BECKHOFF CX9000/CX9010 series embedded controllers

BECKHOFF CX9000/CX9010 series embedded controllers

BECKHOFF CX9000/CX9010 series embedded controller hardware manual, version V2.6, released on July 10, 2015, aimed at professionals in the fields of automation and control. It provides a comprehensive introduction to product parameters, installation, wiring, debugging, fault diagnosis, firmware upgrade, and maintenance

Product Overview

Compliance requirements for use

Installation form: Modular design, compatible with DIN standard rails, can be installed in control cabinets/junction boxes.

Power outage rule: The software must be shut down and run normally before cutting off the power to prevent data loss from flash memory; The shutdown equipment needs to be locked to prevent accidental power on.

Power supply: The whole machine adopts 24V DC power supply.

Product positioning and core features

CX90x0 is a compact high-performance PLC/motion controller positioned between BX bus terminal controller and CX1000 embedded PC:

Hardware architecture: Equipped with Intel IXP420 (XScale architecture) CPU, fanless design, no rotating parts, low power consumption; The system starts from the built-in flash memory and does not require external storage media.

Operating System: By default, it runs Microsoft Windows CE and comes with the automation software TwinCAT CE. It supports PLC, motion control, and visualization functions.

I/O bus classification (two major versions):

E-Bus: docking with EtherCAT terminals, high-speed I/O system;

K-Bus: Docking with traditional Bus Terminal bus terminals.

Network interface: Standard configuration includes 2 RJ45 network ports, built-in switches, and can directly build linear topologies without the need for additional switches; The Ethernet port and EtherCAT bus belong to independent MACs and do not interfere with each other.

Basic module parameters and models

Core hardware parameters

The overall dimensions are 59 × 100 × 91mm, with a weight of approximately 250g and a protection level of IP20; The working temperature is 0-50 ℃, the storage temperature is -25~85 ℃, the relative humidity is ≤ 95% (no condensation), and it meets the industry standards of EMC and vibration impact. Divided into four basic models:

Model: CPU, main frequency, flash memory, I/O bus, maximum power consumption

CX9000-0000 266MHz 16MB (expandable 32MB) 64MB (expandable 128MB) E-Bus 6W

CX9000-1000 266MHz 16MB (expandable 32MB) 64MB (expandable 128MB) K-Bus 6W

CX9010-0000 533MHz 32MB (fixed) 128MB (fixed) E-Bus 6.5W

CX9010-1000 533MHz 32MB (fixed) 128MB (fixed) K-Bus 6.5W

General configuration: 128KB NOVRAM power-off storage, 2A power supply for I/O terminals, insulation withstand voltage of 500V rms; Onboard battery powered clock.

Model Naming and Configuration

Naming convention: CX900x/CX9010-xx0x, with the second digit distinguishing E-Bus (0)/K-Bus (1).

Function selection: You can choose whether to pre install TwinCAT PLC during operation or NC motion control during operation; Optional DVI/USB interface.

Important note: All expansion interfaces are pre installed at the factory and cannot be installed/modified on site.

Onboard interface and wiring

Power interface: The upper end of the basic module is connected to 24V DC, and the lower end is powered by the terminal bus; UL specifications require that infinite current power supply cannot be connected and must be paired with 4A fuses or NEC Class 2 power supply.

RJ45 Ethernet port: standard 8-pin Ethernet definition; It is prohibited to connect two network ports to an external switch at the same time, only for local area networks, and communication lines cannot be connected.

Battery compartment: located between two network ports, using Panasonic CR2032 3V button battery (225mAh) to power the system clock;

Replacement requirement: Replace every 5 years, only Sanyo/Panasonic original batteries can be used;

Safety taboos: Charging, dismantling, and putting into fire are prohibited. Waste batteries should be recycled according to electronic waste regulations.

Dip Switch

There are a total of 4 dialing codes located in the battery compartment. During normal operation, all of them are turned off. They are only used for troubleshooting/debugging/upgrading purposes and are strictly prohibited from being modified during equipment operation

Dial 1 ON: Restore the device to factory default settings;

Dial 2 ON: Output debugging logs to COM1 serial port (serial port parameters: 38400 baud, 8-bit data bits, no checksum, 1 stop bit);

Dial 3 ON: Enter the system image upgrade boot mode;

Dial code 4 ON: Force TwinCAT to start in configuration mode (used to fix startup project faults).

Optional system interface module (pre installed at the factory)

Three types of expansion modules, size 19 × 100 × 51mm, weight approximately 80g, working temperature 0~55 ℃, two options for interfaces of the same type, cannot be used simultaneously:

CX90x0-N010 (DVI+Dual USB 2.0)

DVI-II interface: compatible with DVI digital signal and VGA analog signal, supports up to 5m cable, compatible with Beifu control panel and standard display;

Dual USB-A ports: Each port has a maximum output of 100mA and can be connected to external devices such as mice, keyboards, printers, and USB drives.

CX90x0-N030 (dual RS232 serial port): 2-channel 9-pin D-Sub interface, maximum baud rate of 115kbaud, optoelectronic isolation.

CX90x0-N031 (dual RS422/RS485 serial ports): 2-channel 9-pin D-Sub interface, maximum baud rate 115kbaud; The module comes with an 8-bit dip code, which can be configured with echo display, transceiver mode, terminal resistance, and supports RS422 full duplex and RS485 bus topology (terminal/branch nodes).

Transportation, installation, and wiring

3.1 Transportation and unboxing

Storage environment: Follow the technical parameters for temperature and humidity requirements, and retain the original packaging for secondary transportation.

Condensation protection: After low-temperature transportation, it is necessary to slowly warm up. If condensation occurs, it should be left to stand for 12 hours before powering on.

Open box inspection: Check the list of goods, inspect for transportation damage, and immediately contact Beifu after-sales if there are any abnormalities.

3.2 Mechanical Installation

Rail installation: Standard DIN rail installation, pull the white buckle at the bottom to fix the module, and reset the buckle after installation; Only press the edge of the shell, do not press the interface or buttons.

Heat dissipation requirements: A 30mm ventilation gap must be reserved above and below the module; Ventilation holes should have vertical convection, and illegal postures such as inverted or side mounted are prohibited; The maximum ambient temperature for rail installation is 55 ℃.

Module assembly: The CPU module, expansion interface, and UPS module are assembled through the PC104 bus, with light insertion to avoid damaging the connectors.

3.3 Installation of UPS module

The UPS module is not fully compatible with TwinCAT yet, and the power outage signal needs to be connected to the PLC digital input point to achieve data storage and safe shutdown.

Disassembly and assembly process: Power off first, remove adjacent terminals → release the whole machine rail buckle → disassemble the module → splice the UPS → re fix the wiring.

3.4 Start stop operation

Power on: After connecting to a 24V power supply, the device automatically starts and the pre installed system runs directly.

Power outage: Standard procedure: Close all running software → Close the operating system → Cut off power supply; Do not directly power off to avoid damaging flash data.

Fault diagnosis and debugging

4.1 Interpretation of Status Indicator Lights

4.1.1 E-Bus model indicator light

PWR light: red=TwinCAT stopped, green=TwinCAT running, blue=configuration mode, off=system offline;

LAN1/LAN2: green, corresponding to two network port links/active status;

L/A light: Flashes when EtherCAT bus has data;

HDD light (red): Flashing indicates reading and writing CF cards.

4.1.2 K-Bus model indicator lights

Keep the above lighting effects and add K-Bus indicator lights: off=bus not enabled, green flashing=bus normal, red=bus fault.

4.2 K-Bus fault code (LED flashing diagnosis)

Using flash+two segment slow flash encoding (first segment=fault code, second segment=fault location), list typical faults and their solutions:

Continuous flashing: EMC interference/power fluctuation, increase filtering, check power supply;

1 pulse: EEPROM verification error, cache overflow, restore factory settings, reduce the number of bus terminals;

3 pulses: Bus command error, remove terminal positioning faulty hardware one by one;

4 pulses: Bus disconnection, check the terminal wiring at the corresponding position;

9 pulses: Flash program verification error, factory reset and clear startup items.

Note: After most faults are repaired, they need to be powered on again to clear the fault flicker.

4.3 PLC Program Internal Bus Diagnosis

Using TwinCAT to define local variables to read bus status and achieve software level fault localization:

Core variables: BusState, Error Code, Error Arg, Request;

Configuration method: Associate hardware registers with PLC variables in System Manager, write judgment logic to implement fault reporting and bus reset.

Equipment retirement, dismantling and disposal

Pre operation: Normal shutdown → Cut off the main power → Remove all wiring.

Guide rail disassembly: First remove the terminal next to the CPU → pull open the white buckle at the bottom of the module and remove the entire machine.

Module disassembly: Use a dedicated screwdriver to unlock the rear buckle and separate the PC104 bus module; Modules marked with red seals cannot be disassembled, as forced disassembly will permanently damage the equipment.

Scrap disposal: The entire machine is recycled according to electronic waste regulations; Classify and process components such as batteries and circuit boards.

Appendix: Image Upgrade, Accessories, Certification, and After sales

6.1 System Image Upgrade

Important reminder: Upgrading without manufacturer guidance is strictly prohibited and should only be done under official advice; Upgrading interruptions can cause the device to become unusable.

Image acquisition: Download the corresponding model image from the Beckhoff FTP server (ftp. beck hoff. de), distinguish between CX9000, CX9001/CX9010, and CE5.0/CE6.0 system versions.

Three upgrade methods:

Local tool upgrade: Use Cx9ImageUpdating. exe to transfer the tool and image to the device via FTP/network drive, and perform burning locally;

Network image server upgrade: Set up an image server on a PC, enter boot mode by dialing the device code, and download and burn the image through the network;

Closing after upgrade: Delete old system files, copy new files to the built-in "Hard Disk" partition, restart to complete the upgrade.

Network precautions: It is recommended to connect the PC directly to the device or divide it into independent subnets to prevent other devices in the network from mistakenly upgrading.

6.2 Original Accessories

CF card: Industrial grade wide temperature CF card with a capacity of 128MB~16GB, supporting FAT16/NTFS formatting;

Adapter: DVI to VGA adapter, used to connect traditional VGA displays;

Spare battery: CR2032 original button battery (model CX1900-0102).

6.3 Product Certification

The whole machine has passed CE, UL, GOST-R, and FCC certifications and belongs to Class A industrial digital equipment. It is suitable for industrial environments and is prone to radio frequency interference in civilian environments.