Beckhoff C6525 User manual

Installation and Operating instructions for
Built-in Industrial PC C6525
Version: 1.1
Date: 2021-11-15

Table of contents
1 6525
Table of contents
1. 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
2. Product Description 6
Appropriate Use 6
Access to the Hard Disk, the CF-Slot and the Battery 6
Interfaces 7
Serial interface 7
DVI (Digital Visual Interface) 7
USB-Interfaces 7
Network connection 7
Power Supply 7
Additional plug-in cards (optional) 7
Ground connection 7
3. Installation Instructions 8
Transport and Unpacking 8
Transport 8
Unpacking 8
Installation of the PC in the control cabinet 9
Earthing measures 9
Mounting of the Industrial PC 10
Power Supply Connection 11
Beckhoff power supply technology 11
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
Configuration for shutting down the PC 14
PC_ON and Power Status functions 14
UPS output 14
UPS output function 14
Wiring diagram 15
Connecting devices 16
Connecting cables 16
Check voltage rating and connect 16
Fastening the cables 16
4. Operating Instructions 17
Switching the Industrial PC on and off 17
First switching on and driver installation 17
Maintenance 18
Cleaning the Industrial PC 18
Replacing the battery on the motherboard 18
Servicing 18
Shutting down 18
Disposal 18
5. UPS Software Components (optional) 19
Installation on the PC 19
Help files 19

Table of contents
26525
6. Troubleshooting 20
Fault correction 20
Beckhoff Support & Service 21
Beckhoff branches and partner companies 21
Beckhoff Headquarters 21
Beckhoff Support 21
Beckhoff Service 21
7. Assembly dimensions 22
8. Appendix 23
Technical data 23
Approvals 23
FCC: Federal Communications Commission Radio Frequency Interference
Statement 23
FCC: Canadian Notice 23

General Notes
6525 3
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.

General Notes
46525
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.
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.

General Notes
6525 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 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.

Product Description
66525
Product Description
Appropriate Use
The 6525 Industrial PC is designed for mounting in control cabinets or in
the rear panel of a control or console housing for machine and plant
engineering applications. The heat sink of the IPC is thereby fed to the
outside through a suitable cut-out in the panel of the control cabinet. This
ensures that the power dissipation of the processor and chipset is given off
directly to the surroundings.
View form the top
Configuration
The 6525 is a fanless Industrial PC with passive cooling and can hence be
constructed completely without rotating parts. Integrated seals provide for
an IP 67 closure.
Access to the Hard Disk, the CF-Slot and
the Battery
A 2½-inch SATA hard disk (optional), the CF-slot and the battery are
located behind the cover plate on top of the Industrial PC.
Removing the cover plate
After loosening the two screws (1) and (2) the cover plate can be removed.
Access to the hard disk, the
CF-slot and the battery
1
2
battery
CF-slot
2½-inch SATA hard disk

Product Description
6525 7
Interfaces
Interfaces to the
Industrial PC
Serial interface
RS 232
COM1
The Industrial PC has one serial interfaces, COM1 (X102), using the type
RS232, which is brought to a 9 pin SUB-D plug connector.
DVI (Digital Visual Interface)
DVI
The DVI connection (X103) is used for transferring the video signal.
USB-Interfaces
USB1 –USB4
The four USB interfaces (X105 –X108) are used for connecting peripheral
devices with USB connection. USB2.0 standard is supported.
Network connection
Network 10/100BASE-T
The RJ-45 connector (X109) allows the PC to be connected to a
10/100BASE-T Local Area Network (LAN).
Network
10/100/1000BASE-T
The RJ-45 connector (X110) allows the PC to be connected to a
10/100/1000BASE-T Local Area Network (LAN).
Power Supply
Power supply
The power supply for the Industrial PC is established via the
socket (X111).
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
Ground connection
The Industrial PC is grounded via the stud bolt.
stud bolt
X102
X111
X110
X109
X108
X107
X103
X106
X105

Installation Instructions
86525
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.

Installation Instructions
6525 9
Installation of the PC in the control cabinet
The 6525 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).
Preparation of the control
cabinet
The control cabinet must be provided with the relevant cutout (see chapter
Assembly dimensions).
i
Note
The clearance above and below the housing must be at least 200 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 beside
the power supply connector of the Industrial PC (see chapter Ground
connection).

Installation Instructions
10 6525
Mounting of the Industrial PC
The Industrial PC is mounted with clamping levers.
Mounting of the Industrial
PC with clamping levers
For installation the Industrial PC proceed as follows:
Release clamping levers,
Insert the Industrial PC into the cutout.
Release the clamping levers with a
No. 2.5 Allen key.
folding them out
Turn the clamping levers to the side
through 90°,
and retighten them.
and retighten the screws.
Clamping levers

Installation Instructions
6525 11
Power Supply Connection
Supplied mains power unit
The Industrial PC is fitted with a 24 VDC power supply unit .
i
Note
When the Industrial PC is provided with a power supply unit with integrated
UPS (order option) you can realize an uninterruptible power supply (UPS)
using the battery pack C9900-U330.
Danger
Danger of Explosion if using other battery packs!
Beckhoff power supply technology
Schematic diagram of
power supply unit wirings
Innovative solution for
shutting down Industrial
PCs
Industrial PCs equipped with a UPS are in actual use frequently switched
off by simply turning off the supply voltage. In this case the PC shuts down
via the battery. However, over time this reduces the service life of the
battery.
The new Beckhoff power supply technology approach addresses this
problem and now offers the user the option of switching the PC off without
the need for using the battery, thereby reducing the load on the battery.
In addition to the main switch this innovative solution uses an ON/OFF
switch for the machine. Basically, the main switch remains switched on and
provides the power supply for the PC during shutdown.
Once the PC has shut down, the PC power supply unit issues a signal to
indicate that the process is complete and that the main voltage can be
switched off. This can be done manually via a signal lamp connection or
via a contactor. With this solution the main switch generally only has to be
switched off if the control cabinet has to be opened.

Installation Instructions
12 6525
In order to maintain a screen display for the Industrial PC in the event of a
power failure, the power supply unit is equipped with a UPS output for
connecting a Control Panel. This enables a power failure to be visualised
and displayed to the user. Once the PC has shut down, the UPS output is
switched off in order to avoid total discharge of the battery.
For a detailed functional description please refer to section Connecting
Power Supply.
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
-
Battery Pack
(with UPS only)
2
+
3
UPS+ (Output)
4
5
-
24 V DC
Power Supply
6
+
7
PC_ON
8
Power-Status
1 2 3 4 5 6 7 8

Installation Instructions
6525 13
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.

Installation Instructions
14 6525
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 maximum 16 A.
Configuration for shutting down the PC
The connections for shutting down the Industrial PCs are established via
the PC_ON input and the Power Status output.
PC_ON and Power Status functions
•If the PC_ON input is connected to 24 V via a switch, the PC shuts
down according to the rules. The PC_ON signal is inverted, i.e. the
PC shuts down if the 24 V connection is live.
•If the PC_ON input is NOT connected by the user, the PC can be
booted in the familiar way by connecting the supply voltage and shut
down via the battery by switching off the supply voltage.
Warning
This procedure significantly reduces the service life of the rechargeable
battery and should therefore not be used.
•Once the PC has shut down, the Power Status output is switched
from 24 V to 0 V. Via this output a signal lamp can be connected or a
contactor for de-energising the whole system. The maximum load for
the Power Status output is 0.5 A and a suitable fuse should be
provided.
UPS output
In order to maintain a screen display for the PC in the event of a power
failure, the power supply unit is equipped with a UPS output for connecting
a Control Panel. The maximum load for the output is 2.0 A.
UPS output function
•The 24 V DC connection at the UPS output is live even after a power
failure. The maximum load is 2.0 A.
•Once the PC has been de-energised via the UPS software, the UPS
output is switched to 0 V. Any connected panel is thus switched off,
and total discharge of the rechargeable battery is prevented.

Installation Instructions
6525 15
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
i
Note
The battery pack can only be connected when the Industrial PC is provided
with an integrated UPS (order option).

Installation Instructions
16 6525
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.
Fastening the cables
Fastening the cables
The connecting cables of the
Industrial PC can be fastened with
lacing cords. Therefore the pictured
clips are mounted at the housing (see
arrow).

Operating Instructions
6525 17
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.

Operating Instructions
18 6525
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.