Beckhoff C5240 User manual

Manual | EN
C5240
Panel PC
2023-09-11 | Version: 3.0

Table of contents
C5240 3Version: 3.0
Table of contents
1 Notes on the documentation....................................................................................................................5
2 For your safety ..........................................................................................................................................6
2.1 Signal words......................................................................................................................................6
2.2 Intended use .....................................................................................................................................6
2.3 Fundamental safety instructions .......................................................................................................7
2.4 Operator's obligation to exercise diligence........................................................................................7
2.5 Notes on information security............................................................................................................8
3 Product overview ......................................................................................................................................9
3.1 Structure..........................................................................................................................................10
3.2 Interface description........................................................................................................................11
3.2.1 Power supply.................................................................................................................... 12
3.2.2 PS/2 .................................................................................................................................13
3.2.3 USB.................................................................................................................................. 14
3.2.4 Ethernet RJ45 ..................................................................................................................15
3.2.5 DVI ...................................................................................................................................16
3.2.6 RS232 ..............................................................................................................................16
3.2.7 DisplayPort....................................................................................................................... 17
3.2.8 Audio connections............................................................................................................ 18
3.3 Status LEDs ....................................................................................................................................19
3.4 Name plate......................................................................................................................................20
4 Commissioning .......................................................................................................................................21
4.1 Transport and unpacking ................................................................................................................21
4.2 Rack installation ..............................................................................................................................22
4.3 Connecting the Industrial PC ..........................................................................................................23
4.3.1 Mounting power supply cable........................................................................................... 23
4.3.2 Grounding of the industrial PC ......................................................................................... 24
4.3.3 Connecting cables and power supply .............................................................................. 26
4.3.4 Connecting the 24V power supply .................................................................................. 26
4.4 Switching the Industrial PC on and off ............................................................................................28
5 Configuration...........................................................................................................................................31
5.1 Beckhoff Device Manager ...............................................................................................................31
5.2 UPS configuration ...........................................................................................................................32
6 Decommissioning ...................................................................................................................................35
6.1 Disconnecting the power supply and cables ...................................................................................35
6.2 Disassembly and disposal...............................................................................................................36
7 Maintenance ............................................................................................................................................37
7.1 Cleaning ..........................................................................................................................................37
7.2 Maintenance....................................................................................................................................37
7.2.1 Access to device components.......................................................................................... 39
7.2.2 Replacing the battery .......................................................................................................41
7.2.3 Replacing the storage media ........................................................................................... 42
7.2.4 Exchange filter mat .......................................................................................................... 44
7.2.5 Replacing the fan .............................................................................................................46

Table of contents
C52404 Version: 3.0
8 Troubleshooting......................................................................................................................................49
9 Technical data .........................................................................................................................................50
10 Appendix..................................................................................................................................................51
10.1 Service and support ........................................................................................................................51
10.2 Approvals ........................................................................................................................................52

Notes on the documentation
C5240 5Version: 3.0
1 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.
The following instructions and explanations must be followed during installation and commissioning of the
components. 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.
Disclaimer
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. 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. All illustrations shown are only examples. The configurations depicted may deviate
from the standard.
Trademarks
Beckhoff®, TwinCAT®, TwinCAT/BSD®, TC/BSD ®, EtherCAT®, EtherCAT G®, EtherCAT G10®, EtherCAT P®,
Safety over EtherCAT®, TwinSAFE®, XFC®, XTS® and XPlanar® are registered and licensed trademarks of
Beckhoff Automation GmbH.
Other designations used in this publication may be trademarks whose use by third parties for their own
purposes could violate the rights of the owners.
Patents
The EtherCAT Technology is covered, including but not limited to the following patent applications and
patents: EP1590927, EP1789857, EP1456722, EP2137893, DE102015105702 and similar applications and
registrations in several other countries.
Copyright
© Beckhoff Automation GmbH & Co. KG. Publication of this document on websites other than ours is
prohibited. Offenders will be held liable for the payment of damages. All rights reserved in the event of the
grant of a patent, utility model or design.
Delivery state
All the components are supplied in particular hardware and software configurations appropriate for the
application. Changes to the hardware or software configuration are permitted, provided they are within the
specified limits for power consumption and power loss (please refer to the respective data sheet).
Currentness
Please check whether you are using the current and valid version of this document. The current version is
always available for download from the Beckhoff website. In case of doubt, contact Technical Support.
Delivery conditions
In addition, the general delivery conditions of the company Beckhoff Automation GmbH & Co. KG apply.

For your safety
C52406 Version: 3.0
2 For your safety
The signal words and their meanings are explained in the chapter on safety. They contain fundamental
safety instructions that are essential for the avoidance of personal injuries and damage to property.
Exclusion of liability
Beckhoff shall not be liable in the event of non-compliance with this documentation and thus the use of the
devices outside the documented operating conditions.
2.1 Signal words
The signal words used in the documentation are classified below.
Warning of personal injuries
DANGER
Hazard with high risk of death or serious injury.
WARNING
Hazard with medium risk of death or serious injury.
CAUTION
There is a low-risk hazard that can result in minor injury.
Warning of property and environmental damage
NOTICE
There is a possibility of damage to the environment, equipment or data.
2.2 Intended use
The the Industrial PC is intended for use as a control system for automation, visualization and
communication in machine and system engineering.
The front of the device is designed for an IP50 working environment. There is complete protection against
contact and dust in harmful quantities. It is not protected against water.
The rear of the device is designed for an IP20 working environment. It is protected against the penetration of
fingers and solid foreign bodies of 12.5 mm in diameter or larger in size. It is not protected against water.
Operation of the device in wet and dusty environments is not permitted. The specified limits for technical
data must be adhered to.
The specified limits for technical data must be adhered to.
The device can be used within the documented operating conditions.
Improper use
Do not use the device outside the documented operating conditions.

For your safety
C5240 7Version: 3.0
2.3 Fundamental safety instructions
The following safety instructions must be observed when handling the the Industrial PC.
Application conditions
• Do not use the device under extreme environmental conditions.
• Only use the device in hazardous areas if it is explicitly designed for this purpose.
• Do not carry out any work on the device while it is live. Always switch off the supply voltage for the
device before mounting it, replacing device components or rectifying malfunctions. This does not apply
to the replacement of hard disks in a RAID configuration.
• Never plug or unplug connectors during thunderstorms. There is a risk of electric shock.
• Ensure that the device has a protective and functional earth connection.
Damage to property, loss of data and impairment of functions
• If you change the hardware and software configurations, you must keep within the specified limits of
power consumption and power loss (please refer to the respective data sheet).
• Ensure that only trained specialists with a control and automation engineering background, operate the
device. Use by unauthorized persons can lead to damage to property and loss of data.
• In the case of a 24 V DC power supply unit, fuse the power supply line according to its cross-section to
protect the supply line in the event of a short circuit.
• In case of fire, extinguish the device with powder or nitrogen.
2.4 Operator's obligation to exercise diligence
The operator must ensure that
• the products are used only for their intended purpose (see Chapter 2.2 Intended use [}6]).
• the products are only operated in sound condition and in working order.
• the products are operated only by suitably qualified and authorized personnel.
• the personnel is instructed regularly about relevant occupational safety and environmental protection
aspects, and is familiar with the operating instructions and in particular the safety instructions contained
herein.
• the operating instructions are in good condition and complete, and always available for reference at the
location where the products are used.

For your safety
C52408 Version: 3.0
2.5 Notes on information security
The products of Beckhoff Automation GmbH & Co. KG (Beckhoff), insofar as they can be accessed online,
are equipped with security functions that support the secure operation of plants, systems, machines and
networks. Despite the security functions, the creation, implementation and constant updating of a holistic
security concept for the operation are necessary to protect the respective plant, system, machine and
networks against cyber threats. The products sold by Beckhoff are only part of the overall security concept.
The customer is responsible for preventing unauthorized access by third parties to its equipment, systems,
machines and networks. The latter should be connected to the corporate network or the Internet only if
appropriate protective measures have been set up.
In addition, the recommendations from Beckhoff regarding appropriate protective measures should be
observed. Further information regarding information security and industrial security can be found in our
https://www.beckhoff.com/secguide.
Beckhoff products and solutions undergo continuous further development. This also applies to security
functions. In light of this continuous further development, Beckhoff expressly recommends that the products
are kept up to date at all times and that updates are installed for the products once they have been made
available. Using outdated or unsupported product versions can increase the risk of cyber threats.
To stay informed about information security for Beckhoff products, subscribe to the RSS feed at https://
www.beckhoff.com/secinfo.

Product overview
C5240 9Version: 3.0
3 Product overview
The C5240 is a powerful industrial PC with ATX motherboard for installation in a 19-inch rack. The device is
suitable for various applications and requirements.
The available processor options allow you to use the industrial PC for the following applications, among
others:
• diverse automation and visualization tasks
• wide range of IoT tasks with data preprocessing
• complicated HMI applications
• extensive axis controllers
• short cycle times
• high-volume data handling
The basic configuration of the C5240 includes the following aspects:
• ATX motherboard
• Intel® processor
• DRAM SODIMM
• 3½-inch hard disk
• 100…240VAC power supply unit

Product overview
C524010 Version: 3.0
3.1 Structure
1
2 3 4
5
678
9
10
11
12 13
Fig.1: Structure
Table1: Legend - C5240 structure
No. Component Description
1 Front flap Access to ATX and reset button, USB interfaces, drives, hard
drive caddy, front fan filter mat
2 Front flap lock Opening the front flap
3 Status LEDs Status display for hard disk, fieldbus and power
4 Name plate Information on the equipment of the industrial PC
4 Housing cover Access to exchangeable device components
5 Optional telescopic rails Pull-out rails for installation in 19-inch racks
6 Front fan Cooling the device
7 USB interfaces (X212, X213) Connection of peripheral devices
8 ATX and reset button Starting and shutting down the operating system, restarting the
industrial PC
9 Housing cover Access to exchangeable device components
10 Power supply fan Power supply cooling
11 IEC connector Power supply connection
12 Connection compartment Access to interfaces of the industrial PC
13 Plug-in card slots Additional optional plug-in cards

Product overview
C5240 11Version: 3.0
3.2 Interface description
In the basic configuration, the C5240 includes the following interfaces:
• Power supply (X101)
• PS/2 mouse and keyboard (X103, X104)
• USB (X108-X111, X212, X213)
• Ethernet RJ45 (X112, X113)
• DVI (X114, X115)
• RS232 (X116)
• DisplayPort (X117)
• Audio connections (X120-X122)
Most of the interfaces are located on the rear side of the industrial PC in the connection section (see Fig. 2,
section A). The two USB interfaces X212 and X213 are located in the front of the industrial PC behind the
front flap (section B).
A B
Fig.2: Position interfaces
To access the USB interfaces in the front, you first have to open the front flap. To do this, follow the steps
below as shown in Figure 3:
1. Unlock the front flap with the corresponding key (section A).
2. Turn the front flap down (section B).
ðYou now have access to the USB interfaces.
A B
Fig.3: Opening the front flap

Product overview
C524012 Version: 3.0
3.2.1 Power supply
In its basic configuration, the industrial PC is equipped with a 100-240VAC, 50-60Hz full-range power
supply unit.
Table2: Current carrying capacity power supply unit
Output voltages power supply unit Current load 100-240VAC power supply unit max.
+3.3 V 21A
+5 V 15A
+12 V1 11A
+12 V2 8A
-12 V 0.3A
+5 V stand by 2.5A
The power supply is connected via the IEC socket (X101) on the rear side of the industrial PC. The
assignment includes a protective conductor (1), a neutral conductor (2) and an outer conductor (2) (see Fig.
4).
X101
1
2 2
Fig.4: Power supply socket 100-240V
Optionally, you can order the industrial PC with a 24VDC power supply unit. In this case, the industrial PC
is supplied with a nominal voltage of 24V. The power supply (X101) is connected via a 5-pin socket. The
external wiring (X102) of the industrial PC is done via a 3-pin socket.
The main supply voltage is applied between PIN 1 (24V) and PIN 2 (0V) of the power supply socket (X101).
If the industrial PC is equipped with an integrated uninterruptible power supply (UPS), you can also connect
an external battery pack to PIN 4 and 5.
X101
5
4
3
2
1
Fig.5: Power supply socket 24 V
Table3: Power supply socket (X101) pin assignment
Pin Signal Description
1 +24 V 24V supply voltage, positive pole
2 - 24V supply voltage, negative pole
3 Protective earth
4 +BAT Positive pole of the battery pack
5 -BAT Negative pole of the battery pack
The positive pole of the supply voltage at PIN 1 of the power supply socket (X101) is looped through to PIN 3
of the socket (X102). PIN 3 thus serves as the positive pole for PC-ON.
X102
1 2 3
Fig.6: Socket External wiring

Product overview
C5240 13Version: 3.0
Table4: Socket external wiring (X102) pin assignment
Pin Signal Description
1 P-S Output power status, minus is the negative pole of the power supply (X101)
2 PC-ON Input PC-ON
3 +24 V Supply voltage and positive pole for PC-ON
3.2.2 PS/2
The industrial PC has two PS/2 interfaces (X103, X104). The upper interface (X104) allows the connection of
a PS/2 mouse, the lower interface (X103) allows the connection of a PS/2 keyboard. The connection is made
via standard MiniDIN connectors.
B6 B5
B2 B1
A6 A5
A2 A1
X104
X103
Fig.7: PS/2 mouse and keyboard
Table5: PS/2 interface mouse pin assignment
Pin Name Description
B1 MDAT Mouse Data
B2 N/C Reserved
B3 GND Ground
B4 (S)VCC 5V supply voltage
B5 MCLK Mouse Clock
B6 N/C Reserved
Table6: PS/2 interface keyboard pin assignment
Pin Name Description
A1 KDAT Keyboard data
A2 MDAT Mouse Data
A3 GND Ground
A4 (S)VCC 5V supply voltage
A5 KCLK Keyboard Clock
A6 MCLK Mouse Clock

Product overview
C524014 Version: 3.0
3.2.3 USB
The industrial PC has four USB interfaces (X108-X111) on the rear side of the device and two USB
interfaces (X212, X213) behind the front flap. They are used to connect peripheral devices with USB
connection.
1 2 34
9 8 76 5
1 2 34
9 8 76 5
9 8 76 5
1 2 34
9 8 76 5
1 2 34
X109
X108
X111
X110
Fig.8: USB interfaces rear side pin numbering
Table7: USB interface pin assignment
Pin Connection Typical assignment
1 Vbus Red
2 D - White
3 D + Green
4 GND Black
5 StdA_SSRX - Blue
6 StdA_SSRX + Yellow
7 GND_DRAIN N/A
8 StdA_SSTX - Purple
9 StdA_SSTX + Orange
For USB2.0, only pins 1 to 4 are relevant.

Product overview
C5240 15Version: 3.0
3.2.4 Ethernet RJ45
The industrial PC has two Gigabit LAN ports (X112, X113). The 100BASE-T and 1000BASE-T Ethernet
standards enable the connection of corresponding network components and data rates of 100/1000Mbit/s.
The required speed is selected automatically.
The RJ45 connection technology with twisted-pair cables is used. The maximum length of the cable
connection is 100m.
If you use the Ethernet ports with EtherCAT or for Real-Time Ethernet applications, you have to regard the
following distinction:
The Ethernet port (X113, LAN2) connected via PCIe with the i210 controller is generally suitable for cycle
times <= 1ms and for distributed clock applications with EtherCAT.
The Ethernet port (X112, LAN1) integrated in the chipset with the i219 controller is generally suitable for
EtherCAT and real-time Ethernet applications with cycle times > 1 ms (without distributed clocks).
8181
LAN 1
X112
LAN 2
X113
Fig.9: Ethernet interface pin numbering
Table8: Ethernet interface pin assignment
Pin Signal Description
1 T2 + Pair 2
2 T2 +
3 T3 + Pair 3
4 T1 + Pair 1
5 T1 -
6 T3 - Pair 3
7 T4 + Pair 4
8 T4 -
The LEDs of the LAN interfaces indicate the activity and the speed of the data transmission (Mbit/s). The
LED on the left in the figure indicates whether the interface is connected to a network. If this is the case, the
LED lights up green. The LED flashes when data transmission is in progress on the interface.
The LED on the right in the figure indicates the speed of the data transmission. If the speed is 100Mbit/s the
LED is orange, at 1000Mbit/s it is green.

Product overview
C524016 Version: 3.0
3.2.5 DVI
The industrial PC has two DVI connections (X114, X115) to which a DVI-capable monitor can be connected.
Only digital signals are transmitted.
16
18
2417
9
X114
X115 18
2417
9
Fig.10: DVI interface pin numbering
Table9: DVI interface pin assignment
Pin Connection Pin Connection Pin Connection
1 TDMS Data 2 - 9 TDMS Data 1 - 17 TDMS Data 0 -
2 TDMS Data 2 + 10 TDMS Data 1 + 18 TDMS Data 0 +
3 TDMS Data 2/4 Shield 11 TDMS Data 1/3 Shield 19 TDMS Data 0/5 Shield
4 not connected 12 not connected 20 not connected
5 not connected 13 not connected 21 not connected
6 DDC Clock 14 + 5 V Power 22 TDMS Clock Shield
7 DDC Data 15 Ground (+ 5 V, Analog H/V
Sync)
23 TDMS Clock +
8 Analog Vertical Sync 16 Hot Plug Detect 24 TDMA Clock -
3.2.6 RS232
The serial interface COM1 (X116) is fed out via a 9-pin standard DSUB connector. The signals comply with
the RS232 standard. The port address and the used interrupt are configured automatically, but can also be
set manually with the help of the BIOS setup if required.
15
6 9
X116
Fig.11: RS232 interface pin numbering
Table10: COM1 interface pin numbering
Pin Name Description
1 DCD Data Carrier Detect
2 RXD Receive Data
3 TXD Transmit Data
4 DTR Data Terminal Ready
5 GND Ground
6 DSR Data Set Ready
7 RTS Request to Send
8 CTS Clear to Send
9 RI Ring Indicator

Product overview
C5240 17Version: 3.0
3.2.7 DisplayPort
The industrial PC has a DisplayPort (X117) that enables connection of devices with DisplayPort. Additionally,
DVI signals can be transmitted via an adapter cable. The following ordering option is available to you for this
purpose:
• C9900-Z468: adapter cable DisplayPort to DVI, 40 cm
1
2
19
20
X117
Fig.12: DisplayPort pin numbering
Table11: Pin assignment of DisplayPort
Pin Connection Pin Connection
1 LVDS lane 0 + 2 Ground
3 LVDS lane 0 - 4 LVDS lane 1 +
5 Ground 6 LVDS lane 1 -
7 LVDS lane 2 + 8 Ground
9 LVDS lane 2 - 10 LVDS lane 3 +
11 Ground 12 LVDS lane 3 -
13 Config 1 14 Config 2
15 AUX channel + 16 Ground
17 AUX channel - 18 Hot-plug detection
19 Power supply: ground 20 Power supply: 3.3V / 500mA

Product overview
C524018 Version: 3.0
3.2.8 Audio connections
The industrial PC has three audio connections with the Line In (X122), Line Out (X121) and microphone
input (X120) sockets.
X122
X121
X120
Fig.13: Audio connections
The three sockets are brought out for 3.5 mm jack plugs. The pins of the jack plugs are assigned as follows:
L
R
GND
Fig.14: Jack plug pin assignment
Table12: Jack plug pin assignment
Pin Connection
L Left sound signal
R Right sound signal
GND Common ground (return)

Product overview
C5240 19Version: 3.0
3.3 Status LEDs
The industrial PC has three status LEDs: PWR, FB, HDD. They provide information on the following aspects:
• the status of the power controller
• the fieldbus status
• the hard disk activity
Fig.15: Status LEDs
Table13: Meaning of the Status LEDs
LED Color/flashing interval Meaning
PWR (Power) green
off
Computer on
Computer off
FB (fieldbus) red
blue
blue/red flashing
green
green/red flashing
TwinCAT Stop
TwinCAT Config
TwinCAT Config (fieldbus error)
TwinCAT Run
TwinCAT Run (fieldbus error)
HDD (hard disk) red Accessing storage media
The activity of NVM Express™ SSDs is not displayed via the HDD LED.

Product overview
C524020 Version: 3.0
3.4 Name plate
The name plate provides information on the equipment fitted to the industrial PC. The name plate shown
here serves only as an example.
1
2
3
4
8
7
6
5
9
10 11
12
13
14
1516
xxxxxxxx
xxxxxxxxxxxx
xxxxxxxxxxxx
17
HDD/SSD 0:
HDD/SSD 1:
HDD/SSD 2:
Fig.16: Name plate
Table14: Legend C5240 name plate
No. Description
1 Model: The last four digits indicate the device generation.
2 Serial number (BTN)
3 Date of manufacture
4 Mainboard
5 CPU
6 Main memory
7 MAC addresses of the Ethernet interfaces (X112, X113)
8 Power supply
9 Power supply connection
10 Connection section standard interfaces
11 Connection section optional PCI and PCIe interfaces
12 Symbols
Note: Here are the symbols applicable to the device such as CE, EAC, UKCA, . The
approvals of your device can be found on the name plate and in chapter 10.2 Approvals.
13 FCC approvals
14 Address of the vendor
15 Storage media
16 DVD drive
17 Variant number: commercial number of the order code including ordering options