BECKHOFF C9900-P208 User Manual

Installation and Operating instructions for

C9900-P208 and C9900-P209

Power Supply Units

Version: 1.5
Date: 2012-02-22

Table of contents

Table of contents

1. Foreword 2

Notes on the Documentation 2

Liability Conditions 2
Trademarks 2
Patent Pending 2
Copyright 2
State at Delivery 2
Delivery conditions 2

Description of safety symbols 3
Basic safety measures 4
Operator's obligation to exercise diligence 4

2. Product Description 5

Appropriate Use 5
Beckhoff power supply technology 5
Electrical data 6

3. Installation Instructions 7

Configuration and installation 7
Connection with the motherboard 8

Pin assignment of the pin strips 8

Connection with the Industrial PC 9

Pin assignment of the connector 9
Preparing the cable harness 10

External wiring 10

Cable Cross Sections 10
Power supply of the Industrial PC 11
Configuration for shutting down the PC 11
PC_ON and Power Status functions 11
UPS output, C9900-P209 only 12
UPS output function 12

Wiring diagram 13
Installation of the supply cables 14

Connector installation 14

4. Operating Instructions 15

UPS Software Components (only C9900-P209) 15

Installation on the PC 15
Help files 15

Servicing 15
Shutting down 15

Disposal 15

5. Assembly dimensions 16

6. Troubleshooting 17

Beckhoff Support & Service 17

Beckhoff branches and partner companies 17
Beckhoff Headquarters 17
Beckhoff Support 17
Beckhoff Service 17

7. Appendix 18

Technical data 18
Approvals 18

FCC: Federal Communications Commission Radio Frequency Interference
Statement 18
FCC: Canadian Notice 18

C9900-P208 / C9900-P209 1

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

2 C9900-P208 / C9900-P209

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

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.

C9900-P208 / C9900-P209 3

Foreword

Basic safety measures

Use only with Beckhoff Industrial PCs

Note

The power supply unit must only be used in conjunction with Beckhoff
Industrial PCs!

Switch off the power supply of the system during installation!

Attention

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.

Do not open the power supply unit while voltage is applied!

WARNING

The supply voltage must be switched off before the power supply unit
housing is opened.

Operator's obligation to exercise diligence

Only appropriately trained staff may install the power supply unit!

CAUTION

The operator must ensure that only appropriately trained electricians deal
with installation and wiring of the power supply unit.

4 C9900-P208 / C9900-P209

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 b attery

pack allows the construction of an uninterruptible power supply (UPS).

Risk of explosion!

WARNING

Schematic diagram of
power supply unit wirings

Risk of explosion if other battery packs are used!

Beckhoff power supply technology

Innovative solution for
shutting down Industrial
PCs

C9900-P208 / C9900-P209 5

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. Via the PC ON­input of the power supply the PC gets the command to shut down the
operating system.

Once the PC has shut down, the PC power supply unit sets the Power
Status-output (P-S) to 0, what indicates 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. The battery will only be used in the event of a power failure.

Product Description

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 27 V / 1.4 A for connecting a Control Panel with a display dimension
up to 19 inches. 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.

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

6 C9900-P208 / C9900-P209

Installation Instructions

Installation Instructions

Configuration and installation

View of the power supply
unit

2

1

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).

C9900-P208 / C9900-P209 7

Installation Instructions

Connection with the motherboard

Pin strips
on the output side

1

2

3

Connection with the
motherboard

ATX DC output

5V/ 12V supply for drives

POWER ON

COM interface
(RS 232)

ATX 12V DC-Output

4

The power supply unit is connected

5

Connection Function

with the motherboard according to
the installation instructions of the
board.

Pin assignment of the pin strips

Pin Function Pin Function

Pin Function Pin Function

Pin Function

Pin Function

Pin Function Pin Function

1

3.3V

2

3.3V

3

GND

4

+ 5V

5

GND

6

+ 5V

7

GND

8

PWR OK

9

5VSTB

10

12V

1

+ 12V

2

GND

3

GND

4

+ 5V

1

POWER-ON

2

POWER-ON

3

TXD

5

RXD

9

GND

1

GND

2

GND

1

ATX interface

2

5V/12V supply

3

POWER ON

4

COM interface

5

12V supply

11
12
13
14
15
16
17
18
19
20

5
6
7
8

3
4

3.3V

- 12V
GND
PS ON
GND
GND
GND

- 5V
+ 5V
+ 5V

+ 12V
GND
GND
+ 5V

+ 12V
+ 12V

8 C9900-P208 / C9900-P209

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 onl y).

In addition, the C9900-P209 power supply unit features a UPS output for
connecting a Control Panel.

Input 24V DC UPS-

output

Pin strips

7 6 5 4 3 2 1

1 2

Uninterruptible power supply (UPS)

Note

With the C9900-P209 power supply you can realize an uninterruptible
power supply (UPS) using the battery pack C9900-U330.

Risk of explosion!

Risk of explosion if other battery packs are used!

WARNING

A Control Panel can be connected to the UPS output of the C9900-P224.

The maximum current loading is 1.4 A.

Pin assignment of the connector

The power supply and the external circuit for switching the Industrial PC on

and off are connected via the plug connector.

Pin assignment for

Input 24V DC:
connecting the switch, the
power supply and the
battery pack (optional)

Pin assignment for
connecting a control panel

UPS-output

(C9900-P209 only):
(optional)

Pin Function

1

-

2

+

3
4
5
6
7

Pin Function

1
2

-
+
Power-Status
PC_ON

UPS-
UPS+

Battery Pack
(C9900-P209 only)

24 V DC Power Supply

UPS-output

C9900-P208 / C9900-P209 9

Installation Instructions

Preparing the cable harness

Cable harness wiring
diagram

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-pi n power
supply unit connector and the 3-pin and 5-pin pin strip at the PC case:

Insert fuse

Attention

The power supply of the customized 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 mm

and 2.5 mm

2

/ AWG14 (screened) for connecting the power supply.

2

/ AWG18 for connecting the switch

External wiring

The external wiring consists of the connection of the power supply, the

battery pack (only C9900-P209) and the connection of customized
components for shutting down the PC.

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 mm

2

must be used.

With bigger distances between voltage source and PC, you take the
voltage drop as a function of the cable-cross-section as well as voltage
fluctuations of your distribution voltage into account, so that is secured that
the voltage doesn't fall under 22 V at the power supply.

Insert fuse

The power supply must be protected with 16 A.

Attention

10 C9900-P208 / C9900-P209

Installation Instructions

Power supply of the Industrial PC

Pin assignment for
connecting the power
supply and the battery pack

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.

Pin Function

1

5

4

3

2

1

+

2

-

3
4

+

5

-

24 V DC Power Supply

Battery Pack
(C9900-P209 only)

Pin assignment for
connecting the on/off switch

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.

3
2
1

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.

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.

C9900-P208 / C9900-P209 11

Installation Instructions

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 1.4 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 27 V DC connection at the UPS output is live even after a power

failure. The maximum load is 1.4 A (C9900-P209 only).

 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.

12 C9900-P208 / C9900-P209

Installation Instructions

Wiring diagram

Wiring according to the wiring diagram.

The circuit of PC_ON and Power-Status is symbolical.

Connection of the Battery Pack and UPS Output

Note

C9900-P208 / C9900-P209 13

Connection of the Battery Pack and UPS Output only in combination with
C9900-P209 power supply.

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

Connector installation

Fitting the connector to the
cable

Applying the strain relief

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).

A

C

Strain relief housing

D

B

Fix the upper part (part B) of the strain relief housing by snapping it onto
the lower part.

14 C9900-P208 / C9900-P209

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.

C9900-P208 / C9900-P209 15

Assembly dimensions

Assembly dimensions

Device dimensions and mounting points.

Dimensional notation in mm.

16 C9900-P208 / C9900-P209

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:
Fax: [phone]
e-mail: [e-mail]

+49(0)5246/963-0

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: [phone]
e-mail: [e-mail]

+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: [phone]
e-mail: [e-mail]

Quote the project number If servicing is required, please quote the project number of your product.

+49(0)5246/963-460

C9900-P208 / C9900-P209 17

Appendix

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

Environmental conditions Ambient temperature: 0 to 55°C

Shock resistance

The power supply unit must not be used where there is a risk of
explosion.

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/ s

Impact
(EN 60068-2-27/ -29):

10 to 58 Hz: 0.035 mm

5 G (~ 50 m/ s²), duration: 30 ms

2

)

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 a r e 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.

18 C9900-P208 / C9900-P209