BECKHOFF C5101 User Manual

Installation and Operating instructions for
19 Inch Rack Mount Industrial PC C5101
Version: 1.6 Date: 2012-09-13
Table of contents
1.
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
2.
Product Description 7
Appropriate Use 7 Structure 7 Interfaces 9
Serial interfaces 9 Network connection 9 DVI (Digital Visual Interface) 9 USB interfaces 9 Additional plug-in cards (optional) 9
Interfaces behind the front flap 10
Reset pushbutton 10 LEDs 10 USB interfaces 10 Power pushbutton 10
3.
Installation Instructions 11
Transport and Unpacking 11
Transport 11 Unpacking 11
Installation of the PC in the control cabinet 12 Power Supply Connection 13
Mains Socket 13 Power supply cords 13
Connecting devices 14
Connecting cables 14 Check voltage rating and connect. 14
4.
Operating Instructions 15
Switching the Industrial PC on and off 15
First switching on and driver installation 15
Servicing and Maintenance 16
Cleaning the Industrial PC 16 Servicing 16 Replacing the battery on the motherboard 16 Changing the filter mat 17
Shutting down 17
Disposal 17
5.
Troubleshooting 18
Fault correction 18 Beckhoff Support and Service 19
Beckhoff branches and partner companies 19 Beckhoff company headquarters 19 Beckhoff Support 19 Beckhoff Service 19
6.
Assembly dimensions 20
C5101 1
Table of contents
7. Appendix 21
Technical data 21 Approvals 21
FCC: Federal Communications Commission Radio Frequency Interference Statement 21 FCC: Canadian Notice 21
2 C5101
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 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.
®
are registered trademarks of and licensed by Beckhoff
C5101 3

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
WARNING
CAUTION
Attention
Note
If you do not adhere the safety advise adjoining this symbol, there is immediate danger to life and health of individuals!
Risk of injury!
If you do not adhere the safety advise adjoining this symbol, there is danger to life and health of individuals!
Hazard to individuals!
If you do not adhere the safety advise adjoining this symbol, there is obvious hazard to individuals!
Hazard to devices and environment
If you do not adhere the notice adjoining this symbol, there is obvious hazard to materials and environment.
Note or pointer
This symbol indicates information that contributes to better understanding.
4 C5101

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 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
100 VAC - 240 VAC.
Do not open the power supply unit while voltage is applied!
DANGER
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.
C5101 5

Operator's obligation to exercise diligence

The operator must ensure that
the Industrial PC is only used for its intended use (see also Product
Description).
the Industrial PC is in a sound condition and in working order during operation (see also chapter Servicing and Maintenance).
the operation manual is in good condition and complete, and always available for reference at the location of the Industrial PC.
the Industrial PC is operated, maintained and repaired only by sufficiently qualified and authorized personnel.
the personnel is instructed regularly about relevant occupational safety and environmental protection aspects, and is familiar with the operating manual and in particular the safety notes contained herein.
none of the safety and warning notes attached to the Industrial PC are removed, and that all notes remain legible.
National regulations depending on the machine type
Depending on the type of machine and plant in which the Industrial PC is being used, there will be national regulations for the control of such machines and plant that the operator must observe. These regulations cover, amongst other things, the intervals between inspections of the controller.
The operator must initiate such inspections in good time.
Only trained persons may open the Industrial PC housing!
Attention
Procedure in the event of a fault
The operator is responsible for ensuring that only trained electrical staff opens the housing of the Industrial PC.
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
Software knowledge Every user must be familiar with any of the functions of the software
Every user of the Industrial PC must have read these operating instructions.
installed on the PC that he can reach.
6 C5101
Product Description

Product Description

Appropriate Use

The C5101 Industrial PC has been designed as a rack mount PC for fitting
into 19 inch racks used in machine and plant engineering applications.

Structure

Front view of the C5101
Opening the front flap
Rear view of the C5101
In order to gain access to the power pushbutton and to the drives, open the flap on the front with the key provided for the purpose (see photo above).
Only trained persons may open the Industrial PC housing!
Attention
Before opening the PC housing, the power plug must be drawn.
Fire enclosure!
DANGER
The Industrial PC is equipped with a fire enclosure. Before switching on the PC, the casing must be closed!
C5101 7
Product Description
Opening the housing
In order to open the PC housing, remove the 4 fastening screws at the side of the housing cover (see photo Rear view of the C5101) using a cross­head screwdriver. The cover of the housing can then be lifted up, providing access to the hard drive, processor, memory and plug-in cards (see following photograph).
Removing the card holder
Remove the 2 fastening screws of the card holder (see arrows) using a cross-head screwdriver. The holder can then be lifted up.
View of the open PC
1
2
A plug-in motherboard (1) and a 14-slot passive backplane (2) are located under the housing cover.
5
3
4
The power supply unit (3), the hard drive and the CD/ DVD-drives (4) are easily accessible.
The connections to the outside are located at the rear of the housing (5) and behind the front flap.
8 C5101

Interfaces

Interfaces to the C5101 Industrial PC
9
RS 232
COM1 - COM2
Network 100/1000BASE-T The RJ-45 connector (3) allows the PC to be connected to a
Network 10/100BASE-T The RJ-45 connector (4) allows the PC to be connected to a
DVI-I The DVI connection (5) is used for transferring the video signal.
USB1 – USB3 The USB interfaces (6) (7) and (8) are used to connect peripheral devices

Serial interfaces

The basic version of the C5101 Industrial PC has two serial interfaces, COM1 (1) and COM2 (2), using the type RS232, which are brought to a 9 pin SUB-D plug connector.

Network connection

100/1000BASE-T Local Area Network (LAN).
10/100BASE-T Local Area Network (LAN).

DVI (Digital Visual Interface)

DVI-I standard is supported.

USB interfaces

with USB connections.
Two more USB interfaces are located behind the front flap.
USB2.0 standard is supported.
Type plate

Additional plug-in cards (optional)

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.
C5101 9

Interfaces behind the front flap

Interfaces behind the front flap
9
Reset pushbutton The reset pushbutton (1) allows to reboot the PC.
Power The LED Power (2) indicates correct power supply.
HDD The LED HDD (3) indicates HDD access.
USB4 – USB5 The two USB interfaces (4) are used to connect peripheral devices with
Power pushbutton The Industrial PC is switched on via the power-pushbutton (5).

Reset pushbutton

LEDs

USB interfaces

USB connections.
USB2.0 standard is supported.

Power pushbutton

10 C5101
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 Industrial PC 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.
C5101 11
Installation Instructions

Installation of the PC in the control cabinet

The C5101 Industrial PC is designed for rack mounting in machine and
plant engineering applications.
The ambient conditions specified for operation must be observed (see chapter Technical data).
Preparation of the control cabinet
Four holes for the fixing bolts have to be provided in the control cabinet according to the dimensions of the PC (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.
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.
12 C5101
Installation Instructions

Power Supply Connection

Supplied mains power unit The Industrial PC is fitted with a 100-240 V, 50-60 Hz full range power
supply unit (with the option of an uninterruptible power supply, UPS).
Current carrying capacity of the 100-240 V power supply unit
Output voltages from
the 100-240 V power
+5 V stand by
supply unit
+3,3 V
+12 V
-12 V
Current loading maximum
16 A 2 A
+5 V
-5 V
25 A 0,3 A 13 A 0,8 A

Mains Socket

A mains socket is located at the rear of the PC housing in order to connect
the power supply.
Socket at the PC housing

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.
C5101 13
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.

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.
14 C5101
Operating Instructions

Operating Instructions

Please also refer to chapter Foreword.

Switching the Industrial PC on and off

Switch on The Industrial PC is switched on with the power pushbutton behind the
front flap.
Shutting down and switching off
The Industrial PC is switched off when either of these switches is off.
Control software such as is typically used on Industrial PCs permits various users to be given different rights. A user who may not close software may also not switch the Industrial PC off, since data can be lost from the hard disk by switching off while software is running.
First shut down, then switch off the PC
Attention
Attention
If the Industrial PC is switched off as the software is writing a file to the hard disk, the file will be destroyed. Control software typically writes something to the hard disk every few seconds, so that the probability of causing damage by switching off while the software is running is very high.
Switch off power supply
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.
C5101 15
Operating Instructions
Please also refer to chapter Foreword.

Servicing and Maintenance

Cleaning the Industrial PC

Disconnect from power supply
Attention
The Industrial PC can be cleaned with a soft, damp cloth. Do not use any
Switch off the Industrial PC and all connected devices, and disconnect the Industrial PC from the power supply.
aggressive cleaning materials, thinners, scouring material or hard objects that could cause scratches.

Servicing

The Industrial PC requires no maintenance.

Replacing the battery on the motherboard

A used battery on the motherboard has to be replaced.
Danger of Explosion!
WARNING
The used battery must be disposed of in accordance with national
Replace battery only with the identical type or an alternative type recommended by the manufacturer. Notice correct polarity!
electronics scrap regulations.
16 C5101
Operating Instructions

Changing the filter mat

If the Industrial PC is used in an environment where the air is particularly
dirty, the fan's filter mat should be examined at regular intervals to see how dirty it is, and should be exchanged, if necessary, for an original Beckhoff filter mat (item number C9900-Z213, filter mat for C510x, 10 per pack). Please also refer to chapter Changing the filter mat.
Front view showing the filter drawer
1
3
2
Access to the filter mat Access to the filter mat is obtained behind the front flap. This must be
opened with its key. The filter drawer (1) can then be pulled out towards the right using the retention tongue (2). After the mat (3) has been changed the filter is refitted in the reverse sequence.

Shutting down

Disposal

Dismantling the Industrial PC
Observe national electronics scrap regulations
The device must be fully dismantled in order to dispose of it. The housing can be sent for metal recycling.
Electronic parts such as disk drives and circuit boards must be disposed of in accordance with national electronics scrap regulations.
C5101 17
Troubleshooting

Troubleshooting

Please also refer to chapter Foreword.

Fault correction

Fault Cause Procedure
Nothing happens after the Industrial PC has been switched on
The Industrial PC does not boot fully
Computer boots, software starts, but control does not operate correctly
Memory device access error Faulty CD
The Industrial PC functions only partially or only part of the time, e.g. no or dark picture, but disk drive responds when switching on
No power supply to the Industrial PC
Other cause
CD in drive
Setup settings are incorrect
Other cause
Cause of the fault is either in the software or in parts of the plant outside the Industrial PC
Faulty device
Defective components in the Industrial PC
Check power supply cable
Call Beckhoff Service
Remove CD and press any key
Check the setup settings
Call Beckhoff Service
Call the manufacturer of the machine or the software
Check the disk in another disk drive
Call Beckhoff Service
Call Beckhoff Service
18 C5101
Troubleshooting

Beckhoff Support and 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

Beckhoff company headquarters

Beckhoff Automation GmbH Eiserstraße 5 33415 Verl Germany
Phone: +49(0)5246/963-0 Fax: +49(0)5246/963-198 e-mail: info@beckhoff.com Web: http://www.beckhoff.de/

Beckhoff Support

Beckhoff offers you comprehensive technical assistance, helping you not only with the application of individual Beckhoff products, but also with wide­ranging services:
worldwide support
design, programming and commissioning of complex automation
systems
training program for Beckhoff system components
Hotline: Fax: +49(0)5246/963-9157 e-mail: support@beckhoff.com
+49(0)5246/963-157

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: Fax: +49(0)5246/963-479 e-mail: mailto:service@beckhoff.com
Quote the project number If servicing is required, please quote the project number of your product.
+49(0)5246/963-460
for Beckhoff components there.
C5101 19
Assembly dimensions

Assembly dimensions

Diagrams of the Industrial PC with dimensions in mm.
Assembly orientation
Attention
Industrial PC C5101
The assembly of the unit must take place with the orientation diagrammed here.
Front view
Top view
Side view
20 C5101
Appendix

Appendix

Technical data

Dimensions Dimensions (W x H x D): 483 x 177 x 449 (+ 51 with handles) mm
Weight: 17.0 kg (basic configuration)
Do not use the PC in areas of explosive hazard
Environmental conditions Ambient temperature: 0 to 55°C
Shock resistance
The Industrial PC may not be used in areas of explosive hazard.
The following conditions must be observed during operation:
Atmospheric humidity: Maximum 95%, non-condensing
Sinusoidal vibration: (EN 60068-2-6)
58 to 500 Hz: 0.5 G (~ 5 m/ s2)
During reading of CD-ROM:
58 to 500 Hz: 0.25 G (~ 2.5 m/ s
Impact: (EN 60068-2-27) During reading of CD-ROM: 5 G (~ 50 m/ s²), duration: 11 ms
10 to 58 Hz: 0.035 mm
10 to 58 Hz: 0.019 mm
5 G (~ 50 m/ s²), duration: 30 ms
2
)
Protection class Protection class: IP20
Power supply 100-240 V unit
Electromagnetic Compatibility (EMC)
Transport and storage The same values for atmospheric humidity and shock resistance are to be
power supply
AC
Supply voltage: 100-240 V, 50-60 Hz
Power consumption: C5101-0020: 68 W for the basic version
C5101-0030: 93 W for the basic version
Interference resistance: according to EN 61000-6-2
Emitted resistance: according to EN 61000-6-4
observed during transport and storage as in operation. The shock resistance during transport can be improved by means of suitably packing the Industrial PC. 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.
C5101 21
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