Beckhoff C6240-1007 User manual

Installation and Operating instructions for
Control Cabinet Industrial PC
C6240-1007
Version: 1.0
Date: 2007-12-20

Table of contents
Table of contents
1.
2.
3.
4.
5.
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
Product Description 6
Appropriate Use 6
Opening the Housing 6
Configuration with 100-240 VAC Full Range Power Supply 7
Configuration with 24 VDC Power Supply (optional) 8
Interfaces 9
PS/2 connections 9
Parallel interface 9
Serial interfaces 9
VGA connection 9
USB interfaces 9
Network connection 9
Sound-On-Board 9
Additional plug-in cards (optional) 9
Installation Instructions 10
Transport and Unpacking 10
Transport 10
Unpacking 10
Installation of the PC in the control cabinet 11
Earthing measures 11
Power Supply Connection with 100-240 VAC power supply unit 12
Mains Socket 12
Power supply cords 12
Power Supply Connection with 24 VDC power supply unit 13
Electrical Data 13
Connecting the power supply 13
Power Switch 13
Fitting the Power Supply Cable 14
Fitting the connector 14
Connecting 24V DC Power Supply 15
Cable Cross Sections 15
PC_ON, Power-Status, UPS output 15
Wiring diagram 15
Connecting devices 16
Connecting cables 16
Check voltage rating and connect. 16
Operating Instructions 17
Switching the Industrial PC on and off 17
First switching on and driver installation 17
Servicing and Maintenance 18
Cleaning the Industrial PC 18
Replacing the battery on the motherboard 18
Servicing 18
Shutting down 18
Disposal 18
UPS Software Components (optional) 19
Installation on the PC 19
Help files 19
C6240-1007 1

Table of contents
6.
7.
8.
Troubleshooting 20
Fault correction 20
Service and Support 21
Beckhoff's branch offices and representatives 21
Beckhoff headquarters 21
Beckhoff Support 21
Beckhoff Service 21
Assembly dimensions 22
Configuration with 100-240 VAC Power Supply 22
Configuration with 24 VDC-Power Supply (optional) 23
Appendix 24
Technical data 24
Approvals 24
FCC: Federal Communications Commission 24
Radio Frequency Interference Statement 24
FCC: Canadian Notice 24
2C6240-1007

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.
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.
C6240-1007 3

General instructions
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
100 VAC - 240 VAC or 24 VDC (optional).
Danger
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.
Warning
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.
4C6240-1007

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).
• 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 authorised 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.
C6240-1007 5

Product Description
Product Description
Appropriate Use
The C6240-1007 Industrial PCs is designed for mounting in control
cabinets for machine and plant engineering applications.
Opening the Housing
Front view of C6240-1007,
configuration with
100-240 VAC power supply
2
11
Front view of C6240-1007,
configuration with
24 VDC power supply
(optional)
Opening the housing After solving the two screws (1), the upper housing cover (2) can now be
tilted upwards, thus providing access to the drives, 3½ inch hard disk,
processor, memory and plug-in cards.
2
11
6C6240-1007

Product Description
Configuration with 100-240 VAC Full Range Power Supply
View of the open PC
Under the housing cover is a 7 slot computer core with standard ATX
motherboard for Intel® Core™ Duo and Core™ 2 Duo and a 100-240 VAC
full range power supply.
Front view of the PC
The picture shows the optional configuration of the PC with a removable
hard disk drawer (1) for one Serial-ATA-hard disk drive and a slimline CD/
DVD-ROM drive (2) instead of the standard CD/ DVD-ROM drive.
The connections of the Industrial PC are located at the front of the housing.
removable hard disk
drawer for one Serial-ATA-
hard disk (optional)
card holders
slimline CD/ DVD-ROM
drive (optional)
100-240 VAC
full range power supply 3 ½“ hard disk
7-slot-ATX motherboard
fan
interfaces
1
2
C6240-1007 7

Product Description
Configuration with 24 VDC Power Supply (optional)
View of the open PC
Under the housing cover is a 7 slot computer core with standard ATX
motherboard for Intel® Core™ Duo and Core™ 2 Duo and a fanless
24 VDC power supply unit (optional with UPS).
Front view of the PC
The picture shows the optional configuration of the PC with a multi DVD
drive (1) instead of the standard CD/ DVD-ROM drive.
The connections of the Industrial PC are located at the front of the housing.
multi DVD drive (optional)
instead of CD/DVD-ROM
drive
card holders
24 VDC power supply
fanless with UPS (optional)
3 ½“ hard disk 7-slot-ATX motherboard
fan
interfaces
1
8C6240-1007

Product Description
Interfaces
Interfaces for the C6240-
1007
PS/2 connections
PS/2 The upper PS/2 connector (1) allows a PS/2 mouse to be used, while a PC
keyboard can be connected to the lower PS/2 connector (2).
Parallel interface
Printer
LPT1
The parallel interface (3) corresponds to the Centronics standard, and is
addressed by the software as LPT1.
Serial interfaces
RS 232
COM1 – COM4
The basic version of the Industrial PC has 4 serial interfaces,
COM1 – COM4, using the type RS 232, which are each brought
to a 9 pin SUB-D plug connector.
• COM1 (4) is located in the ATX-slot of the motherboard.
• When the PC is fitted with UPS (optional), COM4 is
used from the power supply unit. When fitted without
UPS, the interface COM4 is located in one of the slots
right beside the ATX-slot.
• COM2 and COM3 are located in a slot right beside the
ATX-slot.
VGA connection
VGA A 15-pin SUB-D socket connector (5) allows a VGA monitor to be
connected.
USB interfaces
USB1 – USB4 The four USB interfaces (6 - 9) are used to connect peripheral devices with
USB connections.
Network connection
Network The RJ-45 connector (10) allows the PC to be connected to a Local Area
Network (LAN).
Sound-On-Board
Sound The Industrial PC has a on-board-interface with the following connectors:
Line In jack (11), Line Out jack (12) and Microphone jack (13).
Additional plug-in cards (optional)
Type plate A type plate is located on top of the PC, providing information about the
Industrial PC equipment as delivered.
310 11
1 12
4568
2 13
79
C6240-1007 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.
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.
10 C6240-1007

Installation Instructions
Installation of the PC in the control cabinet
The C6240-1007 Industrial PC is 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).
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.
C6240-1007 11

Installation Instructions
Power Supply Connection with
100-240 VAC power supply unit
Supplied mains power unit The Industrial PC is serially fitted with a 100-240 VAC, 50-60 Hz full range
power supply unit .
Current carrying capacity of
the 100-240 V power
supply unit
Output voltages from the 100-
240 V power supply unit
Current loading
maximum
+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 on side of the PC housing next to the main
switch in order to connect the power supply.
Mains socket and main
switch at the PC housing
main switch
mains socket
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.
12 C6240-1007

Installation Instructions
Power Supply Connection with
24 VDC power supply unit
Power supply unit The Industrial PC is optionally 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!
Electrical Data
Input voltage: 22 – 30 V DC
Current consumption: 10 A (22 V)
Output capacity: 150 W (max.)
Current carrying capacity of
the 24 V power supply unit
Output voltages from the
24 V power supply unit
Current loading
maximum
+ 5 V 14 A
- 5 V 0.3 A
+ 12 V 12 A
- 12 V 0.5 A
+ 3,3 V 12 A
5 V VSB 1.5 A
Connecting the power supply
A 5-pin male plug connector with CAGE CLAMP connection (see photo) is
installed at the PC housing in order to connect the power supply and the
battery pack.
Pin assignment for
connecting the power
supply and the battery pack
Pin Function
1 +
2 -
24V DC
Power Supply
3
4 +
5 -
Battery Pack (with UPS)
Power Switch
The Industrial PC is switched on and off with an external power switch.
Therefore the PC is equipped with a 3-pole male plug connector with
CAGE CLAMP connection.
Pin assignment for
connecting the power switch
Pin Function
1 Power-Status
2 PC_ON
3 24V DC Power Supply + Pole
54321
1 2 3
C6240-1007 13

Installation Instructions
Fitting the Power Supply 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.
The example shows how to fit the 5-pole plug connector:
Materials for assembly of
the connector
Female plug connector 5-pole
Strain relief housing
A
B
CD
Fitting the connector
Fitting the connector to the
cable
The plug is fitted to the cable as follows:
1. Strip insulation from the cable ends (insulation length 8 – 9 mm).
2. Push the conductors into their mountings, simply by pushing them
in as indicated on the pin assignment label.
3. Push the lower part (part A) of the strain relief housing onto the top
of the female plug connector until it snaps into place.
4. Relieve the strain on the supply cable by fixing it in place with the
cable clamp (part C) and fixing screws (part D).
Applying the strain relief
Fix the upper part (part B) of the strain relief housing by snapping it onto
the lower part.
14 C6240-1007

Installation Instructions
Connecting 24V DC Power Supply
The external wiring consists of the connection of the power supply, the
battery pack (optional) and the connection of customized 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 maximum 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.
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
C6240-1007 15

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.
When fitted with 100-240 VAC 50/60 Hz power supply:
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.
When fitted with the (optional) 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 (see the
section on Fitting the Power Supply Cable) 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 correct type of rechargeable battery
must be used.
16 C6240-1007

Operating Instructions
Operating Instructions
Please also refer to chapter General instructions.
Switching the Industrial PC on and off
Switch on • The Industrial PC is switched on via the main switch beside the
mains socket (see chapter Power Supply Connection with
24 VDC power supply unit).
• The Industrial PC with 24 VDC power supply equipment (optional)
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.
C6240-1007 17

Operating Instructions
Servicing and Maintenance
Please also refer to chapter General instructions.
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.
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.
18 C6240-1007