Installation and Operating instructions for Control Cabinet PCs C63xx - 0020 Version: 1.4 Date: 2009-08-20 Table of contents Table of contents 1. General instructions 3 Notes on the Documentation 3 Liability Conditions 3 Description of safety symbols 3 Basic safety measures 4 Operator’s obligation to exercise diligence 5 Operator requirements 5 2. Product Description 6 Appropriate Use 6 Structure C63x5 – 0020 6 Structure C63x0 – 0020 7 Interfaces 9 USB interfaces 9 Network connection 9 DVI interface 9 USB interface 9 Serial interface 9 Additional plug-in cards (optional) 9 3. Installation Instructions 10 Transport and Unpacking 10 Transport 10 Unpacking 10 Installation of the PC in the control cabinet 11 Power Supply Connection 12 Electrical data 12 Pin assignment of the connector 12 Fitting the cable 13 Material for assembling the connectors 13 Assembling the connectors 13 Connecting Power Supply 14 Cable Cross Sections 14 PC_ON, Power-Status 14 Wiring diagram 14 Connecting devices 15 Connecting cables 15 Check voltage rating and connect 15 4. Operating Instructions 16 Switching the Industrial PC on and off 16 First switching on and driver installation 16 Maintenance 17 Cleaning the Industrial PC 17 Replacing the battery on the motherboard 17 Servicing 17 Shutting down 17 Disposal 17 5. UPS Software Components (optional) 18 Installation on the PC 18 Help files 18 1 C63xx - 0020 Table of contents 6. Troubleshooting 19 Fault correction 19 Beckhoff Support & Service 20 Beckhoff branches and partner companies 20 Beckhoff Headquarters 20 Beckhoff Support 20 Beckhoff Service 20 7. Assembly dimensions 21 8. Appendix 27 Technical data 27 Approvals 27 FCC: Federal Communications Commission Radio Frequency Interference Statement 27 FCC: Canadian Notice 27 2 C63xx - 0020 General instructions General instructions 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. Liability Conditions 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. 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. None of the statements of this manual represents a guarantee (Garantie) in the meaning of § 443 BGB of the German Civil Code or a statement about the contractually expected fitness for a particular purpose in the meaning of § 434 par. 1 sentence 1 BGB. 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. © This documentation is copyrighted. Any reproduction or third party use of this publication, whether in whole or in part, without the written permission of Beckhoff Automation GmbH, is forbidden. 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. This symbol is intended to highlight risks for the life or health of personnel. Danger This symbol is intended to highlight risks for equipment, materials or the environment. Warning This symbol indicates information that contributes to better understanding. i Note C63xx - 0020 3 General instructions 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 on 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 Warning for purposes other than plant control, such as during functional tests 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 24 V . DC Do not exchange any parts when under power! When components are being fitted or removed, the supply voltage must be Danger switched off. 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. 4 C63xx - 0020 General instructions 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 chapter). • the Industrial PC is in a sound condition and in working order during operation. • 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 Warning 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. C63xx - 0020 5 Product Description Product Description Appropriate Use The C63xx – 0020 series Industrial PCs in connection with a DVI / USB- Control-Panel CP68xx or CP78xx are designed for mounting in control cabinets for machine and plant engineering applications. Structure C63x5 – 0020 Example: Front view of Industrial PC C6335 – 0020 in basic configuration 3 1 2 Opening the housing To open the PC housing, release the screw (1) by one turn using a screwdriver. The plastic cap (2) can be then be pulled forward, thereby releasing the lid (3). Top view of the open housing 1 The aluminium lid can now be lifted off. The heatsink (1) enables the fanless operation up to an ambient air o temperature of 45 C. 6 C63xx - 0020 Product Description View of the open PC C6335 – 0020 2 3 1 The computer chassis can now be removed from the housing. The power supply and the hard disk are located in the lower part of the chassis (1) of the C6335 – 0020. The C6325–0020 is equipped with a flash-disk instead of the hard disk, through which this PC makes do without mechanically agitated parts. The slot motherboard (2) is located in the second slot of the housing. The Slim Line CD-ROM drive (3) is visible right on the picture (only C6335– 0020). Structure C63x0 – 0020 Example: Front view of Industrial PC C6350 – 0020 in basic configuration 3 1 2 Opening the housing To open the PC housing, release the screw (1) by one turn using a screwdriver. The plastic cap (2) can be then be pulled forward, thereby releasing the lid (3). C63xx - 0020 7 Product Description Top view of the open housing 1 The aluminium lid can now be lifted off. Avoid damaging the electrical supply line to the fan (1)! View of the open PC C6350 – 0020 2 3 1 The computer chassis can now be removed from the housing. The power supply and the hard disk are located in the lower part of the chassis (1). The slot motherboard (2) is located in the second slot of the housing. The Slim Line CD-ROM drive (3) is visible right on the picture (only C6330 – 0020 and C6350 – 0020). 8 C63xx - 0020 Product Description Interfaces Interfaces to the C63xx–0020 Industrial PCs 3 4 1 7 5 2 6 USB interfaces USB1 – USB2 The two USB interfaces (1) and (2) are used for connecting the Control Panel CP68xx or CP78xx. USB2.0 standard is supported. Alternatively, peripheral devices with USB port may be connected. Network connection Network The PC is connected with the local network via the 10/100 Base-T RJ-45 connectors (3) and (4) of the On-Board Ethernet adapter. DVI interface DVI-I The DVI interface (5) is used for connecting the Control Panel CP68xx or CP78xx. Alternatively, a monitor with DVI input or VGA input can be connected. For connecting a monitor with VGA input the adapter C9900-Z411 or C9900-Z413 is required additionally: • C9900-Z411: Adapter plug DVI-I to VGA • C9900-Z413: Adapter cable DVI-I to DVI and VGA, 15cm USB interface USB3 An additional USB-interface (6) is used for connecting peripheral devices with USB port. USB2.0 standard is supported. Serial interface RS 232 The basic version of the C63xx - 0020 Industrial PC has one serial interface COM2, using the type COM2 RS232, which is brought to a 9 pin SUB-D plug connector. The COM1 interface is internally connected to the power supply unit. Additional plug-in cards (optional) Type plate A type plate is located at the plastic cap of the PC housing, providing information about the Industrial PC equipment as delivered. C63xx - 0020 9 Installation Instructions Installation Instructions Please also refer to chapter General instructions. 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! Warning If the device is transported in cold weather or is exposed to extreme 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. 10 C63xx - 0020 Installation Instructions Installation of the PC in the control cabinet The C63xx - 0020 Industrial PCs are designed for mounting in control cabinets for 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). When the unit is installed in an enclosure, adequate space for i ventilation and for opening the PC must be provided. Note Extreme environmental conditions should be avoided as far as possible. Protect the PC from dust, moisture and heat. Warning The ventilation slots of the PC must not be covered. Earthing measures Earthing connections dissipate interference from external power supply cables, signal cables or cables to peripheral equipment. Establish a low-impedance connection from the earthing point on the PC housing to the central earthing point on the control cabinet wall, in which the computer is being installed. The earthing connection is located at the top of the housing (see photograph on the left). C63xx - 0020 11 Installation Instructions Power Supply Connection Supplied mains power unit The Industrial PC is fitted with a 24 V power supply unit . DC Optional an uninterruptible power supply (UPS) can be realized using the battery pack C9900-U330. Danger of Explosion if using other battery packs! Danger Electrical data Input voltage: 22 – 30 V DC Current consumption: 10 A (22 V) Power consumption: 150 W (max.) Current carrying capacity Output voltages from Current loading the 24 V power supply maximum of the 24 V power supply unit unit + 5 V 10 A - 5 V 0.2 A + 12 V 8 A - 12 V 0.4 A + 3.3 V 12 A 5 V VSB 1.5 A Pin assignment of the connector The Industrial PC becomes switched on and off with an external circuit. Therefore, a 5-pole plug connector (pin 1–pin 5) is located at the PC housing. The Industrial PC is connected to the power supply via the lower 5-pole plug connector (Pin 6 – Pin 10). Upper Connector Pin assignment for Pin Function connecting the switch, the power supply and the 1 PC_ON battery pack (optional) 2 Power-Status 3 4 - 24 V DC Power supply 5 + Lower Connector Pin Function 6 - Battery Pack (with USV) 7 + 8 9 - 24 V DC Power supply 10 + 12 C63xx - 0020 Installation Instructions Fitting the cable Wiring in accordance with Fit the cables for the power supply of the Industrial PC, the connection of wiring diagram the battery pack as well as the connection of the power-switch in accordance with the wiring diagram, using the included material for assembling the connectors. Material for assembling the connectors Material for assembling the connectors Plug connector 5-pole Strain relief housing with lacing cord Assembling the connectors Conductive cross-section The connector is specified for 16 A and can lift conductive cross-sections 2 until 1,5 mm . Fitting the connector to the So the connector is fitted to the cable: cable 1. Strip insulation from the cable ends (Length of stripped conductor is 8 – 9 mm). 2. Screw together the cable ends in the 5-pole plug connector in accordance with wiring diagram. Applying the strain relief Thread the lacing cord into that lower part of the strain relief housing. Putting in the plug connector Put the plug connector into that lower part of the strain relief housing. Tighten the lacing cord and pinch off the plastic strap. Fixing the upper part of the strain relief housing Fix the upper part of the strain relief housing by snapping it onto the lower part. C63xx - 0020 13 Installation Instructions Connecting Power Supply The external wiring consists of the connection of the power supply, the battery pack (optional) and the connection of customised components for shutting down the PC. Cable Cross Sections Note cable cross sections, For the connection of the power supply, wiring with a cable-cross-section 2 avoid voltage drop! of 1,5 mm must be used. With bigger distances between voltage source and PC, you take the voltage drop as a function of the cable-cross-section as well as voltage fluctuations of your distribution voltage into account, so that is secured that the voltage doesn't fall under 22 V at the power supply. Insert Fuse The power supply must be protected with 16 A. PC_ON, Power-Status The circuit for shutting down the Industrial PC is realized using the input- signal PC_ON and the output-signal Power-Status: • The PC starts shutting down if 24 V exists at PC_ON, for example using a switch. • After shutting down, the output-voltage of 24 V at Power-Status is switched to 0 V. This allows for example connecting an air gap switch for disconnecting the system from power supply. Wiring diagram Wiring according to the wiring diagram (the circuit of PC_ON and Power- Status is symbolical): Wiring diagram external switch and power supply 14 C63xx - 0020 Installation Instructions Connecting devices The power supply plug must be withdrawn! Warning 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 Fitted with the 24 V power supply unit: DC 1. Check that the external power supply is providing the correct voltage. 2. Insert the power supply cable that you have assembled (see the section Fitting the cable) into the Industrial PC's power supply socket. Then connect it to your external 24 V power supply. If a 24 V UPS is installed, the same type of rechargeable battery must be used. Warning C63xx - 0020 15 Operating Instructions Operating Instructions Please also refer to chapter General instructions. Switching the Industrial PC on and off Switch on The Industrial PC does not have its own mains switch. The Industrial PC will start when the equipment is switched on, or when it is connected to the power supply. Shutting down and When the plant is switched off, or when it is disconnected from its power switching off supply, the Industrial PC will be switched 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 Warning hard disk, the file will be destroyed. Control software typically writes 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. When you have shut down the Industrial PC, you have to switch off power supply for at least 10 seconds before rebooting the system. Warning 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. 16 C63xx - 0020 Operating Instructions Maintenance Please also refer to chapter General instructions. Cleaning the Industrial PC Switch off the Industrial PC and all connected devices, and disconnect the Industrial PC from the power supply. Danger 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. Replacing the battery on the motherboard A used battery on the motherboard has to be replaced according to the rules of the board manufacturer. Danger of Explosion if battery is incorrectly replaced. Replace only with same or equivalent type recommended by the manufacturer. Dispose of Danger used batteries according to the manufacturer's instructions. Servicing The Industrial PC requires no maintenance. 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 C63xx - 0020 17 UPS Software Components (optional) UPS Software Components (optional) Installing the UPS driver For operating the power supply unit as a UPS, the UPS driver software and the associated UPS driver must be installed on the Industrial PC. software On delivery of the Beckhoff Industrial PC with operating system the software is already installed. Should the software not be installed on your PC, the drivers can be installed from the driver CD provided. Installation on the PC Installation To install the UPS driver software, execute file Beckhoff_UPS_vx.xx.xx.exe from the subdirectory of UPS\… from the CD provided on the Industrial PC (Driver-archive for the Industrial-PC, C9900-S700-xxxx). The program is self-extracting and will guide the user through the installation routine. Help files Beckhoff Information The driver software comes with a detailed help function. System The help files can be called up either directly from the configuration register by clicking the Help button, or under via Start > Programs > Beckhoff > UPS software components. 18 C63xx - 0020 Troubleshooting Troubleshooting Please also refer to chapter General instructions. 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 Floppy disk or CD in the drive. Remove floppy disk or CD fully and press any 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. Floppy disk or CD access error Faulty disk or CD. Check disk or CD in another drive. Faulty disk drive. 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 C63xx - 0020 19 Troubleshooting Beckhoff Support & 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 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 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: service@beckhoff.com Quote the project number If servicing is required, please quote the project number of your product. 20 C63xx - 0020 Assembly dimensions Assembly dimensions The following pages show diagrams of the Industrial PCs, with dimensions in mm. The assembly of the unit must take place with the orientation diagrammed here. Warning Industrial-PC C6320-0020 Mounting plate at the side panel front view side view Mounting plate at the rear panel front view side view C63xx - 0020 21 Assembly dimensions The assembly of the unit must take place with the orientation diagrammed here. Warning Industrial-PC C6325-0020 Mounting plate at the side panel side view front view Mounting plate at the rear panel front view side view 22 C63xx - 0020 Assembly dimensions The assembly of the unit must take place with the orientation diagrammed here. Warning Industrial-PC C6330-0020 Mounting plate at the side panel front view side view Mounting plate at the rear panel front view side view C63xx - 0020 23 Assembly dimensions The assembly of the unit must take place with the orientation diagrammed here. Warning Industrial-PC C6335-0020 Mounting plate at the side panel front view side view Mounting plate at the rear panel front view side view 24 C63xx - 0020 Assembly dimensions The assembly of the unit must take place with the orientation diagrammed here. Warning Industrial-PC C6340-0020 Mounting plate at the side panel front view side view Mounting plate at the rear panel side view front view C63xx - 0020 25 Assembly dimensions The assembly of the unit must take place with the orientation diagrammed here. Warning Industrial-PC C6350-0020 Mounting plate at the side panel front view side view Mounting plate at the rear panel side view front view 26 C63xx - 0020 Appendix Appendix Technical data Industrial-PC C6320-0020 Dimensions (W x H x D): 93 x 196 x 226 mm (without mounting plate) Weight: 4,0 kg (basic configuration) Industrial-PC C6325-0020 Dimensions (W x H x D): 133 x 196 x 226 mm (without mounting plate) Weight: 6,0 kg (basic configuration) Industrial-PC C6330-0020 Dimensions (W x H x D): 107 x 196 x 226 mm (without mounting plate) Weight: 4,6 kg (basic configuration) Industrial-PC C6335-0020 Dimensions (W x H x D): 147 x 196 x 226 mm (without mounting plate) Weight: 6,6 kg (basic configuration) Industrial-PC C6340-0020 Dimensions (W x H x D): 134 x 196 x 226 mm (without mounting plate) Weight: 4,5 kg (basic configuration) Industrial-PC C6350-0020 Dimensions (W x H x D): 148 x 196 x 226 mm (without mounting plate) Weight: 5,1 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/ -29) 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: 22–30V V DC 24 V power pack DC Power consumption: 150 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. C63xx - 0020 27