Beckhoff CP6201 User manual

Installation and Operating instructions for
Economy built-in Panel PC
CP62xx
Version: 2.7
Date: 2012-04-02

Table of contents
Table of contents
1.
2.
3.
4.
Foreword 3
Notes on the Documentation 3
Liability Conditions 3
Trademarks 3
Patent Pending 3
Copyright 3
State at Delivery 3
Delivery conditions 3
Description of safety symbols 4
Basic safety measures 5
Operator’s obligation to exercise diligence 6
Operator requirements 6
Product Description 7
Appropriate Use 7
Interfaces 7
Fieldbus (additional interface, optional) 7
Serial interfaces 7
DVI (Digital Visual Interface) 7
USB-Interfaces 7
Network connection 7
Power supply 8
Additional plug-in cards (optional) 8
Ground connection 8
Access to the drives and the battery 8
Status-LEDs 8
Installation Instructions 9
Transport and Unpacking 9
Transport 9
Unpacking 9
Installation of the PC in the control cabinet 10
Installation in a control cabinet wall 10
Earthing measures 10
Mounting of the Panel-PC 11
Power Supply Connection 12
Beckhoff power supply technology 12
Pin assignment of the connector 13
Fitting the cable 14
Material for assembling the connectors 14
Assembling the connectors 14
Connecting Power Supply 15
Cable Cross Sections 15
Configuration for shutting down the PC 15
PC_ON and Power Status functions 15
UPS output 15
UPS output function 15
Wiring diagram 16
Connecting devices 17
Connecting cables 17
Check voltage rating and connect 17
Operating Instructions 18
Switching the Industrial PC on and off 18
First switching on and driver installation 18
Operation 18
Keyboard codes 19
Servicing and maintenance 21
Cleaning the Industrial PC 21
Servicing 21
CP62xx 1

Table of contents
Replacing the battery on the motherboard 21
Emergency procedures 21
Shutting down 21
Disposal 21
5.
6.
7.
UPS Software Components (optional) 22
Installation on the PC 22
Help files 22
Troubleshooting 23
Fault correction 23
Beckhoff Support & Service 24
Beckhoff branches and partner companies 24
Beckhoff Headquarters 24
Beckhoff Support 24
Beckhoff Service 24
Appendix 25
Assembly dimensions 25
Technical data 26
Approvals 26
FCC: Federal Communications Commission Radio Frequency Interference
Statement 26
FCC: Canadian Notice 26
2 CP62xx

Foreword
Foreword
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.
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.
Liability Conditions
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.
Trademarks
Beckhoff®, TwinCAT®, EtherCAT®, Safety over EtherCAT®, TwinSAFE®
and XFC®are registered trademarks of and licensed by 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.
Patent Pending
The EtherCAT Technology is covered, including but not limited to the
following patent applications and patents:
EP1590927, EP1789857, DE102004044764, DE102007017835
with corresponding applications or registrations in various other countries.
The TwinCAT Technology is covered, including but not limited to the
following patent applications and patents:
EP0851348, US6167425 with corresponding applications or registrations in
various other countries.
Copyright
© Beckhoff Automation GmbH.
The reproduction, distribution and utilization of this document as well as the
communication of its contents to others without express authorization are
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.
State at Delivery
All the components are supplied in particular hardware and software
configurations appropriate for the application. Modifications to hardware or
software configurations other than those described in the documentation
are not permitted, and nullify the liability of Beckhoff Automation GmbH.
Delivery conditions
In addition, the general delivery conditions of the company Beckhoff
Automation GmbH apply.
CP62xx 3

Foreword
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.
Acute risk of injury!!
DANGER If you do not adhere the safety advise adjoining this symbol, there is
immediate danger to life and health of individuals!
Risk of injury!
WARNING If you do not adhere the safety advise adjoining this symbol, there is
danger to life and health of individuals!
Hazard to individuals!
CAUTION If you do not adhere the safety advise adjoining this symbol, there is
obvious hazard to individuals!
Hazard to devices and environment
Attention If you do not adhere the notice adjoining this symbol, there is obvious
hazard to materials and environment.
Note or pointer
Note This symbol indicates information that contributes to better understanding.
4CP62xx

Foreword
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 storage medium is lost. Please
read the section Switching the Industrial PC on and off.
Switch off all parts of the equipment, then uncouple the fieldbus
Attention
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 24VDC.
Do not open the power supply unit while voltage is applied!
CAUTION The supply voltage must be switched off before the power supply unit
housing is opened.
Do not exchange any parts when under power
Attention
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.
High Voltage!
DANGER
Displays used for the control panel’s LC-display are operated with a
voltage of up to 1000 V, depending on type. For that reason:
The supply voltage must be disconnected before the housing of the
Control Panel is opened.
CP62xx 5

Foreword
Operator’s obligation to exercise diligence
The operator must ensure that
• the Industrial PC is only used for its intended purpose (see chapter
Product Description).
• the Industrial PC is only operated in a sound condition and in
working order (see chapter Servicing and maintenance).
• the Industrial PC is operated, maintained and repaired 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 manual and in particular the safety notes contained
herein.
• the instruction manual is in good condition and complete, and
always available for reference at the place of installation of the
Industrial PC.
• none of the safety and warning notes attached to the Industrial PC
are removed, and all notes remain legible.
• every user is familiar with all the functions of the software installed
on the Industrial PC to which he has access.
National regulations
depending on the machine
type
Depending on the type of machine and plant in which the Industrial PC is
used, national regulations governing the controllers of such machines will
apply, and must be observed by the operator. These regulations cover,
amongst other things, the intervals between inspections of the controller.
The operator must initiate such inspections in good time.
Do not open the housing of the build-in Panel PC
Note
For technical support contact Beckhoff Service.
Procedure in the event of a
fault
In the event of faults at the Industrial PC, the list in the section
Troubleshooting can be used to determine the measures to be taken.
Operator requirements
Read the operating
instructions
Anyone who uses the Industrial PC must have read these operating
instructions.
Software knowledge Every user must be familiar with all the functions of the software installed
on the Industrial PC to which he has access.
6CP62xx

Product Description
Product Description
Appropriate Use
The CP62xx Build-in Panel PC is designed for industrial application in
machine and plant engineering. A steel plate housing with aluminum front
contains a TFT display, touch screen/ pad (optional) and a PC keyboard
(optional). The Industrial PC is installed in the front of control cabinets.
Do not use the Build-in Panel PC in areas of explosive hazard!
DANGER
The build-in Panel PC must not be used where there is a risk of explosion.
Interfaces
Interfaces to the CP26xx
with 12“, 15“, 19“ and 24“
display
Fieldbus (additional interface, optional)
X101
Fieldbus
The Industrial PC has one fieldbus-interface (optional), which is brought to
a 9 pin SUB-D plug connector.
Serial interfaces
X102
Serial Interface COM1
The Industrial PC has one serial interface COM1, using the type RS232,
which is brought to a 9 pin SUB-D plug connector.
COM2
Touchpad or additional
interface (optional)
The serial interface COM2 is connected to the touchpad (optional).
When the IPC is delivered without touchpad, you can order an additional
interface, using the type RS232 (C9900-E159), RS485 (C9900-E188) or
RS422 (C9900-E189).
COM3
UPS (optional)
The serial interface COM3 is connected to the UPS (optional).
COM4
Touchscreen (optional)
The serial interface COM4 is connected to the touchscreen (optional).
DVI (Digital Visual Interface)
X103
DVI out
The DVI connection is used for transferring the video signal. DVI-I standard
is supported.
USB-Interfaces
X104 – X107
USB out
The four USB interfaces are used for connecting peripheral devices with
USB connection. USB2.0 standard is supported.
Network connection
X108
LAN1
The RJ-45 connector allows the PC to be connected to a 10/100BASE-T
Local Area Network (LAN).
X109
LAN2
The RJ-45 connector allows the PC to be connected to a 100/1000BASE-T
Local Area Network (LAN).
Knurled screw
CP62xx 7

Product Description
Power supply
X110
Power
The power supply for the Industrial PC is established via the
socket.
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 Control Panel is grounded via the stud bolt.
Access to the drives and the battery
Access to hard-disk, CF-
Card and battery
After solving the knurled screw, the cap can be removed and allows access
to hard disk, battery and CF-Card.
Status-LEDs
Description of the Status-
LEDs
The Status-LEDs (1 – 7) are located
above the COM1 interface (COM1):
1 PWR (Power): green
green blinking
Busy
Standby
2 TC (TwinCAT): red
green
blue
Stop Mode
Run Mode
Configuration Mode
3 IDE: red Access to an IDEdevice
4 FAN: green
red
Fans running
Fan Error
5 USR (User): Programmable
6 FB RUN (Fieldbus activ): green
red
Activ
Not activ
7 FB Error (Fieldbus Error): red Error
1 2 3 4 5 6 7
COM1
8CP62xx

Installation Instructions
Installation Instructions
Please also refer to chapter Foreword.
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 Control Panel should
therefore be protected from excessive mechanical stress. Therefore,
please use the original packaging.
Danger of damage to the unit
Attention
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.
CP62xx 9

Installation Instructions
Installation of the PC in the control cabinet
The built-in Panel PC CP62xx is designed for mounting in control cabinets
in 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 wall must be prepared with the required mounting
opening for the computer unit according to the PC’s dimensions (see
chapter Assembly dimensions).
Circulation of air
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 5 cm in
order to ensure adequate ventilation of the PC.
Please note the following points during installation of the PC:
• Position the PC in such a way that reflections on the screen are
avoided as far as possible.
• Use the position of the screen as a guide for the correct installation
height; it should be optimally visible for the user at all times.
• The PC should not be exposed to direct sunlight.
• When the unit is in its mounting position, the ventilation openings must
not be obstructed.
Avoid extreme environmental conditions
Attention
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.
Installation in a control cabinet wall
Installation in a control
cabinet wall
Proceed as follows:
1. Insert the PC at the intended control cabinet wall position and protect it
from falling out, prior to final mounting.
2. Release the clamping levers, turn the clamping levers to the side and
retighten the screws (see chapter Mounting of the Panel-PC).
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 (see
chapter Assembly dimensions) to the central earthing point on the control
cabinet wall, in which the computer is being installed.
10 CP62xx

Installation Instructions
Mounting of the Panel-PC
Please refer to the tables for Panel-PC cutout dimensions.
Mounting of the Panel-PC
Clamping levers
Release clamping levers,
Insert the 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.
CP62xx 11

Installation Instructions
Power Supply Connection
Supplied mains power unit The Industrial PC is fitted with a 24 VDC power supply unit .
Uninterruptible power supply (UPS)
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 of Explosion!
WARNING
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.
12 CP62xx

Installation Instructions
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 visualized
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 -
2 +
Battery Pack
(with UPS)
3 UPS+ (Output)
4
5 -
6 +
24 V DC
Power Supply
7 PC_ON
8 Power-Status
1 2 3 4 5 6 7 8
CP62xx 13

Installation Instructions
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.
14 CP62xx

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
Attention
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.
Service life of the rechargeable battery
Attention
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-energizing 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 1.4 A.
UPS output function
• The 27 V DC connection at the UPS output is live even after a power
failure. The maximum load is 1.4 A.
• Once the PC has been de-energized 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.
CP62xx 15

Installation Instructions
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
Connection of the Battery Pack and UPS Output
Note
Connection of the Battery Pack and UPS Output only in combination with
integrated UPS (order option).
16 CP62xx

Installation Instructions
Connecting devices
Power supply plug
Attention
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 (see
chapter Fitting the cable) into the Industrial PC's power supply
socket. Then connect it to your external 24 V power supply.
Use same type of rechargeable battery
Attention
If a 24 V UPS is installed, the same type of rechargeable battery must be
used.
CP62xx 17

Operating Instructions
Operating Instructions
Please also refer to chapter Foreword.
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
storage medium by switching off while software is running.
First shut down, then switch off the PC
Attention
If the Industrial PC is switched off as the software is writing a file to the
storage medium, the file will be destroyed. Control software typically
writes something to the storage medium every few seconds, so that the
probability of causing damage by switching off while the software is
running is very high.
Switch off power supply
Attention
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.
Operation
The Panel PC’s membrane keypad may only be actuated by fingertips
Note
Attempts to actuate it with other objects can easily result in the destruction
of the device. Neither may the membrane keypad be operated with a touch
screen pen.
The touch screen may only be actuated by fingertips or with the
touch screen pen
Note The touch screen may only be actuated by finger tips or with the touch
screen pen. The operator may wear gloves but there must be no hard
particles such as metal shavings, glass splinters embedded in the glove.
18 CP62xx

Operating Instructions
Keyboard codes
Type-dependent number of
keys
Depending on the precise type, the Control Panel can have fewer keys
than those described here.
Operation
The cursor is the blinking character that marks the point at which the next
character entered will be displayed. The cursor is also known as the
insertion point. The cursor keys each move the cursor one place in the
associated direction.
Home En d
The Home key moves the cursor to the beginning of the line, while the End
key moves it to the end of the line.
Pg Up Pg Dn
The Pg Up key scrolls one page back, the Pg Dn key scrolls one page
forward.
The Tab key takes the cursor to the next input field, while Shift and Tab
moves to the previous input field.
LR
The mouse cursor can be moved over the screen with the aid of the touch
screen or of the touch pad (optional). The keys correspond to the left and
right hand keys of a Microsoft mouse.
Del
The Del key deletes the character to the right of the cursor.
Ins
The Ins key causes characters to the right of the cursor to be overwritten.
The overwrite mode is cancelled by pressing the key again.
Pr i n t
Print-Screen prints a hard copy of a text screen on the printer.
Pause
The Pause key stops the computer until another key is pressed (only under
MS-DOS).
En t e r
Your input is confirmed with the Enter key.
Backspace deletes the character to the left of the cursor.
Sh i f t
If the Shift key is pressed at the same time as another key, then instead of
the numbers you obtain the character printed above the number, and you
obtain upper case letters instead of lower case letters.
Ca p s
Lock
Pressing the Caps Lock key once activates and locks the Shift key.
Pressing the Shift key cancels this function.
Ct r l Al t
Rather like the effect of the Shift key, Ctrl and Alt also change the meaning
of another key that is pressed at the same time.
This key brings up the Start menu of the operating system in use (Windows
95, 98, ME, NT, 2000, XP).
Pressing this key opens the property sheet of the active (or marked) object.
Esc
The Esc key has the effect of closing dialog windows and of interrupting
some of the computer’s working operations.
Q W
...
1
!
2
@
All other keys bring the character printed on them onto the display at the
position of the cursor.
CP62xx 19