Beckhoff C9900-P208 User manual

Installation and Operating instructions for
C9900-P208/ -P209
Power Supply Unit
Version: 1.3
Date: 2008-09-12

Table of contents
Table of contents
1.
2.
3.
4.
5.
6.
7.
8.
General Notes 2
Notes on the Documentation 2
Liability Conditions 2
Description of safety symbols 2
Basic safety measures 3
Operator's obligation to exercise diligence 3
Product Description 4
Appropriate Use 4
Beckhoff power supply technology 4
Electrical data 5
Installation Instructions 6
Configuration and installation 6
Connection with the motherboard 7
Pin assignment of the pin strips 7
Connection with the Industrial PC 8
Preparing the cable harness 8
External wiring 9
Cable Cross Sections 9
Power supply of the Industrial PC 9
Configuration for shutting down the PC 10
PC_ON and Power Status functions 10
UPS output, C9900-P209 only 10
UPS output function 10
Installation of the supply cables 11
Connector installation 11
Operating Instructions 12
UPS Software Components (only C9900-P209) 12
Installation on the PC 12
Help files 12
Servicing 12
Shutting down 12
Disposal 12
Troubleshooting 13
Beckhoff Support & Service 13
Beckhoff branches and partner companies 13
Beckhoff Headquarters 13
Beckhoff Support 13
Beckhoff Service 13
Assembly dimensions 14
Wiring diagram 15
Appendix 16
Technical data 16
Approvals 16
FCC: Federal Communications Commission Radio Frequency Interference
Statement 16
FCC: Canadian Notice 16
C9900-P208/ -P209 1

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.
2C9900-P208/ -209

Basic safety measures
i
Note
The power supply unit must only be used in conjunction with
Beckhoff Industrial PCs!
Warning
Switch off the power supply of the system during installation!
During assembly, removal and electrical wiring of the power supply unit,
the power supply of the system must be switched off in order to prevent
damage on the power supply unit and the Industrial PC.
Items of equipment that have been switched off must be secured against
being switched on again.
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.
Operator's obligation to exercise diligence
Warning
Only appropriately trained staff may install the power supply unit!
The operator must ensure that only appropriately trained electricians deal
with installation and wiring of the power supply unit.
C9900-P208/ -P209 3

Product Description
Product Description
Appropriate Use
The C9900-P208 and C9900-P209 power supply unit provide the power
supply for Beckhoff Industrial PCs.
The C9900-P209 power supply in conjunction with a C9900-U330 battery
pack allows the construction of an uninterruptible power supply (UPS).
Danger
Risk of explosion if other battery packs are used!
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.
4C9900-P208/ -209

Product Description
The additional contacts for shutting down the PC are connected to a 3-pin
Wago connector that is simply installed in one of the PC slots.
In order to maintain a screen display for the Industrial PC in the event of a
power failure, the C9900-P209 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 External wiring.
Electrical data
Input voltage: 22-30V DC/ 15A
Power output: 250W (max.)
Output voltages: + 5V 14A
+ 12V 12A
+ 3.3V 12A
- 5V 0.3A
- 12V 0.5A
+ 5VSB 1.5A
C9900-P208/ -P209 5

Installation Instructions
Installation Instructions
Configuration and installation
View of the power supply
unit
The power supply unit is installed at the prescribed position in the Industrial
PC.
The supply connections for the power supply unit are located next to the
fan (1). The electrical connections for the motherboard are on the opposite
side (2).
2
1
6C9900-P208/ -209

Installation Instructions
Connection with the motherboard
Pin strips
on the output side
Connection Function
1 ATX interface
2 5V/12V supply
3 POWER ON
4 COM interface
Connection with the
motherboard
The power supply unit is connected
with the motherboard according to
the installation instructions of the
board.
5 12V supply
Pin assignment of the pin strips
Pin Function Pin Function
1 3.3V 11 3.3V
2 3.3V 12 - 12V
3 GND 13 GND
4 + 5V 14 PS ON
5 GND 15 GND
6 + 5V 16 GND
7 GND 17 GND
8 PWR OK 18 - 5V
9 5VSTB 19 + 5V
10 12V 20 + 5V
ATX DC output
Pin Function Pin Function
1 + 12V 5 + 12V
2 GND 6 GND
3 GND 7 GND
4 + 5V 8 + 5V
5V/ 12V supply for drives
Pin Function
1 POWER-ON
2 POWER-ON
POWER ON
Pin Function
3 TXD
5 RXD
9 GND
COM interface
(RS 232)
Pin Function Pin Function
1 GND 3 + 12V
2 GND 4 + 12V
ATX 12V DC-Output
12 3
45
C9900-P208/ -P209 7

Installation Instructions
Connection with the Industrial PC
The power supply unit features an 8-pin contact strip for connecting the
power supply unit inside the Industrial PCs with the respective connection
sockets for power supply, switch and battery pack (C9900-P209 only).
In addition, the C9900-P209 power supply unit features a UPS output for
connecting a Control Panel.
Input 24V DC UPS-
output
Pin strips
Pin assignment for
connecting the switch, the
power supply and the
battery pack (optional)
Input 24V DC:
Pin Function
1 -
2 +
Battery Pack
(C9900-P209 only)
3
4 -
5 +
24 V DC Power Supply
6 Power-Status
7 PC_ON
1 2
7 6 5 4 3 2 1
Pin assignment for
connecting a control panel
(optional)
UPS-output
(C9900-P209 only):
Pin Function
1 UPS-
2 UPS+
UPS-output
Preparing the cable harness
A wiring harness is used for connecting the power supply unit with the
connection sockets in the Industrial PC. Due to different cable lengths, the
harness is produced individually for each type of computer.
The wiring diagram section shows the connection between the 7-pin power
supply unit connector and the 3-pin and 5-pin pin strip at the PC case:
8C9900-P208/ -209

Installation Instructions
Cable harness wiring
diagram
Warning
Insert fuse!
The power supply of the customised components for shutting down the PC
must be protected with a fuse! To this end, a "flying" fuse (6.3A/ medium
time-lag) is inserted in the line.
Note cable cross sections The cable cross sections are 0.75 mm2/ AWG18 for connecting the switch
and 2.5 mm2/ AWG14 (screened) for connecting the power supply.
External wiring
The external wiring occurs according to the wiring diagram, see chapter
Wiring diagram.
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.
Power supply of the Industrial PC
The 5-pin pin strip with CAGE CLAMP connection and mounting flanges
shown on the photograph is mounted on the PC case for connecting the
power supply and the battery pack.
Insert Fuse The power supply must be protected with 16 A.
Pin assignment for
connecting the power
supply and the battery pack
Pin Function
1 +
2 -
24 V DC Power Supply
3
4 +
5 -
Battery Pack
(C9900-P209 only)
1
2
3
4
5
C9900-P208/ -P209 9

Installation Instructions
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. The third contact is
connected to 24 V. To this end, a 3-pin pin strip with CAGE CLAMP
connection and mounting flanges is installed at the PC case.
Pin assignment for
connecting the on/off switch
Pin Function
1 Power-Status
2 PC_ON
3 + 24 V
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, C9900-P209 only
In order to maintain a screen display for the PC in the event of a power
failure, the C9900-P209 power supply unit is equipped with a UPS output
for connecting a Control Panel. The maximum load for the output is 2.0 A.
The UPS output is located on the power supply unit adjacent to the mains
plug (see also section Product Description).
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.
3
2
1
10 C9900-P208/ -209

Installation Instructions
Installation of the supply cables
Wiring according to the
wiring diagram
Install the cables for the power supply of the Industrial PC, the connection
of the battery pack and the connection of the illuminated toggle switch
according to the wiring diagram using the connector assembly material
provided.
Connector assembly is described using the example of the 5-pole female
plug connector:
Materials for assembly of
the connector
Female plug connector, 5-pole
Strain relief housing
A
B
CD
Connector installation
Fitting the connector to the
cable
The plug is fitted to the cable as follows:
1. Remove the insulation from the cable ends (8 - 9 mm).
2. Push the cable into the holders, applying slight pressure according
to the pin assignment label and the wiring diagram.
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) (see photograph
below).
Applying the strain relief
Fix the upper part (part B) of the strain relief housing by snapping it onto
the lower part.
C9900-P208/ -P209 11

Operating Instructions
Operating Instructions
UPS Software Components
(only C9900-P209)
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.
Servicing
The power supply unit is maintenance-free.
Shutting down
Disposal
Dismantling the case
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 must be disposed of in accordance with national
electronics scrap regulations.
12 C9900-P208/ -209

Troubleshooting
Troubleshooting
In the event of a fault contact your Beckhoff Service.
Beckhoff Support & Service
Beckhoff and their partners around the world offer comprehensive support
and service, guaranteeing fast and competent assistance with all questions
related to Beckhoff products and system solutions.
Beckhoff branches and partner companies
Please contact your Beckhoff branch office or partner company for local
support and service on Beckhoff products!
The contact addresses for your country can be found in the list of Beckhoff
branches and partner companies: www.beckhoff.com
You will also find further documentation for Beckhoff components there.
Beckhoff Headquarters
Beckhoff Automation GmbH
Eiserstraße 5
33415 Verl
Germany
Phone: [phone]
Fax: [phone]
e-mail: [email protected]
Beckhoff Support
Beckhoff offers you comprehensive technical assistance, helping you not
only with the application of individual Beckhoff products, but also with wide-
ranging services:
• worldwide support
• design, programming and commissioning of complex automation
systems
• training program for Beckhoff system components
Hotline: [phone]
Fax: [phone]
e-mail: [email protected]
Beckhoff Service
The Beckhoff service center supports you in all matters of after-sales
service:
• on-site service
• repair service
• spare parts service
• hotline service
Hotline: [phone]
Fax: [phone]
e-mail: [email protected]
Quote the project number If servicing is required, please quote the project number of your product.
C9900-P208/ -P209 13

Assembly dimensions
Assembly dimensions
Device dimensions and mounting points.
Dimensional notation in mm.
14 C9900-P208/ -209

Wiring diagram
Wiring diagram
i
Note
Connection of the Battery Pack and UPS Output only in combination with
C9900-P209 power supply. The circuit of PC_ON and Power-Status is
symbolical.
C9900-P208/ -P209 15

Appendix
16 C9900-P208/ -209
Appendix
Technical data
Electrical data Input voltage: 22-30V DC/ 15A
Power output: 250W (max.)
Output voltages: see section Electrical data
Dimensions Dimensions (W x H x D): 97.0 x 44.0 x 204.9 mm
Weight: 0.85 kg
Do not use the power
supply unit in areas of
explosive hazard
The power supply unit must not be used where there is a risk of
explosion.
The following conditions must be observed during operation:
Environmental conditions Ambient temperature: 0 to 55°C
Atmospheric humidity: Maximum 95%, non-condensing
Shock resistance Sinusoidal vibration
(EN 60068-2-6): 10 to 58 Hz: 0.035 mm
58 to 500 Hz: 0.5 G (~ 5 m/ s2)
Impact
(EN 60068-2-27/ -29): 5 G (~ 50 m/ s²), duration: 30 ms
EMC compatibility Resistance to interference: according to EN 61000-6-2
Emission of interference: according to EN 61000-6-4
Transport and storage The same values for atmospheric humidity and shock resistance are to be
observed during transport and storage as in operation. The shock
resistance during transport can be improved by appropriate packaging of
the power supply unit. The ambient temperature during storage and
transport must be between -20°C and +65°C.
Approvals
FCC: Federal Communications Commission
Radio Frequency Interference Statement
FCC Approval for USA This equipment has been tested and found to comply with the limits for a
Class A digital device, pursuant to Part 15 of the FCC Rules. These limits
are designed to provide reasonable protection against harmful interference
when the equipment is operated in a commercial environment. This
equipment generates, uses, and can radiate radio frequency energy and, if
not installed and used in accordance with the instruction manual, may
cause harmful interference to radio communications. Operation of this
equipment in a residential area is likely to cause harmful interference in
which case the user will be required to correct the interference at his own
expense.
FCC: Canadian Notice
FCC Approval for Canada This equipment does not exceed the Class A limits for radiated emissions
as described in the Radio Interference Regulations of the Canadian
Department of Communications.