Beckhoff C6920 User manual

Installation and Operating instructions for
Control Cabinet PCs
C6920, C6925
Version: 1.5
Date: 2007-01-30

Table of contents
Table of contents
1.
2.
3.
4.
5.
General Notes 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
Product Description 6
Appropriate Use 6
Access to the drives 6
Status-LEDs 7
Fan cartridge C6920 7
Interfaces 8
Power Supply 8
Network connection 8
USB-Interfaces 8
DVI (Digital Visual Interface) 8
Serial interface 8
Fieldbus 8
Additional plug-in cards (optional) 8
Installation Instructions 9
Transport and Unpacking 9
Transport 9
Unpacking 9
Installation of the PC in the control cabinet 10
Earthing measures 10
Power Supply Connection 11
Pin assignment of the connector 11
Fitting the cable 12
Material for assembling the connectors 12
Assembling the connectors 12
Connecting Power Supply 13
Cable Cross Sections 13
PC_ON, Power-Status, UPS output 13
Wiring diagram 14
Connecting devices 15
Connecting cables 15
Check voltage rating and connect 15
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
UPS Software Components (optional) 18
Installation on the PC 18
Help files 18
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Table of contents
6.
7.
8.
Troubleshooting 19
Fault correction 19
Service and Support 20
Beckhoff's branch offices and representatives 20
Beckhoff headquarters 20
Beckhoff Support 20
Beckhoff Service 20
Assembly dimensions 21
Appendix 23
Technical data 23
Approvals 23
FCC: Federal Communications Commission Radio Frequency Interference
Statement 23
FCC: Canadian Notice 23
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General Notes
General Notes
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.
Danger
This symbol is intended to highlight risks for the life or health of personnel.
Warning
This symbol is intended to highlight risks for equipment, materials or the
environment.
i
Note
This symbol indicates information that contributes to better understanding.
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General Notes
Basic safety measures
Only switch the PC off after
closing the software
Before the Industrial PC is switched off, software that is running must
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.
Warning
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
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 VDC.
Danger
Do not exchange any parts when under power!
When components are being fitted or removed, the supply voltage must be
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.
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General Notes
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 machine
type
Depending on the type of machine and plant in which the Industrial PC is
being used, there will be national regulations for the control of such
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.
Warning
Only trained persons may open the Industrial PC housing!
The operator is responsible for ensuring that only trained electrical staff
opens the housing of the Industrial PC.
Procedure in the event of a
fault
In the event of a fault in the Industrial PC, appropriate measures can be
determined with the aid of the list in the Fault correction section.
Operator requirements
Read the operating
instructions
Every user of the Industrial PC must have read these operating
instructions.
Software knowledge Every user must be familiar with any of the functions of the software
installed on the PC that he can reach.
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Product Description
Product Description
Appropriate Use
The C6920/ 25 series Industrial PCs are designed for mounting in control
cabinets for machine and plant engineering applications.
Front view of Industrial PC
C6920/ 25
Configuration The C6920 is fitted with a fan cartridge with observated double ball bearing
fans, exchangeable at the front.
The C6925 is a fanless Industrial PC with passive cooling.
Access to the drives
Access to hard-disk
(optional), CF-Card and
battery
Opening the front flap (1) allows access to the battery (2), CF-Card (3) and
the hard disk (4) (optional).
C6920 C6925
1
2
3
4
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Product Description
Status-LEDs
Description of the Status-
LEDs
The Status-LEDs (2) are located near the power supply connector (X101):
PWR (Power): green Busy
green blinking Standby
TC (TwinCAT): red Stop Mode
green Run Mode
blue Configuration Mode
IDE: red
Access to an
IDEdevice
FAN: green Fans running
red Fan Error
USR (User): Programmable
FB RUN (Fieldbus activ): green Activ
red Not activ
FB Error (Fieldbus Error): red Error
2X101
Fan cartridge C6920
View from the top
Exchanging the fan
cartridge For exchanging the fan cartridge, first solve the knurled screw (1). The
cartridge (2) can then be folded down.
1
2
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Product Description
Interfaces
Interfaces to the
C6920/ 25 Industrial PCs
Power Supply
Power supply The power supply for the Industrial PC is established via the
socket (X101).
Network connection
Network 100/1000BASE-T The RJ-45 connector (X102) allows the PC to be connected to a
100/1000BASE-T Local Area Network (LAN).
Network 10/100BASE-T The RJ-45 connector (X103) allows the PC to be connected to a
10/100BASE-T Local Area Network (LAN).
USB-Interfaces
USB1 – USB4 The four USB interfaces (X104 – X107) are used for connecting peripheral
devices with USB connection. USB2.0 standard is supported.
DVI (Digital Visual Interface)
DVI-I The DVI connection (X108) is used for transferring the video signal. DVI-I
standard is supported.
Serial interface
RS 232
COM1
The Industrial PC has one serial interfaces, COM1 (X109), using the type
RS232, which is brought to a 9 pin SUB-D plug connector.
Fieldbus
Fieldbus
The Industrial PC has one fieldbus-interface (X110), which is brought to a
9 pin SUB-D plug connector.
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.
Ground connection
X104
X
105
X106
X
107 X101
X102
X103
X108X109
X110
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Installation Instructions
Installation Instructions
Please also refer to chapter General Notes.
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.
Warning
Danger of damage to the unit!
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.
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Installation Instructions
Installation of the PC in the control cabinet
The C6920/ 25 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
cabinet
Four holes for the fixing bolts have to be provided in the control cabinet
according to the dimensions of the PC (see chapter Assembly dimensions).
i
Note
When the unit is installed in an enclosure, adequate space for
ventilation and for opening the PC must be provided.
The clearance above and below the housing must be at least 50 mm
in order to ensure adequate ventilation of the PC.
Warning
Extreme environmental conditions should be avoided as far as
possible. Protect the PC from dust, moisture and heat.
The ventilation slots of the PC must not be covered.
Earthing measures
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
front side of the housing (see photograph on the left).
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Installation Instructions
Power Supply Connection
Supplied mains power unit The Industrial PC is fitted with a 24 VDC power supply unit .
Optional an uninterruptible power supply (UPS) can be realized using the
battery pack C9900-U330.
Danger
Danger of Explosion if using other battery packs!
Pin assignment of the connector
The power supply and the external circuit for switching the Industrial PC on
and off are connected via the 8-pole plug connector .
Pin assignment for
connecting the switch, the
power supply and the
battery pack (optional)
Pin Function
1 -
2 +
Battery Pack
(with USV)
3 UPS+ (Output)
4
5 -
6 +
24 V DC
Power Supply
7 PC_ON
8 Power-Status
1 2 3 4 5 6 7 8
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Installation Instructions
Fitting the cable
Wiring in accordance with
wiring diagram
Fit the cables for the power supply of the Industrial PC, the connection of
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 8-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
until 1.5 mm2.
Fitting the connector to the
cable
So the connector is fitted to the cable:
1. Strip insulation from the cable ends (Length of stripped conductor
is 8 – 9 mm).
2. Screw together the cable ends in the 8-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.
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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,
avoid voltage drop!
For the connection of the power supply, wiring with a cable-cross-section
of 1.5 mm2 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, UPS output
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 connecting an air gap switch for
disconnecting the system from power supply. The maximum
current loading of the Power-Status output is 0.5 A.
• After power failure, there are still 24 V DC between UPS output
and Battery - Pole, current loading maximum 1.4 A.
• After the PC is disconnected from power supply via UPS software,
the UPS output is switched to 0V too. A connected Panel is thus
switched off, a total-discharge of the battery is not possible.
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Installation Instructions
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
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Installation Instructions
Connecting devices
Warning
The power supply plug must be withdrawn!
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 VDC power supply unit:
1. Check that the external power supply is providing the correct
voltage.
2. Insert the power supply cable that you have assembled into the
Industrial PC's power supply socket. Then connect it to your
external 24 V power supply.
Warning
If a 24 V UPS is installed, the same type of rechargeable battery must
be used.
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Operating Instructions
Operating Instructions
Please also refer to chapter General Notes.
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
switching off
When the plant is switched off, or when it is disconnected from its power
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.
Warning
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
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.
Warning
When you have shut down the Industrial PC, you have to switch off power
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.
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Operating Instructions
Maintenance
Please also refer to chapter General Notes.
Cleaning the Industrial PC
Danger
Switch off the Industrial PC and all connected devices, and disconnect the
Industrial PC from the power supply.
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. See also chapter Product Description.
Danger
Danger of Explosion if battery is incorrectly replaced. Replace only with
same or equivalent type recommended by the manufacturer. Dispose of
used batteries according to the manufacturer's instructions.
Servicing
The Industrial PC requires no maintenance.
Shutting down
Disposal
Dismantling the Industrial
PC
Observe national
electronics scrap
regulations
The device must be fully dismantled in order to dispose of it. The housing
can be sent for metal recycling.
Electronic parts such as disk drives and circuit boards must be disposed of
in accordance with national electronics scrap regulations.
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UPS Software Components (optional)
UPS Software Components (optional)
Installing the UPS driver
software
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.
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
System
The driver software comes with a detailed help function.
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.
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