BECKHOFF CU8803 Launch Box Installation and Explosion proof Guide

BECKHOFF CU8803-000x CP Link 4 Launch Box Installation, Debugging, and Explosion proof Application Guide

In industrial automation systems, it is common to separate the operation panel from the industrial PC for layout - the space inside the control cabinet is limited, and the operation interface needs to be arranged in a location that is convenient for personnel to operate. The Beckhoff CU8803-000x CP Link 4 transmitter is designed for this purpose: it transmits DVI video signals, USB data, and 24V power simultaneously to the remote CP29xx-0010/CP39xx-0010 control panel via a Cat.6A cable, with a maximum distance of 100 meters (One Cable Display Link). More importantly, the launch box has ATEX/IECEx explosion-proof certification and can be used in Zone 2/22 hazardous areas. This article is based on official technical documents, presenting a complete engineering practice manual from model selection, special requirements for explosion-proof installation, wiring debugging to troubleshooting.

Product positioning and model differentiation

CU8803-000x is a transmitting device in the CP Link 4 system, located on the industrial PC side (not more than 1 meter away from the PC), responsible for converting the display signals and USB data of the PC into a format suitable for long-distance transmission, and providing 24V power to the remote panel at the same time.

The only difference between the two models is the video interface on the PC side:

Model PC side video interface applicable scenarios

CU8803-0000 DVI interface connected to standard industrial PC or ATX PC with DVI output

CU8803-0001 DisplayPort interface for connecting C60xx series PC or ATX PC with DP output (DP to DVI adapter cable required)

Supporting control panel: CP29xx-0010, CP39xx-0010, CPX39xx-0010 (all CP Link 4 versions). If using the CU8802 transmission box (Two Cable Display Link), the panel requires additional power supply; CU8803 transmits power and signals simultaneously through a single cable, so it is not allowed to connect a separate 24V power supply to the panel, otherwise double voltage will damage the equipment.

Special requirements for explosion-proof applications (ATEX/IECEx)

CU8803 is one of the few emission boxes that has obtained explosion-proof certification and can be used in Zone 2 (gas) and Zone 22 (dust) hazardous areas. But when installing in an explosion-proof environment, the following mandatory requirements must be strictly followed:

Shell protection: The equipment must be installed in a suitable shell that complies with EN 60079-15 standard and has a protection level of at least IP54.

Temperature range: The ambient temperature limit for use in explosion-proof areas is 0 ° C to+55 ° C (also applicable in non explosion-proof areas).

Transient overvoltage protection: Measures must be taken to prevent transient interference from causing the voltage to exceed the rated operating voltage of 119V or more.

Pollution level: Only for use in areas where the pollution level does not exceed level 2 (IEC 60664-1).

USB stress relief (key!): The USB connector must be secured to a dedicated bracket with zip ties to prevent loosening or pulling off. The C9900-Z484 stress relief kit needs to be ordered and installed on the DIN rail on the right side of the launch box.

Warning: Ignoring any of the above will invalidate the explosion-proof certification and pose a serious safety hazard in the hazardous area.

In addition, the power line requires external fuse protection (up to 16A), and only powder fire extinguishers or nitrogen gas are allowed to be used for extinguishing fires.

Interface Explanation and Connection Specification

The interfaces of CU8803 are all located on the front panel, with a clear layout:

3.1 USB input (X10, Type-B female socket)

Connect to the USB 2.0 port of an industrial PC.

The maximum cable length is 1 meter, and it is recommended to use high-quality shielded USB cables.

Pin definition: 1-Vbus, 2-D -, 3-D+, 4-GND.

3.2 DVI/DisplayPort Input (X20)

CU8803-0000: DVI-I interface, connected to the DVI output of a PC.

CU8803-0001: DisplayPort interface, connected to the DP output of the PC (with accompanying DP to DVI adapter cable).

The maximum line length is 1 meter. If the cable at the signal source end is too long, it will cause signal attenuation and affect the quality of remote display.

3.3 CP Link 4 Output (X30, RJ45)

Connect to the CP Link 4 input of the control panel via Cat.6A Ethernet cable.

Simultaneously transmit DVI, USB 2.0, and 24V power supply (single cable solution).

The maximum length is 100 meters (high-quality Cat.6A shielded cable must be used).

Two LED indicator lights:

P20 (yellow): Flashing indicates that DVI data is being transmitted; Extinguishing indicates no data transmission.

P30 (green): Constant light indicates that the connection with the panel has been established; Extinguishing indicates no connection.

3.4 Power input (X40, 3-pin spring terminal)

Voltage range: 20.4~30V DC (nominal 24V DC), compliant with NEC Class 2.

Maximum current consumption: 4.7A (when fully loaded with control panel).

Pin definition: 1-24V+, 2-0 V, 3-PE (protective grounding).

Connector ordering number (spare part): C9900-P944 (3-pin spring terminal).

Grounding point: The PE pin of the power plug is used to establish a low impedance protective grounding. Be sure to ensure that the PE of the 24V power supply is at the same potential as 0V (PELV system), otherwise it may cause touch drift or communication abnormalities.

DIN rail installation and stress relief assembly

4.1 Installation of Launch Box

CU8803 measures 70 × 100 × 80mm (width × height × depth), weighs 745g, and is installed on a 35mm DIN rail (compliant with EN 50022):

Tilt the launch box from above and hang it onto the guide rail (hook first).

Push the bottom towards the guide rail until the lower hook locks and engages.

4.2 Installation of USB Stress Relief Bracket (C9900-Z484)

The necessary steps for explosion-proof compliance:

Hang the lower hook of the bracket onto the DIN rail on the right side of the launch box.

Align the bracket so that the upper hook clicks into the guide rail.

Tighten the two Torx TX20 screws.

Insert the USB connector into the X10 port of the transmitter box and secure the USB cable to the bracket with a zip tie.

Check the tension, tighten the zip ties if necessary, and cut off excess zip ties.

Attention: If the stress relief bracket is not installed, the USB connector may loosen in a vibrating environment, causing communication interruption and being judged as non compliant in the explosion-proof review.

Debugging and configuration process

5.1 Connection sequence (strictly follow)

Connect the USB cable to the PC and transmitter box X10.

Connect the DVI/DP cable to the PC and transmitter box X20.

Connect the Cat.6A Ethernet cable to the transmitter X30 and control panel CP Link 4 input.

Finally, connect the 24V power supply (connect the wires first and then power on).

Attention: Be sure to complete all signal line connections before turning on the power. Live plugging and unplugging may cause interface damage.

5.2 Power on inspection

The power LED (P10) of the launch box is on green → 24V power supply is normal.

CP Link output P30 lights up green → successfully connected to the panel.

P20 flashing → DVI signal is being transmitted.

The panel screen lights up → the system is working properly.

5.3 Quick Guide to Fault Diagnosis

Possible cause investigation steps for the phenomenon

P10 LED not lit. Power supply not connected or voltage too low. Measure X40 voltage (20.4~30V), check polarity, and check external fuse

P30 does not light up (no connection), Cat.6A cable is broken or the length exceeds the limit, replace the cable; Confirm length ≤ 100m; check panel CP Link 4 input

P20 does not flash, but P30 lights up. The DVI signal has not arrived. Check if the DVI/DP output on the PC is normal; Confirm that the cable length is ≤ 1m

The panel image is blurred or flickering, and the Cat.6A cable quality is poor or interfered with. Use shielded Cat.6A cables; Stay away from high interference sources such as frequency converters

USB devices cannot recognize USB cables that are too long or of poor quality. Confirm that the USB cable from the PC to the transmission box is ≤ 1m. Check if the USB driver is installed

Panel no touch response USB communication interruption check USB cable connection; Check if the stress relief bracket is secure

Comparison with CU8802 and usage warning

Features CU8802 CU8803

Number of cables 2 (signal+power separation) 1 (Cat.6A, signal+power integration)

The panel power supply requires an additional connection of 24V through CP Link cable for power supply

Maximum distance 100m 100m

ATEX/IECEx No Yes

Serious warning: If CU8803 is confused with the previous configuration using CU8802 and an additional 24V power supply is connected to the panel end, it will cause a dual voltage conflict and directly burn the panel or transmitter box. When using CU8803, the 24V power socket on the panel must remain empty (without wiring).

Maintenance and Cleaning

Cleaning method: Only use a vacuum cleaner to clean the casing (IP20 protection level). It is strictly prohibited to use compressed air, otherwise dust may blow into the interior of the equipment and cause a short circuit.

Prohibited cleaning agents: Do not use cleaning agents, metal scrapers, or razor blades containing abrasive ingredients.

No need for regular maintenance: There are no user replaceable parts inside the device.

Quick Overview of Technical Parameters

Parameter specifications

Dimensions (W × H × D) 70 × 100 × 80 mm

Weight 745 g

The power supply voltage is 20.4~30V DC (24V nominal, NEC Class 2）

Maximum current 4.7 A

Working temperature 0~55 ° C

Storage/transportation temperature -25~70 ° C

Protection level IP20

Explosion proof certification ATEX II 3G Ex ec IIC T4 Gc/IECEx

Maximum transmission distance of 100 meters (Cat.6A)

PC side cable length USB/DVI/DP ≤ 1 m

Common Troubleshooting Ladder Table

Prioritize troubleshooting and advanced measures for fault symptoms

The launch box has no response at all. Check the 24V power supply and fuse; Confirm the correct polarity of the power terminal and measure whether the X40 voltage is ≥ 20.4V; check the PE grounding

The panel has no display but the power light is on. Check if the Cat.6A cable is securely plugged in; Confirm the status of the P30 light and replace the Cat.6A cable; Check if the output resolution of the PC graphics card exceeds the supported range of the panel

USB devices cannot be recognized at the panel end. Check if the USB cable (PC → transmitter box) is ≤ 1m. Check if the driver recognizes "Beckhoff Virtual COM" devices in the PC Device Manager

Intermittent black screen cables on the screen are affected by electromagnetic interference or the length is close to the limit. Use shielded Cat.6A cables; Shorten the length; Stay away from high-power frequency converter cables

The installation in the explosion-proof area has been returned without installing the USB stress relief bracket or the enclosure does not meet the IP54 standard. Order C9900-Z484 and install it correctly; Confirm that the protection level of the control cabinet is ≥ IP54

Confirm that the transmission box PE and panel PE are at the same potential due to incorrect touch or drift of the panel touch, poor grounding, or potential difference; Check if the 24V power supply is PELV