Installation and Operating instructions for 19 Inch Rack Mount Industrial PC C5101 Version: 1.6 Date: 2012-09-13 Table of contents Table of contents 1. Foreword 3 Notes on the Documentation 3 Liability Conditions 3 Trademarks 3 Patent Pending 3 Copyright 3 State at Delivery 3 Delivery conditions 3 Description of safety symbols 4 Basic safety measures 5 Operator's obligation to exercise diligence 6 Operator requirements 6 2. Product Description 7 Appropriate Use 7 Structure 7 Interfaces 9 Serial interfaces 9 Network connection 9 DVI (Digital Visual Interface) 9 USB interfaces 9 Additional plug-in cards (optional) 9 Interfaces behind the front flap 10 Reset pushbutton 10 LEDs 10 USB interfaces 10 Power pushbutton 10 3. Installation Instructions 11 Transport and Unpacking 11 Transport 11 Unpacking 11 Installation of the PC in the control cabinet 12 Power Supply Connection 13 Mains Socket 13 Power supply cords 13 Connecting devices 14 Connecting cables 14 Check voltage rating and connect. 14 4. Operating Instructions 15 Switching the Industrial PC on and off 15 First switching on and driver installation 15 Servicing and Maintenance 16 Cleaning the Industrial PC 16 Servicing 16 Replacing the battery on the motherboard 16 Changing the filter mat 17 Shutting down 17 Disposal 17 5. Troubleshooting 18 Fault correction 18 Beckhoff Support and Service 19 Beckhoff branches and partner companies 19 Beckhoff company headquarters 19 Beckhoff Support 19 Beckhoff Service 19 6. Assembly dimensions 20 C5101 1 Table of contents 7. Appendix 21 Technical data 21 Approvals 21 FCC: Federal Communications Commission Radio Frequency Interference Statement 21 FCC: Canadian Notice 21 2 C5101 Foreword Foreword Notes on the Documentation This description is only intended for the use of trained specialists in control and automation engineering who are familiar with the applicable national standards. It is essential that the following notes and explanations are followed when installing and commissioning these components. The responsible staff must ensure that the application or use of the products described satisfy all the requirements for safety, including all the relevant laws, regulations, guidelines and standards. Liability Conditions The documentation has been prepared with care. The products described are, however, constantly under development. For that reason the documentation is not in every case checked for consistency with performance data, standards or other characteristics. In the event that it contains technical or editorial errors, we retain the right to make alterations at any time and without warning. No claims for the modification of products that have already been supplied may be made on the basis of the data, diagrams and descriptions in this documentation. Trademarks ® ® ® ® ® Beckhoff , TwinCAT , EtherCAT , Safety over EtherCAT , TwinSAFE ® and XFC are registered trademarks of and licensed by Beckhoff Automation GmbH. Other designations used in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owners. Patent Pending The EtherCAT Technology is covered, including but not limited to the following patent applications and patents: EP1590927, EP1789857, DE102004044764, DE102007017835 with corresponding applications or registrations in various other countries. The TwinCAT Technology is covered, including but not limited to the following patent applications and patents: EP0851348, US6167425 with corresponding applications or registrations in various other countries. Copyright © Beckhoff Automation GmbH. The reproduction, distribution and utilization of this document as well as the communication of its contents to others without express authorization are prohibited. Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a patent, utility model or design. State at Delivery All the components are supplied in particular hardware and software configurations appropriate for the application. Modifications to hardware or software configurations other than those described in the documentation are not permitted, and nullify the liability of Beckhoff Automation GmbH. Delivery conditions In addition, the general delivery conditions of the company Beckhoff Automation GmbH apply. C5101 3 Description of safety symbols The following safety symbols are used in this operating manual. They are intended to alert the reader to the associated safety instructions. Acute risk of injury!! If you do not adhere the safety advise adjoining this symbol, there is DANGER immediate danger to life and health of individuals! Risk of injury! If you do not adhere the safety advise adjoining this symbol, there is WARNING danger to life and health of individuals! Hazard to individuals! If you do not adhere the safety advise adjoining this symbol, there is CAUTION obvious hazard to individuals! Hazard to devices and environment If you do not adhere the notice adjoining this symbol, there is obvious Attention hazard to materials and environment. Note or pointer This symbol indicates information that contributes to better understanding. Note 4 C5101 Basic safety measures Only switch the PC off after Before the Industrial PC is switched off, software that is running must closing the software be properly closed. Otherwise it is possible that data on the hard disk is lost. Please read the section Switching the Industrial PC on and off. Switch off all parts of the equipment, then uncouple the fieldbus Before opening the housing of the PC, and whenever the PC is being used for purposes other than plant control, such as during functional tests Attention following repair, all parts of the equipment must first be switched off, after which the Industrial PC can be uncoupled from the plant. Pulling out the fieldbus connection plug uncouples the PC (optional). Items of equipment that have been switched off must be secured against being switched on again. The Industrial PC’s power supply unit must be supplied with 100 V - 240 V . AC AC Do not open the power supply unit while voltage is applied! The supply voltage must be switched off before the power supply unit housing is opened. DANGER Do not exchange any parts when under power When components are being fitted or removed, the supply voltage must be switched off. Attention Fitting work on the Industrial PC can result in damage: • if metal objects such as screws or tools fall onto operating circuit boards. • if connecting cables internal to the PC are removed or inserted during operation. • if plug-in cards are removed or inserted when the PC is switched on. C5101 5 Operator's obligation to exercise diligence The operator must ensure that • the Industrial PC is only used for its intended use (see also Product Description). • the Industrial PC is in a sound condition and in working order during operation (see also chapter Servicing and Maintenance). • the operation manual is in good condition and complete, and always available for reference at the location of the Industrial PC. • the Industrial PC is operated, maintained and repaired only by sufficiently qualified and authorized personnel. • the personnel is instructed regularly about relevant occupational safety and environmental protection aspects, and is familiar with the operating manual and in particular the safety notes contained herein. • none of the safety and warning notes attached to the Industrial PC are removed, and that all notes remain legible. National regulations Depending on the type of machine and plant in which the Industrial PC is depending on the machine being used, there will be national regulations for the control of such type machines and plant that the operator must observe. These regulations cover, amongst other things, the intervals between inspections of the controller. The operator must initiate such inspections in good time. Only trained persons may open the Industrial PC housing! The operator is responsible for ensuring that only trained electrical staff Attention opens the housing of the Industrial PC. Procedure in the event of a In the event of a fault in the Industrial PC, appropriate measures can be fault determined with the aid of the list in the Fault correction section. Operator requirements Read the operating Every user of the Industrial PC must have read these operating instructions instructions. Software knowledge Every user must be familiar with any of the functions of the software installed on the PC that he can reach. 6 C5101 Product Description Product Description Appropriate Use The C5101 Industrial PC has been designed as a rack mount PC for fitting into 19 inch racks used in machine and plant engineering applications. Structure Front view of the C5101 Opening the front flap In order to gain access to the power pushbutton and to the drives, open the flap on the front with the key provided for the purpose (see photo above). Rear view of the C5101 Only trained persons may open the Industrial PC housing! Before opening the PC housing, the power plug must be drawn. Attention Fire enclosure! The Industrial PC is equipped with a fire enclosure. Before switching on DANGER the PC, the casing must be closed! C5101 7 Product Description Opening the housing In order to open the PC housing, remove the 4 fastening screws at the side of the housing cover (see photo Rear view of the C5101) using a cross- head screwdriver. The cover of the housing can then be lifted up, providing access to the hard drive, processor, memory and plug-in cards (see following photograph). Removing the card holder Remove the 2 fastening screws of the card holder (see arrows) using a cross-head screwdriver. The holder can then be lifted up. View of the open PC 5 1 3 2 4 A plug-in motherboard (1) and a 14-slot passive backplane (2) are located under the housing cover. The power supply unit (3), the hard drive and the CD/ DVD-drives (4) are easily accessible. The connections to the outside are located at the rear of the housing (5) and behind the front flap. 8 C5101 Interfaces Interfaces to the C5101 Industrial PC 3 1 7 4 5 2 8 9 6 Serial interfaces RS 232 The basic version of the C5101 Industrial PC has two serial interfaces, COM1 (1) and COM2 (2), using the type RS232, which are brought to a 9 COM1 - COM2 pin SUB-D plug connector. Network connection Network 100/1000BASE-T The RJ-45 connector (3) allows the PC to be connected to a 100/1000BASE-T Local Area Network (LAN). Network 10/100BASE-T The RJ-45 connector (4) allows the PC to be connected to a 10/100BASE-T Local Area Network (LAN). DVI (Digital Visual Interface) DVI-I The DVI connection (5) is used for transferring the video signal. DVI-I standard is supported. USB interfaces USB1 – USB3 The USB interfaces (6) (7) and (8) are used to connect peripheral devices with USB connections. Two more USB interfaces are located behind the front flap. USB2.0 standard is supported. Additional plug-in cards (optional) Type plate There is a type plate on the top of the Industrial PC which provides information about the hardware configuration of the Industrial PC at the time it was supplied. C5101 9 Interfaces behind the front flap Interfaces behind the front flap 1 2 3 4 5 9 Reset pushbutton Reset pushbutton The reset pushbutton (1) allows to reboot the PC. LEDs Power The LED Power (2) indicates correct power supply. HDD The LED HDD (3) indicates HDD access. USB interfaces USB4 – USB5 The two USB interfaces (4) are used to connect peripheral devices with USB connections. USB2.0 standard is supported. Power pushbutton Power pushbutton The Industrial PC is switched on via the power-pushbutton (5). 10 C5101 Installation Instructions Installation Instructions Please also refer to chapter Foreword. Transport and Unpacking The specified storage conditions must be observed (see chapter Technical data). Transport Despite the robust design of the unit, the components are sensitive to strong vibrations and impacts. During transport, your Industrial PC should therefore be protected from excessive mechanical stress. Therefore, please use the original packaging. Danger of damage to the unit If the device is transported in cold weather or is exposed to extreme Attention variations in temperature, make sure that moisture (condensation) does not form on or inside the device. Prior to operation, the unit must be allowed to slowly adjust to room temperature. Should condensation occur, a delay time of approximately 12 hours must be allowed before the unit is switched on. Unpacking Proceed as follows to unpack the unit: 1. Remove packaging. 2. Do not discard the original packaging. Keep it for future relocation. 3. Check the delivery for completeness by comparing it with your order. 4. Please keep the associated paperwork. It contains important information for handling the unit. 5. Check the contents for visible shipping damage. 6. If you notice any shipping damage or inconsistencies between the contents and your order, you should notify Beckhoff Service. C5101 11 Installation Instructions Installation of the PC in the control cabinet The C5101 Industrial PC is designed for rack mounting in machine and plant engineering applications. The ambient conditions specified for operation must be observed (see chapter Technical data). Preparation of the control Four holes for the fixing bolts have to be provided in the control cabinet cabinet according to the dimensions of the PC (see chapter Assembly dimensions). Circulation of air When the unit is installed in an enclosure, adequate space for ventilation and for opening the PC must be provided. Note The clearance above and below the housing must be at least 5 cm in order to ensure adequate ventilation of the PC. Avoid extreme environmental conditions Extreme environmental conditions should be avoided as far as possible. Attention Protect the PC from dust, moisture and heat. The ventilation slots of the PC must not be covered. 12 C5101 Installation Instructions Power Supply Connection Supplied mains power unit The Industrial PC is fitted with a 100-240 V, 50-60 Hz full range power supply unit (with the option of an uninterruptible power supply, UPS). Current carrying capacity Output voltages from Current loading the 100-240 V power maximum of the 100-240 V power supply unit supply unit +3,3 V 16 A +5 V stand by 2 A +5 V 25 A -5 V 0,3 A +12 V 13 A -12 V 0,8 A Mains Socket A mains socket is located at the rear of the PC housing in order to connect the power supply. Socket at the PC housing Power supply cords Power cords Europe In the area Europe you use the provided cable with inlet connector for non- heating apparatus to connect the Industrial-PC to the power supply. Power cords USA / Canada In the area USA / Canada the power supply cable must show the following specifications according to the supply voltage: Listed, Detachable, maximum 4.5 m (14.76 ft.) long; rated minimum 125 V, 10 A, Type SJT or Type SVT; one end terminates in NEMA 5-15P/-20P grounding-type attachment plug, other end in appliance coupler or Listed, Detachable, maximum 4.5 m (14.76 ft.) long; rated minimum 250 V, 10 A, Type SJT or Type SVT; one end terminates in NEMA 6-15P/-20P grounding-type attachment plug, other end in appliance coupler. C5101 13 Installation Instructions Connecting devices Power supply plug The power supply plug must be withdrawn! Attention Please read the documentation for the external devices prior to connecting them. During thunderstorms, plug connector must neither be inserted nor removed. When disconnecting a plug connector, always handle it at the plug. Do not pull the cable! Connecting cables The connections are located at the top of the Industrial PC and are documented in the product description chapter. When connecting the cables to the Industrial PC, proceed according to the following sequence: • Switch off all the devices that are to be connected. • Disconnect all the devices that are to be connected from the power supply. • Connect all the cables between the Industrial PC and to the devices that are to be connected. • Connect all data transfer cables (if present) to the appropriate plug-in receptacles of the data/telecommunication networks. • Reconnect all devices to the power supply. Check voltage rating and connect. 1. Check that the mains voltage is correct. 2. Insert the provided power supply cable into the Industrial PC's power supply socket. Then connect it to a power socket with a grounded earth connection. 14 C5101 Operating Instructions Operating Instructions Please also refer to chapter Foreword. Switching the Industrial PC on and off Switch on The Industrial PC is switched on with the power pushbutton behind the front flap. Shutting down and The Industrial PC is switched off when either of these switches is off. switching off Control software such as is typically used on Industrial PCs permits various users to be given different rights. A user who may not close software may also not switch the Industrial PC off, since data can be lost from the hard disk by switching off while software is running. First shut down, then switch off the PC If the Industrial PC is switched off as the software is writing a file to the hard disk, the file will be destroyed. Control software typically writes Attention something to the hard disk every few seconds, so that the probability of causing damage by switching off while the software is running is very high. Switch off power supply When you have shut down the Industrial PC, you have to switch off power Attention supply for at least 10 seconds before rebooting the system. After resetting power supply the PC will start booting automatically. First switching on and driver installation When you switch on the Industrial PC for the first time, the pre-installed operating system (optional) will be started. In this case, all the required drivers for any additional, optional hardware components ordered with the PC will already have been installed. If the PC was ordered without operating system, you have to install the operating system and the driver software for any auxiliary hardware yourself. Please follow the instructions in the documentation for the operating system and the additional devices. C5101 15 Operating Instructions Servicing and Maintenance Please also refer to chapter Foreword. Cleaning the Industrial PC Disconnect from power supply Switch off the Industrial PC and all connected devices, and disconnect the Industrial PC from the power supply. Attention The Industrial PC can be cleaned with a soft, damp cloth. Do not use any aggressive cleaning materials, thinners, scouring material or hard objects that could cause scratches. Servicing The Industrial PC requires no maintenance. Replacing the battery on the motherboard A used battery on the motherboard has to be replaced. Danger of Explosion! Replace battery only with the identical type or an alternative type WARNING recommended by the manufacturer. Notice correct polarity! The used battery must be disposed of in accordance with national electronics scrap regulations. 16 C5101 Operating Instructions Changing the filter mat If the Industrial PC is used in an environment where the air is particularly dirty, the fan's filter mat should be examined at regular intervals to see how dirty it is, and should be exchanged, if necessary, for an original Beckhoff filter mat (item number C9900-Z213, filter mat for C510x, 10 per pack). Please also refer to chapter Changing the filter mat. Front view showing the filter drawer 1 3 2 Access to the filter mat Access to the filter mat is obtained behind the front flap. This must be opened with its key. The filter drawer (1) can then be pulled out towards the right using the retention tongue (2). After the mat (3) has been changed the filter is refitted in the reverse sequence. Shutting down Disposal Dismantling the Industrial The device must be fully dismantled in order to dispose of it. The housing PC can be sent for metal recycling. Observe national Electronic parts such as disk drives and circuit boards must be disposed of electronics scrap in accordance with national electronics scrap regulations. regulations C5101 17 Troubleshooting Troubleshooting Please also refer to chapter Foreword. Fault correction Fault Cause Procedure Nothing happens after the Industrial No power supply to the Industrial Check power supply cable PC has been switched on PC Other cause Call Beckhoff Service The Industrial PC does not boot CD in drive Remove CD and press any fully key Setup settings are incorrect Check the setup settings Other cause Call Beckhoff Service Computer boots, software starts, Cause of the fault is either in the Call the manufacturer of the but control does not operate software or in parts of the plant machine or the software correctly outside the Industrial PC Memory device access error Faulty CD Check the disk in another disk drive Faulty device Call Beckhoff Service The Industrial PC functions only Defective components in the Call Beckhoff Service partially or only part of the time, e.g. Industrial PC no or dark picture, but disk drive responds when switching on 18 C5101 Troubleshooting Beckhoff Support and Service Beckhoff and their partners around the world offer comprehensive support and service, guaranteeing fast and competent assistance with all questions related to Beckhoff products and system solutions. Beckhoff branches and partner companies Please contact your Beckhoff branch office or partner company for local support and service on Beckhoff products! The contact addresses for your country can be found in the list of Beckhoff branches and partner companies: www.beckhoff.com You will also find further documentation for Beckhoff components there. Beckhoff company headquarters Beckhoff Automation GmbH Eiserstraße 5 33415 Verl Germany Phone: +49(0)5246/963-0 Fax: +49(0)5246/963-198 e-mail: info@beckhoff.com Web: http://www.beckhoff.de/ Beckhoff Support Beckhoff offers you comprehensive technical assistance, helping you not only with the application of individual Beckhoff products, but also with wide- ranging services: • worldwide support • design, programming and commissioning of complex automation systems • training program for Beckhoff system components Hotline: +49(0)5246/963-157 Fax: +49(0)5246/963-9157 e-mail: support@beckhoff.com Beckhoff Service The Beckhoff service center supports you in all matters of after-sales service: • on-site service • repair service • spare parts service • hotline service Hotline: +49(0)5246/963-460 Fax: +49(0)5246/963-479 e-mail: mailto:service@beckhoff.com Quote the project number If servicing is required, please quote the project number of your product. C5101 19 Assembly dimensions Assembly dimensions Diagrams of the Industrial PC with dimensions in mm. Assembly orientation The assembly of the unit must take place with the orientation diagrammed Attention here. Front view Industrial PC C5101 Top view Side view 20 C5101 Appendix Appendix Technical data Dimensions Dimensions (W x H x D): 483 x 177 x 449 (+ 51 with handles) mm Weight: 17.0 kg (basic configuration) Do not use the PC in areas The Industrial PC may not be used in areas of explosive hazard. of explosive hazard The following conditions must be observed during operation: Environmental conditions Ambient temperature: 0 to 55°C Atmospheric humidity: Maximum 95%, non-condensing Shock resistance Sinusoidal vibration: (EN 60068-2-6) 10 to 58 Hz: 0.035 mm 2 58 to 500 Hz: 0.5 G (~ 5 m/ s) During reading of CD-ROM: 10 to 58 Hz: 0.019 mm 2 58 to 500 Hz: 0.25 G (~ 2.5 m/ s ) Impact: (EN 60068-2-27) 5 G (~ 50 m/ s²), duration: 30 ms During reading of CD-ROM: 5 G (~ 50 m/ s²), duration: 11 ms Protection class Protection class: IP20 Power supply Supply voltage: 100-240 V, 50-60 Hz 100-240 V power supply AC Power consumption: C5101-0020: 68 W for the basic version unit C5101-0030: 93 W for the basic version Electromagnetic Interference resistance: according to EN 61000-6-2 Compatibility (EMC) Emitted resistance: according to EN 61000-6-4 Transport and storage The same values for atmospheric humidity and shock resistance are to be observed during transport and storage as in operation. The shock resistance during transport can be improved by means of suitably packing the Industrial PC. The ambient temperature during storage and transport must be between -20°C and +65°C. Approvals FCC: Federal Communications Commission Radio Frequency Interference Statement FCC Approval for USA This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense. FCC: Canadian Notice FCC Approval for Canada This equipment does not exceed the Class A limits for radiated emissions as described in the Radio Interference Regulations of the Canadian Department of Communications. C5101 21