BECKHOFF CX1100-000x User Manual

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Documentation for Power supply units and I/O interfaces for CX Embedded PC Systems

CX1100-0001

CX1100-0002 (K-bus)

CX1100-0003 (IP Link und K-bus)

CX1100-0004 (E-bus)

version: 1.9 date: 2007-03-06

Table of Contents

1. Foreword

Notes on the Documentation 3

Safety Instructions 4

Documentation issue status 5

2. Product overview 6

Appropriate use 6

System overview 7

Architecture 11

Memory mapping 13

Display 14

Technical data 14

Operating the display 15

Operating the display via ADS codes 19

Table of Contents

4 + 1 navigation switch 20

Operating the switch 20

CX1100-0001 23

Overview 23

Techical data 24

CX1100-0001 architecture 25

CX1100-0002 26

Overview 26

Techical data 27

CX1100-0002 (K-Bus) architecture 30

CX1100-0003 32

Overview 32

Techical data 33

CX1100-0003 (IP-Link Bus) architecture 36

CX1100-0004 38

Overview 38

Techical data 39

CX1100-0004 (E-Bus) architekture 40

3. Transport 41

Unpacking, installation and transport 41

4. Fitting and wiring 42

Mechanical assembly 42

Dimensions 42

Mechanical installation 44

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Commissioning 46

Electrical connection 46

5. Error handling and diagnostics 48

Bus diagnosis in PLC 48

LED CX1100-0001 52

LED CX1100-0002 53

LED CX1100-0003 55

LED CX1100-0004 58

6. Decommissioning 59

Removal and Disposal 59

7. Appendix 61

ADS errorcodes 61

Certifications 63

Support 64

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Foreword

1. 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.

Liability Conditions

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.

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. None of the statements of this manual represents a guarantee (Garantie) in the meaning of § 443 BGB of the German Civil Code or a statement about the contractually expected fitness for a particular purpose in the meaning of § 434 par. 1 sentence 1 BGB. 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.

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Foreword

Safety Instructions

Safety Rules

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.

Personnel Qualification

This description is only intended for the use of trained specialists in control and automation engineering who are familiar with the applicable national standards.

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.

Danger

This symbol is intended to highlight risks for the life or health of personnel.

Warning

This symbol is intended to highlight risks for equipment, materials or the environment.

Note

This symbol indicates information that contributes to better understanding.

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Documentation Issue Status

Version Changes

1.9 Notes on wire installation added

1.8 Notes on terminal bus diagnosis with firmware > B7 added

1.7 Terminal bus diagnosis in PLC program added

1.6 Notes on hardware revision added

1.5 Blink codes for IP-Link errors added

1.4 Display control via ADS commands added

1.3 Changes in GCB – Watchdog Error Counter

1.2 Blink codes for CX1100-0004 (EtherCAT) extended

1.1 library for 4 + 1 navigation switch added

1.0 memory mapping / fieldbus connections

0.2 revised version description of four power supplies CX10xx architecture description

0.1 preliminarily version

Foreword

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Product overview

2. Product overview

Appropriate Use

The CX1020 device series is a modular control system designed for DIN rail installation. The system is scalable, so that the required modules can be assembled and installed in the control cabinet or terminal box as required.

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CX1100-000x

power supply units and I/O interfaces

One of four power supply modules can be selected for a CX10x0 system. The power supply of all other system components is ensured via the internal PC104 bus; no separate supply lines are required. However, the CX1100 components offer further important characteristics that go beyond a pure power supply: an integrated NOVRAM enables the fail-safe storage of process data, an LCD display with two lines of 16 characters each is used for displaying system and user messages. Local I/O signals are connected via the CX1100-0002 power supply variant, to which all Beckhoff Bus Terminals can be connected, or via CX1100-0003, which in addition to the Bus Terminals enables the connection of Extension Box IExxxx type Beckhoff Fieldbus Box modules. The option to connect Bus Terminals or Fieldbus Box modules creates a control system with a very variable, expandable I/O level with large signal variety. The I/O data are stored in a DPRAM, which is accessible by the CPU via the system bus. The power supplies of the CX system can be changed in the field: If, for example, local I/O via Bus Terminals is required, CX1100-0001 can be replaced with CX1100-0002 in the field. Local I/O signals are connected via the CX1020 and the CX1100-0002 power supply variants (Bus Terminals), CX1100-0003 (Bus Terminals and Fieldbus Box modules via IP-Link) or CX1100-0004 for EtherCAT Terminals. With CX1100-0004 the I/O data are stored directly in the main memory of the CPU; a DPRAM is no longer required. The CX1100-0004 power supply unit for EtherCAT Terminals can only be connected in conjunction with the basic CX1020 CPU module.

The technical data are as follows:

 CX1100-0001

 CX1100-0002

 CX1100-0003

 CX1100-0004

An overview about architecture with the common system components GCB, ACB, NOVRAM, Display und Taster are described together in one chapter. Special interfaces are described in the power supply units containing the

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interfaces.

 Architecture

 Display

 Taster

Architecture of the power supply units

The four power supply units for the CX10x0-System accomplish more task than supporting the system with power. Each module has three basic functions. Additional each model supports different connection to communication busses. Caused by these different connections the internal architecture differ. At first the common functions are described.

All power supply feature, except for power supply, the following functions:

1. Display 2 x 16 characters

2. 4+1 navigation switch

3. Non Volatile RAM

These functions are managed by the control program via the PC104 bus. The structure of the CX1100-0001 is shown in the following figure:

"General Control Block" (GCB)

The top 16 byte of the system control area (starting at the physical hex address D0000 + Offset FF0) form the general control block GCB, which holds the control byte required to start the I/O processing of the K-Bus and IP-Link.

The CPU of the main module controls the whole architecture. With memory mapped I/O regions data can be exchanged. The data needed to run the system is combined in the "General Control Block" (GCB). Its base address is "0xD1000". The figure shows the Data and the offset. Some registers are not needed in all units. So only the requested registers are mapped other addresses are masked out.

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Firmware Version:

These two bytes contain the hex decimally coded version number of the CX1100 firmware. E.g. the first byte could show B3(hex): this results in firmware version B3.

Firmware Revision:

These two bytes contain the hex decimally coded revision number of the CX1100 firmware. E.g. the byte could show 00: this results in revision 00.

Service Request / Response Bitfield: (nur für CX1100-0002 / -0003)

These two bytes contain a sequence of bits, by which certain service functions may be executed. The service function is invoked by setting the appropriate request bit, the controller executes and sets the response bit. Before the same function can be invoked again, the request bit must be set to zero and wait until the response bit is also set to zero. An execution error is signaled by raising response bit 7.

Bitfeld Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0

Request - - - - - Link Images Remap Reset Node

Response Error - - - - Images Linked Remapped Reset Done

Reset Node:

with this bit, a software reset of the 80C165 microcontroller can be performed. This is different from the hardware reset which may be performed in the Auxiliary Control Block (ACB).

Remap:

with this bit, the two-byte PLC interfaces normally residing in the input/output process areas can be remapped into the general control block for K-Bus and IP-Link. Thus the input/output process image areas can be kept clean and for the sole purpose of storing I/O-data.

Link Images:

if set, this bit links the K-Bus logically to the IP-Link in the case of error occurrence - meaning that if one of them stops operating, the other one is stopped as well. By default, this bit is set so stopping both I/O systems in case of error is the standard behavior.

Watchdog Time:

With the request of an I/O cycle through "PD cycle request", a watchdog timer with this specified millisecond time ist started. If the cycle is not being restarted by a next "PD cycle request", the watchdog elapses and as a consequence the output process image is zeroed. This resets all outputs to a safe state (OFF). If another value than the default 100ms is written to this cell, a "Reset node" is needed to activate the change.

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Cycle Time:

This is the time elapsed between the initiation and termination of an I/O process image update (K-Bus + IP-Link ). The time is recorded in units of microseconds and starts with writing a new cycle request to the field "PD cycle request" and it stops with the termination response in the field "PD cycle ready". For CX1100-0002 this time reflects the K-Bus update time, for CX1100-0003 it is the sum of K-Bus update time and IP-Link update time.

Watchdog Error Counter:

If the Watchdog Time exceeds the value in this register is increased by one. In this way the user can get the numbers of watchdog-time errors. (available since firmware revision B6)

Processdata Error:

This byte contains the information on the error status of the I/O blocks. The possible bit codes are:

Bitfeld Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0

Processdata Error - - - - - - IP-Link Error K-Bus Error The bit is set to "TRUE", if an error occurred. If both bits are zero, there is no error on either bus system. Error

recovery may be attempted by invoking the "Reset bus" service in the corresponding CB of either K-Bus or IP-Link.

Processdata Cycle Overrun:

This byte contains a counter, which is incremented each time a new process data cycle is requested although the previous cycle has not yet completed. This can happen only due to a handshake programming error or if the user task cycle time is shorter than the time for I/O update.

PD Cycle Ready / PD Cycle Request:

These two bytes contain the request value and the ready value for operating a process data (PD) I/O cycle. The user program is supposed to write a pattern (e.g. an up-counter value ) to the request byte, thus triggering the I/O cycle. Once the I/O cycle is finished, the microcontroller will set the ready byte to match the request byte. A new request can then be written to the request byte.

"Auxiliary Control Block" (ACB)

The Auxiliary Control Block of CX1100 is a block of 16 bytes and starts at address D1000 (hex). It is a miscellaneous control block for controlling:

- the 2x16char FSTN LCD Display

- the navigation switch

- the hardware reset of the 80C165 microcontroller

The following schematic shows the layout of the ACB and is followed by a description of the single bits contained in it.

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Display Cmd Register:

Bit 0 R/#W

Bit 1 DATA/#CMD Bit 2 EN

Bit 7 BL OFF

R/#W: This bit control the Read or Write operation for programming the display2x16 char LCD display.

DATA/#CMD: This bit controls whether the byte "Display Data Reg" holds a command or display data.

EN: This is the enable bit for executing the operation with the display controller.

BL OFF: If set, this bit turns of the backlight of the LCD Display. This feature may be used for blinking with the

backlight, thus attracting the users attention to an important message on the display. It may also be

used to save power in the case of power loss and UPS operation.

Display Data Register:

These are the data bits for issuing commands or reading/writing data to the display controller. These bits are operated in conjunction with bits 0,1,2 of the Display Cmd Reg. For more detailed information please refer to the display controller documentation.

In Register:

These bits reflect the contact status of the 4+1 direction navigation switch on the front side of the CX1100 unit. These events may be used by a software for implementing a menu driven data input/output together with the LCD display.

Bit 0 UP Bit 1 DOWN Bit 2 LEFT Bit 3 RIGHT Bit 4 SELECT Bit 5 PWR-FAIL (reserved for future use - do not use)

An example for access the switch is given in the detailed description of the switch.

Out Register:

Bit 0 RES C165 This bit resets the microcontroller 80C165 and restarts the initialization of the K-Bus and IP-Link circuit. For doing the reset, this bit must be set high and then set back to low. There is no need for an explicit hold time. This bit may be used to recover from K-Bus faults such as removing a terminal during operation. It needs to be set at least once at startup or initialization of the user software before operating the k-Bus.

Bit 1 IRQ0 (reserved for future use - do not enable) Bit 2 IRQ1 (reserved for future use - do not enable) Bit 3 IRQ2 (reserved for future use - do not enable)

Memory region 0xD1004 to 0xD1008:

In this region the type of the power supply module is encoded. By adding the four registers the type description is given:

CX1101 CX1100-0001 power supply unit with display, 4 + 1 navigation switch and NOVRam

CX1102 CX1100-0002 power supply unit with display, 4 + 1 navigation switch, NOVRam and K-bus connection

CX1103 CX1100-0003 power supply unit with display, 4 + 1 navigation switch, NOVRam, K-bus-connection and IP-Link-connection

CX1104 CX1100-0004 power supply unit with display, 4 + 1 navigation switch, NOVRam and E-bus connectio.

Das Non Volatile RAM

The NOVRAM is one of the most important functions of the power supply unit. The access is realized via the PC104 bus. The mapping to PLC is realized by TwinCAT System Manager. Here needed variables can be defined and mapped to memory. Further details are given in the TwinCAT documentation.

K-BUS and IP-LINK Operation

This section describes how to trigger the K-Bus (and in the case of CX1100-0003 also the I/O-boxes connected to IP-

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Link) in order to read input values and write output values. The procedure is the same for IP-Link, the description limits itself to K-Bus for textual simplicity.

The I/O operation is done through the bytes named "PD cycle ready" and "PD cycle request" in the GCB. The K-Bus cycle is triggered by a write operation to the byte "PD cycle request". Although the value being written to this byte does not matter (it is only the write operation which is important), it is recommendable write a counter-up value to this byte. The microcontroller for the K-Bus will react to the write operation by performing a K-Bus cycle and gathering the I/O data. Once the cycle is completed and the electrical signal input data are written to the DP-RAM, the microcontroller will set the content of byte "PD cycle ready" equal to the content of "PD cycle request", thus signaling the completion of the I/O cycle. The time required to run a K-Bus cycle depends on the number of terminals attached to CX1100: it is minimum 700 microseconds and typically well below 5 milliseconds. The K-Bus cycle time can be viewed by using the TwinCAT System Manager tool, by entering the exact terminal configuration.

At startup of the user program, before going into cyclic operation, it is mandatory to reset the K-Bus controller by triggering the "RES C165" bit in the Auxiliary Control Block section of CX1100. Please refer to the description of the ACB for how to do this.

The sequence of operating the K-Bus can be explained by assuming a cyclic automation task executed each 10 ms on the main CX1000 CPU:

Task cycle "n":

- check if K-Bus operation of previous cycle has finished: is "PD cycle ready" = "PD cycle request" ? Proceed if yes, issue error message and abort cyclic task operation if not, because a K-Bus cycle does not need 10 milliseconds to finish !

- read the input data from the DP-RAM (these are the input data gathered by the previous cycle "n-1" )

- write the output data to the DP-RAM (these are the outputs calculated by the previous cycle "n-1" ).

- increment and write the new value to "PD cycle request"

- perform task user code

Task cycle "n+1":

- read the input data from the DP-RAM (these are the input data gathered by the previous cycle "n" )

- write the output data to the DP-RAM (these are the outputs calculated by the previous cycle "n" ).

- increment and write the new value to "PD cycle request"

- perform task user code

Of course only the I/O bytes needed should be copied to or from the DP-RAM, since each read or write operation over PC104 is time consuming. Please note that the terminal outputs need a K-Bus refresh no later than 100 milliseconds, otherwise the watchdog in each terminal will shut off the outputs. This means that the task cycle time should be below 100 milliseconds. Also, if more than one cyclic automation task needs access to K-Bus I/O, it is important that only one task operates the K-Bus and the other tasks implement an I/O buffering in order to have a consistent I/O image. In this scenario, the task with the highest priority has the shortest cycle time and will trigger the K-Bus.

Please note also that it is assumed that in each cycle the integrity of the K-Bus is being checked by examining the "Processdata error" field in the GCB. Cyclic operation should be aborted in the case of an I/O error and user should be prompted for corrective actions. Cyclic operation can be resumed after resetting the faulty bus over the service request fields of the control block.

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Adapter RAM Hardware address overview

available memory addresses CX1020: D0000-DFFFF (hex)

Base Address (hex)

D0000 D0FFF 1000 R/W CX1100-0002/3 Dual Ported RAM

D1000 D100F 10 R/W CX1100 Auxiliary Control Block( LCD

D1010 D101F 10 R/W CX1100-0900 UPS Control Block

D2000 D3FFF 2000 R/W CX1100 Non Volatile RAM

D4000 D5FFF 2000 R/W CX1500-M310 Profibus Master DPRAM

D6000 D7FFF 2000 R/W CX1500-M510 CANopen Master

D8000 D9FFF 2000 R/W CX1500-M520 DeviceNet Master

DA000 DBFFF 2000 R/W CX1500-M200 Lightbus Master DPRAM

DC000 DDFFF 2000 R/W CX1500-M750 Sercos Master DPRAM

For some fieldbus connections (all Slave modules) the base addresses are mapped in the memory region upper DFFFF(hex). So this modules must be ordered with other base addresses. The same situation takes place if more than two or more master modules of same type are used (for more see note below). The order numbers for the modules are:

order number alternative ISA-Adresse

Master connection

CX1500-Mxxx-0001 D4000

CX1500-Mxxx-0002 D6000

CX1500-Mxxx-0003 D8000

CX1500-Mxxx-0004 DA000

CX1500-Mxxx-0005 DC000

Slave connection

CX1500-Bxxx-0001 D4000

CX1500-Bxxx-0002 D6000

CX1500-Bxxx-0003 D8000

CX1500-Bxxx-0004 DA000

CX1500-Bxxx-0005 DC000

Replace xxx with the following number for the requested fieldbus system:

End Address (hex) Size(Bytes)(hex)

Access Type Description

Display, misc. registers)

DPRAM

 200 for Lightbus

 310 for Profibus

 510 for CAN-open

 520 for DeviceNet

 750 for Sercos (only Master connection available)

Note

Two connection modules (master or slave) can be used simultaneously. If more than two connections are needed call Beckhoff Automation GmbH for further information.

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Display

Display setup

The display built-in the CX1100-000x units, is a LCD display. It features 2 lines with 16 characters. Each character has a resolution of 5 x 8 pixel. The font is named SPLC780C-11 and is fixed. The following figure shows the the font with all available characters.

For easy reading a background illumination is integrated to the display. The illumination can be switch on and off. This blinking can be used to attract the user in certain situations. The state can be set via the controller. The controller reads the registers in "Auxiliary Control Block" and addresses the display in the desired manner.

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Representing text on the display

The display can be controlled in two ways with the aid of TwinCAT. One version is programming through the System Manager. A second possibility is for the display to be written by a function block directly from the PLC program.

Settings in the System Manager

When the TwinCAT system starts, the text specified in the configuration can be written to the display. This text is set in the System Manager.

This is done by selecting the CX10x0 device in the hierarchy browser. Under the CX1100 tab it is possible to write both lines of the display in the "Display settings" area. This requires the fields at the location for initialisation and writing to be selected. The changes only take effect after the configuration has been written. When TwinCAT restarts, the set text is then displayed.

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The display can be controlled directly through the Display tab. The corresponding functions are carried out immediately through the switches. It is possible to execute the following functions:

 Switch the display on/off (text is displayed/hidden)

 Background illumination on/off

 Clear the display (text is cleared, and must be re-entered)

 Cursor on/off (the cursor is displayed)

 Cursor flash on/off (the cursor flashes)

The desired text is entered into the text input field. The "Write current" switch inserts the text at the current position of the cursor.

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Using the "Write At" switch, the numerical input box and the "Second Line" check box, it is possible to write to a specified position on the display. The useful range of values for the position extends from 0 to 15. The user should also, however, consider the length of the text. (Each line has 16 characters!) In the example illustrated below, the text "CX1100-000x" is written to Position 0 (the start of the line) on Line 2.

Settings in the PLC program

The function block FB_CX1000SetTextDisplay is provided in the library for the CX family (TcCX1000System.lib) in order to operate the display from a PLC program. All the functions of the display can be manipulated from this function block. The library must, however, be integrated through the library administrator. If this has been done, the block is available as a function block. It is instanced as such in the declarations part of the program.

PROGRAM MAIN

VAR

Display_0 : FB_CX1000SetTextDisplay;

END_VAR

It is then called from the program with its parameters. There are five parameters for this function block:

 bExecute : BOOL

 nDevID : UDINT

 nMode : E_CX1000_DisplayModes

 stLine : STRING(20)

 nCursorPos : DWORD

The command is executed in response to a rising edge at "bExecute". "nDevID" provides the Device ID of the CX1100 that is to be written to. The ID is displayed in the System Manager. (The General tab for the CX1100, top right). The parameter "stLine" is used to pass a text of at most 20 characters. Only the first 16 of these characters, however, will be displayed. The writing position of the text uses quoted through "nCursorPos". 0 to 15 is a useful range for this value. "nMode" selects the operating mode of the function block. The modes are:

 e_CX1000_DisplayNoAction : No action.

 e_CX1000_DisplayOn : Switch on the display.

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 e_CX1000_DisplayOff : Switch off the display.

 e_CX1000_CursorOn : Switch on the cursor.

 e_CX1000_CursorOff : Switch off the cursor.

 e_CX1000_CursorBlinkOn : Switch on the cursor flashing.

 e_CX1000_CursorBlinkOff : Switch off the cursor flashing.

 e_CX1000_BackLightOn : Switch on the background illumination.

 e_CX1000_BackLightOff : Switch off the background illumination.

 e_CX1000_ClearDisplay : Clear the content of the screen.

 e_CX1000_WriteLine1 : Write to the first line.

 e_CX1000_WriteLine1 : Write to the second line.

The call then looks like this:

Display_0(

bExecute := write_now, (*write_now is a bool, function: switch)

nDevID := 1, (*DeviceID of the CX1100*)

nMode := e_CX1000_WRITELine1, (*Write to the first line of the display*)

stLine := 'Beckhoff CX1100', (*Fixed text or variable*)

nCursorPos := 0 (*Writing position, e.g. 0 for start line*)

);

The block supplies a few status signals for evaluating the program environment. These can be used to provide feedback to the PLC program. There are three response signals from the function:

 bBusy : BOOL

 bErr : BOOL

 nErrorID : UDINT

"bBusy" indicates that the command is at present being transferred by ADS. No new command will be accepted as long as "bBusy" remains TRUE. "bErr" reports an error in a call to a function block. (The signal becomes TRUE). "nErrorID" permits the error that has occurred to be analysed by means of an error number. The error number refers to an error in the ADS protocol.

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LCD Display

The LCD display of the power supply units has two rows of 16 characters each and is used for displaying system and user messages.

"Index-Group/Offset" Specification for the LCD Display

ADS Port 300

Index Group

0x00005000 + DeviceID

Data

Index Offset Access

0xFFFF90FF R&W Cursor OFF

0xFFFF91FF R&W Cursor ON

0xFFFF92FF R&W Cursor blink

0xFFFF93FF R&W Cursor blink ON

0xFFFF94FF R&W Display OFF

0xFFFF95FF R&W Display ON

0xFFFF96FF R&W Backlight OFF

0xFFFF97FF R&W Backlight ON

0xFFFFA0FF R&W Write Text line 1

0xFFFF00FF R&W Write Text line 2

type

Phys. unit

Def. range

Description Remarks

OFF

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4 + 1 navigation switch

Operating principle of the switch

The CX1100-000x power supply units all have 4 + 1 navigation switches. The switches can therefore be used to input five basic states:

1. UP

2. DOWN

3. LEFT

4. RIGHT

5. SELECT

Combined inputs, such as UP + RIGHT or UP + RIGHT + SELECT can also be entered. The values of the switches are stored in a register of the "Auxiliary Control Block", ACB. Details may be referred to in the architectural description.

The register can be accessed from within a PLC program, and the value can be assessed. This requires a variable of type USINT first to be created in the PLC program. This is then linked in the TwinCAT System Manager to the INregister of the CX1100.

The figure shows the linked signals (with a bright red background). The switch can be accessed from the PLC program through the Switch variable. The PLC program takes the form described below. To begin an external variable is declared as an input. (In this example it is at address 0)

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PROGRAM MAIN

VAR

Taster AT %IB0 : USINT;

END_VAR

A simple CASE statement can then be used to evaluate the switch, and the desired function can be initiated, e.g.:

CASE Taster OF

0: ACTION := NONE;

1: ACTION := UP;

2: ACTION := DOWN;

4: ACTION := LEFT;

8: ACTION := RIGHT;

16: ACTION := SELECT;

END_CASE;

In this case, "ACTION" is a newly defined ENUM type. It is also possible for the desired action to be activated immediately.

The sum of the numerical values is used for the combined functions. In other words, UP (1) and RIGHT (8) would be 8 + 1 = 9. In this way, only sensible combinations are possible. In other words, switch positions that are opposite to one another cannot be selected without damaging the switch.

If the programmer does not want to carry out the evaluation, the TwinCAT System provides a library function that implements conversion of the switch input into an ENUM type. For this purpose, the library for the CX Systems, TcSystemCX.lib, must be integrated into the library manager. The function is called "F_CXNaviSwitch(iCX1100_IN : USINT)", and returns an ENUM type. This encodes the direction of the switch that has been pressed as names, for example e_CX1100_NaviSwitch_MIDDLE for <Middle>. The full list of valid possibilities is:

 e_CX1100_NaviSwitch_IDLE

 e_CX1100_NaviSwitch_MIDDLE

 e_CX1100_NaviSwitch_TOP

 e_CX1100_NaviSwitch_TOPRIGHT

 e_CX1100_NaviSwitch_RIGHT

 e_CX1100_NaviSwitch_BOTTOMRIGHT

 e_CX1100_NaviSwitch_BOTTOM

 e_CX1100_NaviSwitch_BOTTOMLEFT

 e_CX1100_NaviSwitch_LEFT

 e_CX1100_NaviSwitch_TOPLEFT

 e_CX1100_NaviSwitch_MIDDLE_TOP

 e_CX1100_NaviSwitch_MIDDLE_TOPRIGHT

 e_CX1100_NaviSwitch_MIDDLE_RIGHT

 e_CX1100_NaviSwitch_MIDDLE_BOTTOMRIGHT

 e_CX1100_NaviSwitch_MIDDLE_BOTTOM

 e_CX1100_NaviSwitch_MIDDLE_BOTTOMLEFT

 e_CX1100_NaviSwitch_MIDDLE_LEFT

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 e_CX1100_NaviSwitch_MIDDLE_TOPLEFT

Further details on the function can be read in the TwinCAT documentation. The function can be used in a program as follows: (The declaration and linking are as given in the example above)

CASE F_CXNaviSwitch(Taster) OF

e_CX1100_NaviSwitch_IDLE :; (* do nothing *)

e_CX1100_NaviSwitch_MIDDLE :call_select; (* select item *)

e_CX1100_NaviSwitch_TOP :call_prev_item; (* previous menue item *)

e_CX1100_NaviSwitch_RIGHT :call_inc_value; (* increase value *)

e_CX1100_NaviSwitch_BOTTOM :call_next_item; (* next menue item *)

e_CX1100_NaviSwitch_LEFT :call_dec_value; (* decrease value *)

END_CASE;

Further evaluation of the switch inputs is then done later in the program.

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CX1100-0001

CX1100-0001 connections

This power supply unit does not have an I/O interface. The power supply is therefore connected through the 5-pin open pluggable connector. The power supply unit supplies all further system components with a voltage of 24 V DC (15 %/+20%) via the PC104 bus. The dielectric strength of the power supply unit is 500 V The integrated NOVRAM permits storage of process data that is safe against power failure.

rms

Pin Allocation Open Style Connector:

Pin Assignmnet

1 +24 V DC

2 0 V DC

3 GROUND

4 reserved / don't use

5 reserved / don't use

LED:

With proper connection of the power supply unit and with power supply turned on, the power LED (PWR) lights up green. In the case of a short-circuit, it lights up red.

Embedded PC 23

Product overview

Technical data CX1100-0001

dimensions:

One of power supply modules can be selected for a CX10x0 system. The power supply of all other system components is ensured via the internal PC104 bus; no separate supply lines are required. However, the CX1100 components offer further important characteristics that go beyond a pure power supply: an integrated NOVRAM enables the fail-safe storage of process data, an LCD display with two lines of 16 characters each is used for displaying system and user messages.

The power supply CX1100-N001 has no I/O interfaces.

Technical data CX1100-0001

Power supply 24 V DC (-15%/+20%)

Dielectric strength 500 V

Max. power consumption 2.5 W

Recommended fuse at 24 V 4 A

K-bus connection -

E-bus connection -

IP-Link connection -

K-bus power supply to -

connection type 1 x Open Pluggable Connector, 5-pin

NOVRAM 8 kByte

Display FSTN display 2 lines x 16 characters of text, illuminated

I/O-DPRAM -

Diagnose LED 1 x PWR

Dimensions (W x H x D) 45 mm x 100 mm x 91 mm

weight app.180 g

operating/storage temperature 0° C ... +55° C / -25° C ... +85° C

Relative humidity 95% no condensation

Vibration/shock resistance conforms to EN 60068-2-6 / EN 60068-2-27/29

EMC resistance burst / ESD conforms to EN 61000-6-2 / EN 61000-6-4

protection class IP 20

(supply / internal electronics)

eff

24 Embedded PC

Product overview

Architecture of power supply CX1100-0001

This power supply features, except for power supply, the following functions:

1. Display 2 x 16 characters

2. 4+1 navigation switch

3. Non Volatile RAM

These functions are managed by the control program via the PC104 bus. The structure of the CX1100-0001 is shown in the following figure:

This power supply unit features only the basic functions. These functions are described in the architecture overview.

Embedded PC 25

Product overview

CX1100-0002

CX1100-0002 connections

This power supply unit is equipped with an I/O interface, which permits connection of the Beckhoff Bus Terminals. The power is supplied via the upper spring-loaded terminals labelled “24V” and “0V”.

The supply voltage feeds the CX system and supplies a voltage of 24 V DC (-15 %/+20%) to the Bus Terminals via the K-Bus. The dielectric strength of the power supply unit is 500 V

on, a further power supply is necessary for the Bus Terminals. This is provided by means of the power contacts, which are not connected to the power supply. The integrated NOVRAM permits storage of process data that is safe against power failure.

. Since the K-Bus does no more than pass data

rms

LED:

With proper connection of the power supply unit and with power supply turned on, the power LED (PWR) lights up green. In the case of a short-circuit, it lights up red.

The I/O LEDs display the operation status of the Bus Terminals. Error-free start-up of the configuration is signalled by

the red "I/O ERR" LED being extinguished. If the ”I/O ERR" LED blinks, an error in the area of the terminals is indicated. The error code can be determined from the frequency and number of blinks.

PE power contacts

The ”PE" power contact must not be used for other potentials.

26 Embedded PC

Technical data CX1100-0002

dimensions:

Product overview

Technical data CX1100-0002

Power supply 24 V DC (-15%/+20%)

Dielectric strength 500 V

Max. power consumption 3.5 W

Recommended fuse at 24 V 4 A

K-bus connection yes (adapter terminal)

E-bus connection -

IP-Link connection -

K-bus power supply to 1.75 A

connection type Cage-Clamp (adapter terminal)

NOVRAM 8 kByte

Display FSTN display 2 lines x 16 characters of text, illuminated

I/O-DPRAM 2 kByte

Diagnose LED 1 x PWR, 1 x I/O Run, 1 x 1/O Err

Dimensions (W x H x D) 40 mm x 100 mm x 91 mm

weight app.250 g

operating/storage temperature 0° C ... +55° C / -25° C ... +85° C

Relative humidity 95% no condensation

Vibration/shock resistance conforms to EN 60068-2-6 / EN 60068-2-27/29

EMC resistance burst / ESD conforms to EN 61000-6-2 / EN 61000-6-4

protection class IP 20

(supply / internal electronics)

eff

Embedded PC 27

Product overview

Architecture of power supply CX1100-0002

This power supply features, except for power supply, the following functions:

1. Display 2 x 16 characters

2. 4+1 navigation switch

3. Non Volatile RAM

4. K-bus connections

These functions are managed by the control program via the PC104 bus. The structure of the CX1100-0002 is shown in the following figure:

This power supply unit features the basic functions. These functions are described in the architecture overview. Further the k-bus is supported. The access to the bus is managed by a 4 KB dual-ported-RAM (DPRAM). A microcontroller (80C165) manages the data transfer to the k-bus. The DPRAM is accessed by the CPU (via PC104 bus) and the microcontroller. The following figure shows the memory setup of the DPRAM:

28 Embedded PC

Product overview

The memory image of the K-bus resides in the lower memory region (D000 to D0400). This region separates in input and output region. Since firmware version ≥ B3 it is possible to shift the I/O regions. In this way the process image

can be adapted to the needed space. To each I/O-region the is a control block. Each block consists of 8 byte for diagnosis purpose. These regions can be shifted, too. The following table shows the structure of the interface. The offset addresses are default values.

Legacy PLC interface (inputs)

Offset default

0x1F8 [2] diagnosis CX1100-0002 to K-Bus

0x1FA [2] 2 Byte PLC Interface CX1100-0002 to K-Bus

0x1FC [4] reserved

Legacy PLC interface (outputs)

Offset default

0x3F8 [2] diagnosis K-Bus to CX1100-0002

0x3FA [2] 2 Byte PLC Interface K-Bus to CX1100-0002

0x3FC [4] reserved

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Product overview

The K-Bus Control Block (CB K-Bus)

This section describes the layout of the control block for the K-bus portion of a CX1100-0002 or CX1100-0003. This control block is located in the memory just below the General Control Block GCB.

CB K-Bus

Offset Default

0xFD0[2] K-Bus 2 byte plc interface to CX1100-0002/3

0xFD2[2] K-Bus 2 byte plc interface from CX1100-0002/3

0xFD4[2] K-Bus diagnosis to CX1100-0002/3

0xFD6[2] K-Bus diagnosis from CX1100-0002/3

0xFD8 K-Bus service request bitfield

0xFD9 K-Bus service response bitfield

0xFDA K-Bus error code

0xFDB K-Bus error argument

0xFDC[2] K-Bus base ptr Inputs 0x000

0xFDE[2] K-Bus base ptr Outputs 0x200

0xFE0-0xFE1 K-Bus cycle count

0xFE2-0xFE3 K-Bus cycle time [µs]

0xFE4 K-Bus bus status

0xFE5-0xFEE Reserved

0xFEF Retry counter

K-Bus 2 byte plc interface to CX1100-0002/3 / K-Bus 2 byte plc interface from

CX1100-0002/3

These two bytes for each direction - from the main CPU to CX1100 and back - special communication with the register model of the I/O microcontroller. Through this interface, a communication to K-Bus terminals can take place. The so called register model description can be found in the hardware description manuals of the terminals and bus couplers. This communication is typically used for extended diagnosis or configuration of terminals if they need to deviate from the delivery standard, e.g. changing the baud rate for RS232-terminals or gain/offset values with analog terminals.

K-Bus diagnosis to CX1100-0002/3 / K-Bus diagnosis from CX1100-0002/3

With these two bytes in each direction it is possible to retrieve diagnostic information from the attached terminals. Since the same diagnostic information is reflected in the process image input area per each terminals, there is in general no need to use this interface.

K-Bus service request bitfield / K-Bus service response bitfield

IThese two bytes contain a sequence of bits, by which certain service functions may be executed. The service function is invoked by setting the appropriate request bit, the controller executes and sets the response bit. Before the same function can be invoked again, the request bit must be set to zero and wait until the response bit is also set to zero. An execution error is signaled by raising response bit 7.

Bitfeld Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0

Request - - - - - - Free Run Reset Bus

Response Error - - - - - Free Run Active Reset Done

Reset Bus:

with this bit, a reset of the K-Bus may be performed. This is necessary after the occurrence of an error (detected by examination of the "Processdata error"-byte in the GCB) e.g. after a terminal has been pulled out. After performing the K-Bus reset, the error code and error argument may be read from the locations "K-Bus error code" and "K-Bus error argument" in the CB K-Bus. If there is no error after reset, the K-Bus is ready for operation again.

30 Embedded PC

Product overview

Free Run:

not implemented. Reserved for future use..

K-Bus error code K-Bus error argument

If the K-Bus operation fails (bad terminal, missing end-terminal, severe EMC interference), an error flag is raised in the GCB and after a K-Bus reset, these two bytes contain the error code and error argument of the occurred fault - if it still persists.

K-Bus base ptr Inputs / K-Bus base ptr Outputs

These two byte values contain the starting offset for the K-Bus input and output process image area. In most cases the default offsets should be left unchanged. When changing one of these offsets, a "Remap" or "Reset node" in the GCB service is needed. Also care must be taken not to overlap with the IP-Link process image area, because in the CB IP-Link the offset pointers for these areas may also be changed. The Beckhoff automation software TwinCAT makes use of this base ptr feature and compacts the I/O images in the best way possible.

K-Bus cycle count

This two-byte counter is incremented with each I/O-cycle.

K-Bus cycle time

This is the time elapsed between the initiation and termination of an I/O process image update (K-Bus + IP-Link ). The time is recorded in units of microseconds and starts with writing a new cycle request to the field "PD cycle request" and it stops with the termination response in the field "PD cycle ready", in case of CX1100-0002. In case of CX1100-0003, this time reflects only the K-Bus portion of the total I/O time.

K-Bus bus status

This byte value can take only two states:

1. Byte = 0 → K-bus is ok

2. Byte ≠ 0 → K-bus fault

This information is also reflected in the "Processdata error" field (bit0) of the GCB.

Retry counter

This is a retry counter which is incremented each time the microcontroller needs to redo a cycle because of a communication error. This counter can be used for judgment of the K-Bus signal quality.

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Product overview

CX1100-0003

CX1100-0003 connections

This power supply unit permits not only the connection of the Beckhoff Bus Terminals, but also the serial connection of the Beckhoff fieldbus box modules of the type extension box IExxxx. The power is supplied via the upper spring-

loaded terminals labelled “24V” and “0V”. The supply voltage feeds the CX system and, over the K-Bus, the Bus Terminals. Since the K-Bus does no more than pass data on, a further power supply is necessary for the Bus Terminals. This is provided by means of the power contacts, which are not connected to the power supply.

Fieldbus connection:

Plug the IP link connector into the respective connections, i.e. one fibre-optic cable each into IN (x03) and OUT (x04). You then connect the other end with the corresponding IP link interface of the extension box. The connection must be made so that the output of the fieldbus connection is connected to the input of the extension box and vice versa.

LED:

With proper connection of the power supply unit and with power supply turned on, the power LED (PWR) lights up green. In the case of a short-circuit, it lights up red. The I/O LEDs display the operation status of the Bus Terminals. Error-free start-up of the configuration is signalled by the red "I/O ERR" LED being extinguished. If the ”I/O ERR" LED

blinks, an error in the area of the terminals is indicated. The error code can be determined from the frequency and number of blinks.

PE power contacts

The ”PE" power contact must not be used for other potentials.

32 Embedded PC

Technical data CX1100-0003

Product overview

Technical data CX1100-0003

Power supply 24 V DC (-15%/+20%)

Dielectric strength 500 V

Max. power consumption 4 W

Recommended fuse at 24 V 4 A

K-bus connection yes (adapter terminal)

E-bus connection -

IP-Link connection yes

K-bus power supply to 1.75 A

connection type Cage-Clamp (adapter terminal)

NOVRAM 8 kByte

Display FSTN display 2 lines x 16 characters of text, illuminated

I/O-DPRAM 4 kByte

Diagnose LED 1 x PWR, 1 x I/O Run, 1 x 1/O Err

Dimensions (W x H x D) 58 mm x 100 mm x 91 mm

weight app.350 g

operating/storage temperature 0° C ... +55° C / -25° C ... +85° C

Relative humidity 95% no condensation

Vibration/shock resistance conforms to EN 60068-2-6 / EN 60068-2-27/29

EMC resistance burst / ESD conforms to EN 61000-6-2 / EN 61000-6-4

protection class IP 20

(supply / internal electronics)

eff

Embedded PC 33

Product overview

Architecture of power supply CX1100-0003

This power supply features, except for power supply, the following functions:

1. Display 2 x 16 characters

2. 4+1 navigation switch

3. Non Volatile RAM

4. K-bus connections

5. IP-Link bus connection

These functions are managed by the control program via the PC104 bus. The structure of the CX1100-0003 is shown in the following figure:

This power supply unit features the basic functions. These functions are described in the architecture overview. Further the k-bus is supported. This interface is described in the architecture of the CX1100-0002 unit. This unit also features the access to the IP-Link bus. A fiber optics ring can be connected to the power supply The access is realized by a 4 KB dual-ported RAM. A microcontroller (80C165) manages the data transfer to the IP-Link-bus. The DPRAM is accessed by the CPU (via PC104 bus) and the microcontroller. The following figure shows the memory setup of the DPRAM:

34 Embedded PC

Product overview

The memory image of the IP-Link bus resides in the lower memory region (D400 to D0A00). This region separates in input and output region. Since firmware version ≥ B3 it is possible to shift the I/O regions. In this way the process

image can be adapted to the needed space. Each block jhas a size of 768 bytes. The following table shows the structure of the interface. The offset addresses are default values.

Embedded PC 35

Product overview

The IP-Link Control Block (CB IP-Link)

This section describes the layout of the control block for the IP-Link bus of CX1100-0003. This control block is located in the memory just below the I/O region of the K-bus interface.

CB IP-Link

Offset Default

0xFB0[2] IPL 2 byte plc interface to CX1100-0002/3

0xFB2[2] IPL 2 byte plc interface from CX1100-0002/3

0xFB4[2] IPL diagnosis to CX1100-0002/3

0xFB6[2] IPL diagnosis from CX1100-0002/3

0xFB8 IPL service request bitfield

0xFB9 IPL service response bitfield

0xFBA IPL error code

0xFBB IPL error argument

0xFBC[2] IPL base ptr Inputs 0x400

0xFBE[2] IPL base ptr Outputs 0x700

0xFC0-0xFC1 IPL cycle count

0xFC2-0xFC3 IPL cycle time [µs]

0xFC4 IPL bus status

0xFC5-0xFCE Reserved

0xFCF Retry counter

IP-Link 2 byte plc interface to CX1100-0003 / IP-Link 2 byte plc interface from

CX1100-0003

IP-Link diagnosis to CX1100-0003 / IP-Link diagnosis from CX1100-0003

IP-Link service request bitfield / IP-Link service response bitfield

Bitfeld Bit 7 Bit 6 Bit 5 Bit 4 Bit 3 Bit 2 Bit 1 Bit 0

Request - - - - - - Free Run Reset Bus

Response Error - - - - - Free Run Active Reset Done

Reset Bus:

36 Embedded PC

Product overview

the K-Bus reset, the error code and error argument may be read from the locations "K-Bus error code" and "K-Bus error argument" in the CB K-Bus. If there is no error after reset, the K-Bus is ready for operation again.

Free Run:

not implemented. Reserved for future use..

IP-Link error code K-Bus error argument

IP-Link base ptr Inputs / K-Bus base ptr Outputs

IP-Link cycle count

This two-byte counter is incremented with each I/O-cycle.

IP-Link cycle time

This is the time elapsed between the initiation and termination of an I/O process image update (K-Bus + IP-Link ). The time is recorded in units of microseconds and starts with writing a new cycle request to the field "PD cycle request" and it stops with the termination response in the field "PD cycle ready", in case of CX1100-0002. In case of CX1100-0003, this time reflects only the K-Bus portion of the total I/O time.

IP-Link bus status

This byte value can take only two states:

1. Byte = 0 → K-bus is ok

2. Byte ≠ 0 → K-bus fault

This information is also reflected in the "Processdata error" field (bit0) of the GCB.

Retry counter

This is a retry counter which is incremented each time the microcontroller needs to redo a cycle because of a communication error. This counter can be used for judgment of the K-Bus signal quality.

Embedded PC 37

Product overview

CX1100-0004

CX1100-0004 connections

The supply voltage feeds the CX system and supplies a voltage of 24 V DC (-15 %/+20%) to the Bus Terminals via the E-Bus. The dielectric strength of the power supply unit is 500 V

. Since the E-Bus does no more than pass data

rms

LED:

With proper connection of the power supply unit and with power supply turned on, the power LED (PWR) lights up green. In the case of a short-circuit, it lights up red.

PE power contacts

The ”PE" power contact must not be used for other potentials.

Note

This power supply is designed for use with CX1020 systems only. Operation with CX1000 systems is not possible because the EtherCAT protocol is not implemented / designed in the hardware of the CX1000 systems.

Note

The power supply CX1100-0004 can only be used instead and not simultaneously with system interface CX1020-N060

Warning

It is important to keep attention to the hardware revision of the power supply. Power supplies with a hardware revision > 2.0 only work with CX1020 systems with a hardware revision > 2.1 !

38 Embedded PC

Technical data CX1100-0004

Product overview

With the CX1100-0004 power supply EtherCAT Terminals can be connected to the CX1020-System. With CX11000004 the I/O data are stored directly in the main memory of the CPU; a DPRAM is no longer required. The CX11000004 power supply unit for EtherCAT Terminals can only be connected in conjunction with the basic CX1020 CPU module.

Technical data CX1100-0004

Power supply 24 V DC (-15%/+20%)

Dielectric strength 500 V

Max. power consumption 3.5 W

Recommended fuse at 24 V 4 A

K-bus connection -

E-bus connection yes (adapter terminal)

IP-Link connection -

E-bus power supply to 2 A

connection type Cage-Clamp (adapter terminal)

NOVRAM 8 kByte

Display FSTN display 2 lines x 16 characters of text, illuminated

I/O-DPRAM -

Diagnose LED 1 x PWR, 1 x L/A Run, 1 x RUN

Dimensions (W x H x D) 40 mm x 100 mm x 91 mm

weight app.250 g

operating/storage temperature 0° C ... +55° C / -25° C ... +85° C

Relative humidity 95% no condensation

Vibration/shock resistance conforms to EN 60068-2-6 / EN 60068-2-27/29

EMC resistance burst / ESD conforms to EN 61000-6-2 / EN 61000-6-4

protection class IP 20

(supply / internal electronics)

eff

Embedded PC 39

Product overview

Architecture of power supply CX1100-0004

This power supply features, except for power supply, the following functions:

1. Display 2 x 16 characters

2. 4+1 navigation switch

3. Non Volatile RAM

4. E-bus connection

These functions are managed by the control program via the PC104 bus. The structure of the CX1100-0004 is shown in the following figure:

This power supply unit features the basic functions. These functions are described in the architecture overview. Further the E-bus is supported. The access to the bus is transparent for the user. The unit transfers the signals from EtherCAT-bus to E-bus. The control is managed by the CPU. The E-bus terminals are accessed by TwinCAT similar to the K-bus terminals.

40 Embedded PC

Transport

3. Transport

Unpacking, installation and transport

The specified storage conditions must be adhered to (see "Technical data").

Dimensions and weight of the individual modules:

Module CX1100-0001 CX1100-0002 CX1100-0003 CX1100-0004

Dimensions (W x H x D)

Weight app. 180 g app. 250 g app. 350 g app. 250 g

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.

45 mm x 100 mm x 91 mm

40 mm x 100 mm x 91 mm

58 mm x 100 mm x 91 mm

40 mm x 100 mm x 91 mm

Warning

Danger of damage to the unit!

During transport in cold conditions, or if the unit is subjected to extreme temperature swings, condensation on and inside the unit must be avoided. 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.

Installation

The devices are designed for installation in control cabinets. You will find installation instructions in the chapter mechanical mounting.

Shipping and relocation

Despite the robust design of the unit, the components are sensitive to strong vibrations and impacts. During transport, your computer should therefore be protected from excessive mechanical stress. Therefore, please use the original packaging.

Embedded PC 41

Fitting and wiring

4. Fitting and wiring

Mechanical assembly

Dimensions

The CX1000 product range is characterized by small overall installed size and high modularity. For project planning purposes, a CPU module, a power supply unit and the associated system interfaces and fieldbus interfaces have to be provided. The overall width of the application is made up of the individual modules. With a height of 100 mm, the module dimensions exactly match those of the Beckhoff Bus Terminals. Together with the lowered connector surfaces, this means that it can be used in a standard terminal box with a height of 120 mm.

CX1100-0001:

CX1100-0002:

42 Embedded PC

CX1100-0003:

Fitting and wiring

CX1100-0004:

Embedded PC 43

Fitting and wiring

Mechanical assembly of the basic module

Assembly of the CPU and the power supply unit

The individual modules are simply plugged together. The PC104 connector plugs should be handled carefully in order to avoid damage. When correctly assembled, no significant gap can be seen between the attached housings.

Engaging on the DIN rail

On the bottom of the modules, there is a white tension strap, which is connected with a latching mechanism. These tension straps must be pulled down before attaching to the DIN rail. This can be done using an ordinary screwdriver and a slight turn.

Then fix the CX1020 block on the DIN rail using the latching straps. You should hear a soft click.

44 Embedded PC

Fitting and wiring

Do not force the module or apply

excessive pressure!

Only apply pressure at insensitive points of the housing (edges). Never apply pressure on the display, the buttons or movable parts of the CX10x0 system. After successful latching on the DIN rail the straps should be pushed back to their original position.

At least the power connections must be installed. The upper connections "24v" and "0V" must be connected to power supply. If the power supply CX1100-0001 is used the power supply is connected via the 5-pin open style connector. (see connections / wiring)

Embedded PC 45

Fitting and wiring

Commissioning

The power connections for the power supplies slightly differs. All units are powers by 24 V DC. A tolerance of -15% u to +20 % is possible. The PE connection must be installed either. The following figures show the different connection variations.

CX1100-0001 connections

This power supply unit has no I/O interface, though it is connected via a 5-pin "Open Pluggable Connector". In older versions of the unit the lower inputs are labeled with UPS+/-. These inputs are not in use and must not be connected.

CX1100-0002 connections

This power supply unit has a k-bus interface. The k-bus will be connected separately to the power supply. It is possible to disable control and bus electronic separately.

46 Embedded PC

Fitting and wiring

CX1100-0003 connections

This power supply unit has also a k-bus interface. Additional it has an IP-Link interface. The power supply is equal to CX1100-0002.

CX1100-0004 connections

This power supply unit was especially designed to connect E-bus terminal to the CX1020-system. The upper connections supply the CX-System and the E-bus. The lower power connections can be connected to +24V.

Embedded PC 47

Error handling and diagnostics

5. Error handling and diagnostics

Terminal Bus Analysis in PLC-Program

To analyze the terminal bus (K-Bus and IP-Link) the programmer can access the registers described in the architecture. The access to the PLC-program is realzed via TwinCAT. To have the access to the necessary registers the extended DPRAM model has to be activated (only in Firmware > B3). The registers are described in the architecture of the terminal bus connectors.

Though the handling is identical for both sub busses the explaination is done generally. For analysis four signals / variables are used:

 BusState (describes the state of the bus: 0 -> no error, 1 -> bus error)  ErrorCode (same error code as the LED blink code)  ErrorArg (same argument code LED blink code)  Request[0] (output to request error codes / reset bus)

In the PLC program some external variables must be defined:

VAR

k_bus_request AT %QX0.0 : BOOL;

k_bus_err_code AT %IB0 : USINT;

k_bus_err_arg AT %IB1 : USINT;

k_bus_state AT %IB2 : USINT;

ip_bus_request AT %QX0.1 : BOOL;

ip_bus_err_code AT %IB3 : USINT;

ip_bus_err_arg AT %IB4 : USINT;

ip_bus_state AT %IB5 : USINT;

END_VAR

In the PLC program the analysis can be done as follows: (this is only pseudo code)

48 Embedded PC

Error handling and diagnostics

....

IF k_bus_state = 1 THEN (* an error occured on K-Bus*)

k_bus_request := TRUE; (* request vaules for ErrCode and ErrArg *)

CASE k_bus_err_code OF

0 : return; (* should not happen, though an error occured *)

1 : CASE k_bus_arg OF

0 : report error; (* EEPROM checksum error *)

1 : report error; (* overflow in code buffer *)

2 : report error; (* unknown datatype *)

END_CASE;

2 : CASE k_bus_arg OF

0 : report error; (* programmed configuration, wrong table entry *)

ELSE report error; (* wrong table entry *)

END_CASE;

3 : report error (* K-Bus command error *)

4 : CASE k_bus_arg OF

0 : report error; (* break after power supply *)

ELSE report error; (* break after terminal 'k_bus_arg' *)

END_CASE;

5 : report error (* K-Bus-error during register-communication with

terminal 'k_bus_arg' *)

9 : CASE k_bus_arg OF

0 : report error; (* checksum error in program flash *)

ELSE report error; (* terminal 'k_bus_arg' does not exist in boot

configuration *)

END_CASE;

14 : report error (* 'k_bus_arg'-th terminal has wrong format *)

15 : report error (* wrong number of bus terminals *)

16 : report error (* length of K-Bus data is invalid *)

END_CASE

k_bus_request := TRUE; (* reset bus, if reason for error is removed, bus

starts again *)

....

To make the control work, the register and the program must be linked in System Manager. If the PLC program is attached in System Manager the following signals are available:

Embedded PC 49

Error handling and diagnostics

Analog the registers of the terminal bus are shown in System Manager:

Link signals and variables :

k_bus_err_code with ErrorCode k_bus_err_arg with ErrorArg k_bus_state with BusState

and

k_bus_request with Request[0]

The same handling for IP-Link signals:

50 Embedded PC

ip_bus_err_code with ErrorCode

ip_bus_err_arg with ErrorArg

Error handling and diagnostics

ip_bus_state with BusState

ip_bus_request with Request[0]

If all signals are linked the programmer can load configuration and PLC program onto the system.

Firmware > B7

With a new firmware release B7 it is easier to access the diagnosis values. The solution described above clears the error code if the reason for the error is no longer present. With the firmware > B7 its possible to get the error codes directly in the case of the error. To access the error codes the Bit 4 in GCB must be set to 1. So for diagnosis its a good idea to set the bit in the initialization of error routine or PLC program. The bit must be linked to the bit 4 in GCB:

Embedded PC 51

Error handling and diagnostics

CX1100-0001 power supply LEDs

Anzeige LED Meaning

Power The LED lights up green when the power supply is correct, but red if there is a short

circuit.

52 Embedded PC

Error handling and diagnostics

CX1100-0002 power supply LEDs

After switching on, the power supply immediately checks the connected Bus Terminal configuration. Error-free start-

up is signalled by the red "I/O ERR” LED being extinguished. If the ”I/O ERR" LED blinks, an error in the area of the terminals is indicated. The error code can be determined from the frequency and number of blinks. This permits rapid rectification of the error.

Display LED Meaning

Power Power supply

The LED lights up green when the power supply is correct, but red if there is a short circuit.

I/O Run

I/O Error

The I/O error LED blink code

Fast blinking Start of the error code

First slow sequence Error code

Second slow sequence Error code argument

K-Bus diagnostics The green LED lights up in order to indicate fault-free operation. "Fault-free" means that the communication with the fieldbus system is also running.

K-Bus diagnostics The red LED flashes to indicate an error. The red LED blinks with two different frequencies.

LEDs for K-Bus diagnosis

Error code

Persistent, continuous blinking

1 pulse

2 pulses

3 pulses 0 K-Bus command error - No Bus Terminal inserted

4 pulses

5 pulses n K-Bus error in register

9 pulses 0 Checksum error in Flash

argument

0 EEPROM checksum error Revert to the manufacturer’s setting

1 Code buffer overflow Insert fewer Bus Terminals. The programmed

2 Unknown data type Software update required for the power supply

0 Programmed configuration

n (n > 0) Table comparison (Bus

0 K-Bus data error, break

n Break behind Bus Terminal nCheck whether the Bus End Terminal 9010 is

Description Remedy

EMC problems - Check power supply for overvoltage or

undervoltage peaks

- Implement EMC measures

- If a K-Bus error is present, it can be localised by a restart of the power supply (by switching it off and then on again)

configuration has too many entries in the table

Check programmed configuration for

has an incorrect table entry

Terminal n)

behind the power supply

communication with Bus Terminal n

program

correctness

Incorrect table entry

- One of the Bus Terminals is defective; halve the number of Bus Terminals attached and check whether the error is still present with the remaining Bus Terminals. Repeat until the defective Bus Terminal is located.

Check whether the n+1 Bus Terminal is correctly connected; replace if necessary.

connected.

Exchange the nth bus terminal

Revert to the manufacturer’s setting

Embedded PC 53

Error handling and diagnostics

n (n>0) Bus Terminal n is not

consistent with the configuration that existed when the boot project was created

14 pulses n nth Bus Terminal has the

wrong format

15 pulses n Number of Bus Terminals is

no longer correct

16 pulses n Length of the K-Bus data is

no longer correct

Error code argument

The number of pulses indicates the position of the last Bus Terminal before the fault. Passive Bus Terminals, such as a power feed terminal, are not included in the count.

In the case of some errors, rectification does not cause the power supply to leave the blink sequence. The power supply can only be restarted by switching its supply voltage off and on again.

Note:

The supply voltage of the power supply unit, which is necessary to supply power to the CX1000 system, must not be interrupted in the middle of operation. Switching off the supply voltage to the power supply unit refers here to the power supply on the power contacts.

Revert to the manufacturer's setting which will clear the boot project.

Start the power supply again, and if the error occurs again then exchange the Bus Terminal.

Start the power supply up again.

54 Embedded PC

Error handling and diagnostics

CX1100-0003 power supply LEDs

After switching on, the power supply immediately checks the connected Bus Terminal configuration. Error-free startup is signalled by the red "I/O ERR” LED being extinguished. If the ”I/O ERR" LED blinks, an error in the area of the

terminals is indicated. The error code can be determined from the frequency and number of blinks. This permits rapid rectification of the error. Though the power supply supports two bus systems both bus errors are reported by the "I/OErr" LED. An error ob K-Bus is reported by rapid blinking. One long flash (app. 2 sec.) reports errors on IP-Link-bus.

Display LED Meaning

Power Power supply

The LED lights up green when the power supply is correct, but red if there is a short circuit.

I/O Run

I/O Error

K-Bus diagnostics The green LED lights up in order to indicate fault-free operation. "Fault-free" means that the communication with the fieldbus system is also running.

K-Bus diagnostics The red LED flashes to indicate an error. The red LED blinks with two different frequencies.

LEDs for K-Bus diagnosis

The I/O error LED blink code

Fast blinking Start of the error code

First slow sequence Error code

Second slow sequence Error code argument

LEDs for K-Bus diagnosis

Error code

Persistent, continuous blinking

1 pulse

2 pulses

3 pulses 0 K-Bus command error - No Bus Terminal inserted

4 pulses

5 pulses n K-Bus error in register

argument Description Remedy

EMC problems - Check power supply for overvoltage or

undervoltage peaks

- Implement EMC measures

- If a K-Bus error is present, it can be localised by a restart of the power supply (by switching it off and then on again)

0 EEPROM checksum error Revert to the manufacturer’s setting

1 Code buffer overflow Insert fewer Bus Terminals. The programmed

configuration has too many entries in the table

2 Unknown data type Software update required for the power supply

0 Programmed configuration

has an incorrect table entry

n (n > 0) Table comparison (Bus

Terminal n)

0 K-Bus data error, break

behind the power supply

n Break behind Bus Terminal nCheck whether the Bus End Terminal 9010 is

communication with Bus Terminal n

Check programmed configuration for correctness

Incorrect table entry

Check whether the n+1 Bus Terminal is correctly connected; replace if necessary.

connected.

Exchange the nth bus terminal

Embedded PC 55

Error handling and diagnostics

9 pulses

14 pulses n nth Bus Terminal has the

15 pulses n Number of Bus Terminals is

16 pulses n Length of the K-Bus data is

Error code argument

The number of pulses indicates the position of the last Bus Terminal before the fault. Passive Bus Terminals, such as a power feed terminal, are not included in the count.

In the case of some errors, rectification does not cause the power supply to leave the blink sequence. The power supply can only be restarted by switching its supply voltage off and on again.

Note:

The power source to the power supply unit which is necessary to supply power to the CX-system, must not be interrupted during operation. Switching off the supply voltage to the power supply unit refers here to the power supply on the power contacts.

0 Checksum error in Flash

program

n (n>0) Bus Terminal n is not

consistent with the configuration that existed when the boot project was created

wrong format

no longer correct

Revert to the manufacturer’s setting

Revert to the manufacturer's setting which will clear the boot project.

Start the power supply again, and if the error occurs again then exchange the Bus Terminal.

Start the power supply up again.

LEDs for IP-Link-diagnosis

LEDs for IP-Link-Bus-Diagnosis

After a long flash (app.. 2 sec.) an IP-Link-Bus error has occurred. The following tables describe the error codes and help to find the reason for the error. IP-Link errors most often turn out to be a result of inappropriate use of the optical fiber.

I/O Err Description Remedy

off No data exchange Module in synchronous mode or - activate

Profibus cyclic data

1 0 EEPROM checksum error Set manufacturer’s setting with the KS2000

software

2 Reserved -

3 Break location has been recognized Interruption before the master's receiver

3 n Break location has been recognized n-th module before the master's receiver

3 n m Break location has been recognized (n*10)+m-th module before the master's

receiver

4 n Too many faulty telegrams have

been detected (more than 25%)

The optical fiber wiring in front of the nth extension module should be checked

56 Embedded PC

Error handling and diagnostics

5 n Register access to complex

modules has failed

11 n Complex module working incorrectly Exchange the nth module

12 n More than 120 modules in the ring Connect fewer modules

13 n nth module unknown Firmware update required

off Module is exchanging data no error

Note

If an error occurs on both terminal busses (K-Bus and IP-Link-Bus) the error on K-Bus is reported at first. The IP-Link-Bus error is reported as second. Both error codes are introduced by their typical blink signal.

Check the nth module

Embedded PC 57

Error handling and diagnostics

CX1100-0004 power supply LEDs

Display LED Meaning

power supply

PWR

The LED lights up green when the power supply is correct, but red if there is a short circuit.

L / A

RUN

The functions for L/A and RUN LED are available in hardware revision > 2.0. The LEDs have on function in older revisions.

off E-Bus is not connected on E-Bus is connected / no data traffic on E-bus blink E-Bus is connected / data traffic on E-bus

Indicates the state of the EtherCAT bus:

off INIT

blink

single flash

on OPERATIONAL

flickering

double flash

triple flash

quadruple flash

PRE-OPERATIONAL (frequency: 200 ms on / 200 ms off)

SAVE-OPERATIONAL (frequency: 200 ms on / 1000ms off)

BOOTSTRAP (frequency: 50 ms on / 50 ms off)

reserved for future use (frequency: 200 ms on / 200 ms off / 200 ms an / 1000 ms off)

reserved for future use (frequency: 200 ms on / 200 ms off / 200 ms an / 200 ms off / 200 ms an / 1000 ms off)

reserved for future use (frequency: 200 ms on / 200 ms off / 200 ms on / 200 ms off / 200 ms on / 200 ms off / 200 ms on / 1000 ms off)

58 Embedded PC

Decommissioning

6. Decommissioning

Removal and disposal

A CX10x0 hardware configuration is dismantled in 2 stages:

0. Switching off and disconnecting the power supply

Before a CX10x0 system can be dismantled, the system should be switched off, and the power supply should be disconnected.

1. Removing from the DIN rail:

Before the individual CX10x0 modules are disconnected, the whole CX1020 hardware block should be removed from the DIN rail. Proceed as follows:

1.1. Release and remove the first Terminal next to the power supply unit on the DIN rail.

First remove any wiring from power supply unit and then from the first terminal on the DIN rail next to the power supply unit. If the wiring is to be reused for another system, it is advisable to make a note of the connections. Then pull the orange terminal release (see arrow) to release the terminal and pull it out.

1.2. Releasing the CX10x0 system

In order to release the CX10x0 block, pull the white straps at the bottom of the module in the direction of the arrows. They will lock in the extended position. After pulling the terminal release of the power supply unit, the block can be removed carefully from the DIN rail.

2. Separating the individual modules

2.1. Separating the power supply unit, the CX10x0 CPU and other components

Place the CX10x0 block onto a suitable support with the front facing down. Then insert a flat screwdriver with

Embedded PC 59

Decommissioning

dimensions 1.0 x 5.5 x 150 mm into the locking mechanism, and then operating the slider by turning it about 90 degrees. The locking mechanism on the rear affects an approx. 2-3 mm wide clearance of the module latching mechanism, pushing them apart. The plug connectors of the PC 104 interface can then be pulled apart carefully.

Only modules (CPU, fieldbus connections and UPS modules) that can be separated non-destructively feature a release device. Modules that cannot be separated only feature a marking point (with or without red paint seal). Applying force to these elements will destroy them.

Warning

Forcibly opening the module housing (e.g. removing the cover) will destroy the housing.

Disposal

The device must be fully dismantled in order to dispose of it.

Electronic parts must be disposed of in accordance with national electronics scrap regulations.

60 Embedded PC

Appendix

ADS Return-Codes

Hex Dec Description

0x000 0 no error

0x001 1 Internal error

0x002 2 No Rtime

0x003 3 Allocation locked memory error

0x004 4 Insert mailbox error

0x005 5 Wrong receive HMSG

0x006 6 target port not found

0x007 7 target machine not found

0x008 8 Unknown command ID

0x009 9 Bad task ID

0x00A 10 No IO

0x00B 11 Unknown AMS command

0x00C 12 Win 32 error

0x00D 13 Port not connected

0x00E 14 Invalid AMS length

0x00F 15 Invalid AMS Net ID

0x010 16 Low Installation level

0x011 17 No debug available

0x012 18 Port disabled

0x013 19 Port already connected

0x014 20 AMS Sync Win32 error

0x015 21 AMS Sync Timeout

0x016 22 AMS Sync AMS error

0x017 23 AMS Sync no index map

0x018 24 Invalid AMS port

0x019 25 No memory

0x01A 26 TCP send error

0x01B 27 Host unreachable

0x500 1280 Router: no locked memory

0x502 1282 Router: mailbox full

0x700 1792 error class <device error>

0x701 1793 Service is not supported by server

0x702 1794 invalid index group

0x703 1795 invalid index offset

0x704 1796 reading/writing not permitted

0x705 1797 parameter size not correct

0x706 1798 invalid parameter value(s)

0x707 1799 device is not in a ready state

0x708 1800 device is busy

0x709 1801 invalid context (must be in Windows)

0x70A 1802 out of memory

Appendix

Embedded PC 61

Appendix

Hex Dec Description

0x70C 1804 not found (files, ...)

0x70D 1805 syntax error in command or file

0x70E 1806 objects do not match

0x70F 1807 object already exists

0x710 1808 symbol not found

0x711 1809 symbol version invalid

0x712 1810 server is in invalid state

0x713 1811 AdsTransMode not supported

0x714 1812 Notification handle is invalid

0x715 1813 Notification client not registered

0x716 1814 no more notification handles

0x717 1815 size for watch too big

0x718 1816 device not initialized

0x719 1817 device has a timeout

0x71A 1818 query interface failed

0x71B 1819 wrong interface required

0x71C 1820 class ID is invalid

0x71D 1821 object ID is invalid

0x71E 1822 request is pending

0x71F 1823 request is aborted

0x720 1824 signal warning

0x721 1825 invalid array index

0x740 1856 Error class <client error>

0x741 1857 invalid parameter at service

0x742 1858 polling list is empty

0x743 1859 var connection already in use

0x744 1860 invoke ID in use

0x745 1861 timeout elapsed

0x746 1862 error in win32 subsystem

0x748 1864 ads-port not opened

0x750 1872 internal error in ads sync

0x751 1873 hash table overflow

0x752 1874 key not found in hash

0x753 1875 no more symbols in cache

62 Embedded PC

Appendix

Certifications

All products of the Embedded PC family are CE, UL and GOST-R certified. Since the product family is continuously developed further, we are unable to provide a full listing here. The current list of certified products can be found on the Embedded PC certificates web page or at www.beckhoff.de under Embedded PC.

Embedded PC 63

Appendix

Support and Service

Beckhoff and their partners around the world offer comprehensive support and service, making available fast and competent assistance with all questions related to Beckhoff products and system solutions.

Beckhoff Support

Support offers you comprehensive technical assistance, helping you no only with the application of individual Beckhoff products, but also with other, wide-ranging services:

 world-wide support

 design, programming and commissioning of complex automation systems

 and extensive training program for Beckhoff system components

Hotline: +49(0)5246/963-157

Fax: +49(0)5246/963-9157

e-mail: support@beckhoff.com

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: +49(0)5246/963-460

Fax: +49(0)5246/963-479

e-mail: service@beckhoff.com

You will find further support and service addresses on our Internet pages under http://www.beckhoff.com.

Beckhoff Headquarters

Beckhoff Automation GmbH

Eiserstr. 5

33415 Verl

Germany

Phone: +49(0)5246/963-0

Fax: +49(0)5246/963-198

e-mail: info@beckhoff.com

The addresses of Beckhoff's branch offices and representatives round the world can be found on her internet pages: http://www.beckhoff.com You will also find further documentation for Beckhoff components there.

64 Embedded PC

BECKHOFF CX1100-000x User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual