTD).
TIOC-555M: Mixed I/O module combining 16 digital I/O + 4 analog channels.
TIOC-PWR: Dedicated DIN-rail power distribution module for supplying multiple TIOC-555HD units.
TIOC-ETHSW: 4-port unmanaged Ethernet switch designed for daisy-chained TIOC networks.
TIOC-TERM: Terminal block adapter kit for simplified field wiring to TIOC-555HD.
Allen-Bradley 1734-AENT: Comparable EtherNet/IP I/O adapter; TIOC-555HD offers higher density at lower cost.
Wago 750-8212: PLC with integrated I/O; TIOC-555HD serves as a more scalable remote option.
Installation and Maintenance
Pre-installation preparation: Before installing the CCC TIOC-555HD, confirm that the 24 VDC power supply can deliver at least 2 A continuous current to support all 32 outputs under load. Mount the unit on a standard 35 mm DIN rail within an IP54-rated cabinet if used in dusty or wet environments. Use shielded cables for sensor/actuator wiring, grounding shields at the cabinet end only. Assign a static IP or enable DHCP on your network; use CCC’s free Discovery Tool or access http://[module_IP] to configure protocol settings before connecting to the PLC.
Maintenance recommendations: Regularly inspect the CCC TIOC-555HD’s status LEDs—green “Run” and “Comms” indicate normal operation, while red “Fault” may signal over-temperature or output short. Clean dust from ventilation slots annually using dry compressed air. If communication is lost, power-cycle the unit or use the web interface to reset the network stack. Avoid hot-swapping field wiring under load to prevent MOSFET degradation. Firmware updates can be performed remotely via the web UI to add new features or fix rare protocol edge cases.
