Beckhoff C6640 User manual

Installation and Operating instructions for
Control Cabinet Industrial PC
C6640, C6650
Version: 1.1
Date: 2010-04-08

Table of contents
Table of contents
1.
2.
3.
4.
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 8
Interfaces 9
PS/2 connections 9
Serial interface 9
Parallel interface 9
VGA connection 9
USB interfaces 9
Network connection 10/100MBit 9
Network connection 1Gbit (optional) 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 (optional) 13
Beckhoff power supply technology 13
Electrical Data 14
Pin assignment of the connectors 14
Pin assignment power supply 14
Pin assignment external wiring 15
Fitting the Cables 15
Fitting the connector 15
Connecting Power Supply 16
Cable Cross Sections 16
Configuration for shutting down the PC 16
PC_ON and Power Status functions 16
UPS output 16
UPS output function 16
Wiring diagram 17
Connecting devices 18
Connecting cables 18
Check voltage rating and connect. 18
Operating Instructions 19
Switching the Industrial PC on and off 19
First switching on and driver installation 19
Servicing and Maintenance 20
Cleaning the Industrial PC 20
Replacing the battery on the motherboard 20
Replacing the fan 20
Servicing 21
C6640, C6650 1

Table of contents
Shutting down 21
Disposal 21
5.
6.
7.
8.
UPS Software Components (optional) 21
Installation on the PC 21
Help files 21
Troubleshooting 22
Fault correction 22
Beckhoff Support & Service 23
Beckhoff branches and partner companies 23
Beckhoff Headquarters 23
Beckhoff Support 23
Beckhoff Service 23
Assembly dimensions 24
C6640, Configuration with 100-240 VAC Power Supply 24
C6640, Configuration with 24 VDC-Power Supply (optional) 25
C6650, Configuration with 100-240 VAC Power Supply 26
C6650, Configuration with 24 VDC-Power Supply (optional) 27
Appendix 28
Technical data 28
Approvals 28
FCC: Federal Communications Commission 28
Radio Frequency Interference Statement 28
FCC: Canadian Notice 28
2C6640, C6650

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.
C6640, C6650 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.
4C6640, C6650

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.
C6640, C6650 5

Product Description
Product Description
Appropriate Use
The C6640 and C6650 Industrial PCs are designed for mounting in control
cabinets for machine and plant engineering applications.
Opening the Housing
View of the C6650,
configuration with
100-240 VAC power supply
The housing cover is locked by a latch. After pressing the key (1) the cover
can be fold up a little in the region of the connectors.
Opening the housing
After folding up the cover as shown, it can be pulled out of the slides in
direction of the arrow.
unlock key (1)
6C6640, C6650

Product Description
Taking off the housing
cover
Now the housing cover can be taken off completely, so providing access to
the components.
The reassembly of the cover takes place in reverse order. Ensure that the
cover engages into the slides (2).
slides on both sides (2)
C6640, C6650 7

Product Description
Configuration with 100-240 VAC Full Range Power Supply
View of the C6650 with 100-240 VAC full range power supply.
Removing the card holder
After loosening the knurled screw the card holder can be lifted off
(see arrow).
Components of the PCs
Under the housing cover there is a 7 slot computer core with standard ATX
motherboard and different processor configuration.
T
he following configuration options of the motherboard are available:
Order option Intel®
Celeron®M
Intel®
Pentium M
Intel®
Core™ Duo
Intel®
Core™ 2 Duo
Intel®
Core™ 2 Quad
C6640-0000 1,5 GHz 1,8 GHz
C6640-0010 2,0 GHz 2,16 GHz
C6640-0020 2,53 GHz 2,26 GHz
C6650-0010 2,0 GHz 2,16 GHz
C6650-0020 2,53 GHz 2,26 GHz
The connections of the Industrial PC are located on top of the housing.
card holde
r
knurled scre
w
2 mobile racks for
3 ½“ serial-ATA HDD
(C6650 only) 3 ½“ serial-ATA HDD
(C6640 only)
position of the
CF card (optional)
fan
100-240 VAC full
range power supply
7-Slot-AT
X
motherboard
main switch
interfaces
8C6640, C6650

Product Description
Interfaces
Interfaces to the
C6640, C6650
PS/2 connections
PS/2 A PC keyboard can be connected to the upper PS/2 connector (X103),
while the lower PS/2 connector (X104) allows a PS/2 mouse to be used.
Serial interface
RS 232
COM1
The basic version of the Industrial PC has 1 serial interface COM1, using
the type RS232. The interface is brought to a 9 pin SUB-D plug connector
(X105).
Parallel interface
Printer
LPT1
The parallel interface (X106) corresponds to the Centronics standard and
is addressed by the software as LPT1.
VGA connection
VGA A 15-pin SUB-D socket connector (X107) allows a VGA monitor to be
connected.
USB interfaces
USB1 – USB4 The four USB interfaces (X108 – X111) are used to connect peripheral
devices with USB connections. The USB2.0 standard is supported.
Network connection 10/100MBit
Network 10/100MBit The RJ-45 connector (X112) allows the PC to be connected to a
10/100MBit Local Area Network (LAN).
Network connection 1Gbit (optional)
Network 1GBit The RJ-45 connector (X113) allows the PC to be connected to a
1GBit Local Area Network (LAN).
Sound-On-Board
Sound The Industrial PC has a on-board-sound interface with the following
connectors:
Microphone jack (X114), Line Out jack (X115) and Line In jack (X116).
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.
X
103
X114
X
108
X
110 X105
X
107
X
111
X
109
X115
X
104
X
113
X
112
X
106
X116
C6640, C6650 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 C6640, C6650

Installation Instructions
Installation of the PC in the control cabinet
The C6640 and C6650 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).
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.
C6640, C6650 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 top 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 C6640, C6650

Installation Instructions
Power Supply Connection with
24 VDC power supply unit (optional)
The Industrial PC is optionally 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.
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
C6640, C6650 13

Installation Instructions
switched off in order to avoid total discharge of the battery.
For a detailed functional description please refer to section Connecting
Power Supply.
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
Pin assignment of the connectors
Two 5-pin plug connectors with CAGE CLAMP connection (see photo) are
installed at the PC housing in order to connect the 24 VDC power supply
and the external components.
Plug connectors with CAGE
CLAMP connection
Pin assignment power supply
Pin assignment for
connecting the power
supply and the battery pack
(optional)
X101
Pin Function
1 -
2 +
Battery Pack (with USV)
3
4 -
5 +
24V DC
Power Supply
X101
X102
1
2
3
4
5
14 C6640, C6650

Installation Instructions
Pin assignment external wiring
Pin assignment for
connecting PC-ON, Power-
Status und UPS-Output
X102
Pin Function
1 -
2 +
UPS-Output
3 Power-Status
4 PC-ON
5 24V DC power supply +pole
Fitting the Cables
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
1
2
3
4
5
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.
C6640, C6650 15

Installation Instructions
Connecting 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.
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.
16 C6640, C6650

Installation Instructions
Wiring diagram
Wiring according to the wiring diagram (the circuit of PC_ON and Power-
Status is symbolical):
Wiring diagram power
supply and external switch
i
Note
The battery pack can only be connected when the Industrial PC is provided
with an integrated UPS (order option).
C6640, C6650 17

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 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.
18 C6640, C6650