Beckhoff CX1100-0910, CX1100-0900, CX1100-0930, CX1100-0920 Hardware Documentation

Hardware Documentation

CX1100-09xx

UPS for Embedded PCs CX10x0

Version:
Date:

1.4
2015-07-02

Table of contents

Table of contents

1 Foreword ....................................................................................................................................................4

1.1 Notes on the documentation............................................................................................................. 4

1.2 Safety instructions ............................................................................................................................ 5

1.3 Documentation Issue Status............................................................................................................. 5

2 Product overview.......................................................................................................................................7

2.1 Appropriate Use................................................................................................................................ 7

2.2 System overview............................................................................................................................... 7

2.3 Technical Data CX1100-0900, CX1100-0910, CX1100-0920, CX1100-0930 .................................. 9

2.4 CX1100-09xx Connections ............................................................................................................. 10

2.5 Technical data CX1100-0900, CX1100-0910, CX1000-0920, CX1100-0930................................. 12

3 Transport..................................................................................................................................................13

3.1 Unpacking, installation and transport.............................................................................................. 13

4 Fitting and wiring.....................................................................................................................................14

4.1 Mechanical assembly ..................................................................................................................... 14

4.1.1 Dimensions .........................................................................................................................14

4.1.2 Mechanical installation of the UPS Module......................................................................... 16

5 Commissioning........................................................................................................................................19

5.1 Charging time ................................................................................................................................. 19

5.2 Discharging time ............................................................................................................................. 20

5.3 Setting retention time...................................................................................................................... 25

5.4 Register settings CX1100-09xx ...................................................................................................... 26

5.5 Settings in the System Manager..................................................................................................... 27

5.6 Controlling theUPS from the PLC ................................................................................................... 31

6 Error handling and diagnostics .............................................................................................................36

6.1 LEDs CX1100-09xx ........................................................................................................................ 36

7 Decomissioning.......................................................................................................................................37

7.1 Removal and disposal .................................................................................................................... 37

8 Appendix ..................................................................................................................................................39

8.1 Certifications ................................................................................................................................... 39

8.2 Support and Service ....................................................................................................................... 40

CX1100-09xx 3

Version: 1.4

Foreword

1 Foreword

1.1 Notes on the documentation

This description is only intended for the use of trained specialists in control and automation engineering who
are familiar with the applicable national standards.
It is essential that the following notes and explanations are followed when installing and commissioning
these components.

The responsible staff must ensure that the application or use of the products described satisfy all the
requirements for safety, including all the relevant laws, regulations, guidelines and standards.

Disclaimer

The documentation has been prepared with care. The products described are, however, constantly under
development.
For that reason the documentation is not in every case checked for consistency with performance data,
standards or other characteristics.
In the event that it contains technical or editorial errors, we retain the right to make alterations at any time
and without warning.
No claims for the modification of products that have already been supplied may be made on the basis of the
data, diagrams and descriptions in this documentation.

Trademarks

Beckhoff®, TwinCAT®, EtherCAT®, Safety over EtherCAT®, TwinSAFE®, XFC®and XTS® are registered
trademarks of and licensed by Beckhoff Automation GmbH.
Other designations used in this publication may be trademarks whose use by third parties for their own
purposes could violate the rights of the owners.

Patent Pending

The EtherCAT Technology is covered, including but not limited to the following patent applications and
patents:
EP1590927, EP1789857, DE102004044764, DE102007017835
with corresponding applications or registrations in various other countries.

The TwinCAT Technology is covered, including but not limited to the following patent applications and
patents:
EP0851348, US6167425 with corresponding applications or registrations in various other countries.

EtherCAT® is registered trademark and patented technology, licensed by Beckhoff Automation GmbH,
Germany

Copyright

© Beckhoff Automation GmbH & Co. KG, Germany.
The reproduction, distribution and utilization of this document as well as the communication of its contents to
others without express authorization are prohibited.
Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a
patent, utility model or design.

Version: 1.4

CX1100-09xx4

Foreword

1.2 Safety instructions

Safety regulations

Please note the following safety instructions and explanations!
Product-specific safety instructions can be found on following pages or in the areas mounting, wiring,
commissioning etc.

Exclusion of liability

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 & Co. KG.

Personnel qualification

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

Description of symbols

In this documentation the following symbols are used with an accompanying safety instruction or note. The
safety instructions must be read carefully and followed without fail!

Serious risk of injury!

Failure to follow the safety instructions associated with this symbol directly endangers the

DANGER

life and health of persons.

Risk of injury!

Failure to follow the safety instructions associated with this symbol endangers the life and

WARNING

health of persons.

Personal injuries!

Failure to follow the safety instructions associated with this symbol can lead to injuries to

CAUTION

persons.

Damage to the environment or devices

Failure to follow the instructions associated with this symbol can lead to damage to the en-

Attention

vironment or equipment.

Tip or pointer

This symbol indicates information that contributes to better understanding.

Note

1.3 Documentation Issue Status

Version Changes

1.4 new UPS CX1100-0930 added

1.3 usage with CX systems added

CX1100-09xx 5

Version: 1.4

Foreword

Version Changes

1.2 technical data for charge corrected

1.1 annotations to usage of CX1100-0900 and CX1020

1.0 released version

0.4 revision of discharge graphs, licenses added

0.3 resorting / small corrections

0.2 revised version

0.1 preliminarily version

Version: 1.4

CX1100-09xx6

Product overview

2 Product overview

2.1 Appropriate Use

The CX10x0 device series is a modular control system designed for top-hat 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.

The UPS Modules are designed to supply CX10x0 Embedded PCs and their bus terminals.

2.2 System overview

UPS module is available in four variations:

• CX1100-0900

• CX1100-0910

• CX1100-0920

• CX1100-0930

The UPS module is used for the uninterruptible power supply of CX CPUs and any connected CX
components. In the event of a failure of the external supply, the module ensures that the application software
can save important data, e. g. on a Compact Flash card, NOVRAM or in a database via the network. During
the UPS retention time, the machine or process can be transferred into a defined state, and the operating
system can be shut down. The retention time can be set via a rotary switch or via software.

The use of state of the art capacitors makes this UPS module – unlike other battery powered techniques –
absolutely maintenance-free and offers rapid charging. The module can simply added to a CX system. Only
a 24 V DC supply cable is needed. The 24 V DC output voltage of the UPS is protected against short circuit
and overload. The CX1100-09xx may be retrofitted on site. A DPRAM user interface provides options for
settings and UPS status messages.

The functionality of the UPS is therefore independent of the operating system to be used. No driver software
is required. The TwinCAT System Manager recognizes the UPS module automatically, and the UPS signals
are available to the PLC programmer. A controlled 24 V DC power supply unit with a minimum output current
of 4 A is required.

CX1100-09xx 7

Version: 1.4

Product overview

Setup of UPS module:

sample configuration1:

sample configuration 2:

Also see about this

2 CX1100-09xx Connections [}10]

Version: 1.4

CX1100-09xx8

Product overview

2.3 Technical Data CX1100-0900, CX1100-0910, CX1100-0920, CX1100-0930

The UPS-Modules are available in four versions. The user can choose the fitting version for his purpose. The
table shows differences and common properties:

Technical data CX1100-0900 CX1100-0910 CX1100-0920 CX1100-0930

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

Storage technology capacitive

Charge 20 As 20 As 40 As 40 As

Retention time adjustable, load-dependent

Output current
max.

Charging current max. 4 A

Diagnostics LED 24 V DC-Input, 24 V DC-Output, CHARGE

System bus 16 Bit ISA (PC104 standard)

Max. power
consumption

Dimensions (W x H
x D)

weight app. 345 g app. 465 g app. 617 g app. 650 g

Operating
temperature

Storage
temperature

Relative humidity 95% no condensation

Vibration/Shock
resistance

EMC resistance
burst / ESD

protection class IP 20

550 mA (24 V DC) 1.1 A (24 V DC) 1.1 A (24 V DC) 2.0 A (24 V DC)

2 W

57 mm x 100 mm x
91 mm

0 °C ... +55 °C

-25 °C ... +85 °C

conforms to EN 60068-2-6 / EN 60068-2-27/29

conforms to EN 61000-6-2 / EN 61000-6-4

76 mm x 100 mm x
91 mm

95 mm x 100mm x
91 mm

95 mm x 100mm x
91 mm

The maximal output current for UPS module CX1100-0900 is 550 mA! For higher output
current make use of the UPS modules (CX1100-0910 / CX1100-0920), with bigger output
current.

Note

CX1100-09xx 9

The maximal output current is not suitable for the CX1020 Embedded PCs. So it is strongly
recommended to make use of the UPS modules (CX1100-0910 / CX1100-0920), with big­ger output current.

Version: 1.4

Product overview

2.4 CX1100-09xx Connections

The UPS-Modules are supplied with power by 5-pin "Open Pluggable Connector". The other components of
the embedded system are supplied via the PC 104 bus with 24V DC. (-15 % to +20 % tolerance)

Table1: Pin assignment "Open Pluggable Connector":

Pin Assignment

5 0 V DC OUT ( UPS output current)

4 24 V DC OUT ( UPS output current)

3 PWR FAIL (digital output)

2 0 V DC IN (UPS incoming power supply)

1 24 V DC IN (UPS incoming power supply)

Connection to power supply

For power supply units with K-bus / E-bus connection (CX1100-0002, CX1100-0003 und CX1100-004) the
supply is realized as follows:

Though the power supply CX1100-0001 has no terminal bus interface the module is connected to the upper
input connectors (24V). Older versions of the power supply are labeled with UPS -/+. These input are not
used and more and must not be connected. The figure shows the correct connection.

Version: 1.4

CX1100-09xx10

Product overview

Power-Fail-Signal Connection

The UPS modules can also be used to supply other bus couplers. To use the UPS module with the bus
coupler the power supply has to be connected with the UPS. The power supply for the bus terminals has to
be connected seperaty. This depends on the terminal bus load. The Power-Fail connection should be
connected to a digital input terminal. (see picture below)

In case of power failure the UPS module rises the POWER-FAIL signal. The PLC program reads the input
via the terminal bus and can shutdown the application. In this mode the control of the UPS module is
controlled by the torque switch at the front side of the module.

CX1100-09xx 11

Version: 1.4

Product overview

2.5 Technical data CX1100-0900, CX1100-0910, CX1000-0920, CX1100-0930

Depending on the performance and the operating system the different CPU-Modules of the CX systems
need different UPS modules. The following table show the recommended combinations of CPU and UPS
modules. The view is kept in the CPU module and the system interfaces only. Terminals are not part on the
scope.

CX System CX1100-0900 CX1100-0910 CX1100-0920 CX1100-0930

CX9000 (with
WINDOWS CE)

CX9010 (with
WINDOWS CE)

CX1000 (with
WINDOWS CE)

CX1000 (with
WINDOWS XP)

CX1010 (with
WINDOWS CE)

CX1010 (with
WINDOWS XP)

CX1020 (with
WINDOWS CE)

CX1020 (with
WINDOWS XE)

CX1030 (with
WINDOWS CE)

CX1030 (with
WINDOWS XE)

yes* yes* yes* yes*

yes* yes* yes* yes*

yes yes yes yes

yes yes yes yes

yes yes yes yes

yes yes yes yes

no no yes yes

no no yes yes

no no no yes

no no no yes

* at the moment only the FAIL-Signal control is supported (see chapter connections [

Version: 1.4

}10])

CX1100-09xx12

Transport

3 Transport

3.1 Unpacking, installation and transport

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

Dimensions and weight of the individual modules:

Module CX1100-0900 CX1100-0910 CX1100-0920 CX1100-0930

Dimensions (W x H
x D)

Weight 345 g 465 g 617 g 650 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.

57 mm x 100 mm x
91 mm

76 mm x 100 mm x
91 mm

95 mm x 100 mm x
91 mm

95 mm x 100 mm x
91 mm

Danger of damage to the unit!

Attention

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.

CX1100-09xx 13

Version: 1.4

Fitting and wiring

4 Fitting and wiring

4.1 Mechanical assembly

4.1.1 Dimensions

The CX10x0 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.

the three available UPS-Modules for the CX10x0-family have different dimensions:

CX1100-0900 UPS Module:

CX1100-09xx14 Version: 1.4

CX1100-0910 UPS Module:

Fitting and wiring

CX1100-0920 UPS Module:

CX1100-09xx 15Version: 1.4

Fitting and wiring

CX1100-0930 UPS Module:

4.1.2 Mechanical installation of the UPS Module

The UPS module can be connected to the Embedded PC System at any positions. It is recommended to
place it between CPU basic module and power supply unit. (see picture in system overview)

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 top-hat rail:

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

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

First remove any wiring from power supply unit and then from the first terminal on the top-hat 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.

CX1100-09xx16 Version: 1.4

Fitting and wiring

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 top-hat rail.

1.3 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
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.

2 Assembly of the CPU basic module, the UPS and the power supply unit

2.1 Assembly the the CX10x0 system block

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.

CX1100-09xx 17

Version: 1.4

Fitting and wiring

2.2 Engaging on the top-hat rail

Before engaging the system back on the top-hat rail the user should ensure all white tension straps are
pulled down. The user should take care of the space between the terminals and the Embedded PC system.
The space for the removed terminal must be kept to reinstall the terminal.

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

Do not force the module or apply excessive pressure!

Attention

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 top-hat rail the straps should be pushed back to their original position.

2.3 Connecting the Embedded PC to the terminal bus

By reinstalling the once removed terminal the system is connected to the bus.

Finally the wiring must be reinstalled. The removed terminal is reconnected as before. The power supply is
now connected via the UPS-connectors. (see chapter connections for details)

Also see about this

2 System overview [}7]

2 CX1100-09xx Connections [}10]

Version: 1.4

CX1100-09xx18

Commissioning

5 Commissioning

5.1 Charging time

The charging time of the UPS module depends on actual the discharge and can not be measured exactly. It
is possible to estimate the "maximal charging time". This time describes the charging behavior of completely
discharged storage cells. The test units were discharged over night. Then the time to system start was
measured. The following table shows the results of the measurements.

Charging time

Model Charging time

CX1100-0900 42 s

CX1100-0910 46 s

CX1100-0920 116 s

CX1100-0930 65 s

The given times are average values. In operation the time for discharging must be added to
the time. In mode "No Abort" e.g. the storage cells will be discharged before the charging
starts.

Note

CX1100-09xx 19

Version: 1.4

Commissioning

5.2 Discharging time

The measure the time for discharging of the different UPS modules a precision load was connected to the
UPS. The retention time was measured depending of load and switch setting. The test scene is shown in the
picture below.

A measurement starts app. 30 seconds after the module signals full charge (CHARGE glows green). The
power supply to the UPS is disconnected by releasing the switch. At the same time a clock is triggered. The
measurement stops when the LEDs at the front of the module extinguish. Several series of measurements
have been processed. The following diagrams show the retention time in relation to switch setting. As load
the maximal load for the CX1100-0900 is used.

The maximal output current for UPS module CX1100-0900 is 550 mA!For higher output
current make use of the UPS modules (CX1100-0910 / CX1100-0920), with bigger output
current.The maximal output current is not suitable for the CX1020 Embedded PCs. So it is

Note

The other UPS module have a maximal load of 1100 mA. The results are shown below.

strongly recommended to make use of the UPS modules (CX1100-0910 / CX1100-0920),
with bigger output current.

Retention time in relation to load at switch setting 0

For maximal discharging the torque switch is set to 0. The load is increased by steps of 50 mA. The curves
show the measured retention times.

Version: 1.4

CX1100-09xx20

Commissioning

Measurements with sample configurations

As an example for a real load some Embedded PC configurations have been tested. The retention time was
measured in relation to switch setting. The first test configuration is a CX1000 System (CX1000-0111) with
typical configuration. Only the system interface N001 is connected to the basic system. The K-bus is
supplied via the UPS, too. As terminals one digital input and one output terminal are connected to the bus.
The system configuration shown in the picture.

CX1100-09xx 21

Version: 1.4

Commissioning

The retention times are:

The second test configuration is an Embedded PC with maximal configuration. CX1000-System
(CX1000-0122) with system interfaces N001 (2x USB, DIV), N002 (2x RS232), N003 (Audio), M200 (IP-Link­Master) und M319 (Profibus-Master). A keyboard with a hub and a mass storage device are connected to
the USB ports as load. The system configuration is shown below.

The light bus is shorted by a fiber optic cable. The PROFI bus master connection is connected to a BK3100
with terminals. The retention times are measured in relation to switch setting.

The third test configuration consists of a CX1020-System (CX1020-0120). The configuration is typical. Only
the system interface N010 is connected to the basic module. The terminal bus is an E-bus. One digital output
terminal is connected to the bus.

Version: 1.4

CX1100-09xx22

The results are as folows:

Commissioning

The next test configuration is a CX1020-system in maximal configuration. The test connections are the same
as in the test 2.

The retentions times are:

The last tested configuration is a CX900-system (CX9000-0002). The configuration is typical. Video, USB
and serial interfaces are connected to the basic system. The load connected to the USB ports are the same
as before.

CX1100-09xx 23

Version: 1.4

Commissioning

The retention times are:

CX1100-09xx24 Version: 1.4

Commissioning

5.3 Setting retention time

The retention time is set via the torque switch.

Switch / position retention time

0 100 %

9 90 %

8 80 %

7 70 %

6 60 %

5 50 %

4 40 %

3 30 %

2 20 %

1 10 %

The position 0 (=100%) means that the full capacity of UPS can be used. Depending of the connected load
the power supply can be secured for some minutes. The time can be reduced if the connected system shuts
down fast. If the system shuts down fast the restart can be accelerated.

The retention time should last longer than system shutdown time. For secure operation a
time reserve is advised (XPe shutdown time plus 20-30 %)

Note

The retention time can also be set in TwinCAT system manager:

The description can be found in "Settings for UPS module in System Manager".

Also see about this

2 Settings in the System Manager [}27]

CX1100-09xx 25

Version: 1.4

Commissioning

5.4 Register settings CX1100-09xx

Bit7 Bit6 Bit5 Bit4 Bit3 Bit2 Bit1 Bit0

0x0D1010IN-

Register

+1 charge

state

+2 OUT-

Register

+3 DIP-

DATA

+4 identifier

0

+5 identifier

1

+6 identifier

2

+7 identifier

3

base address 0D1010

C = charge state 0% = 00h, 100% = FFh

IRQ = binary coded IRQ number; 0000 = disabled

DIP_DIS = 1 : disable DIP switch with DIP-DATA

State_3 State_2 State_1 State_0 reserved reserved 24V_IN_OK24V_OU

C7 C6 C5 C4 C3 C2 C1 C0

IRQ3 IRQ2 IRQ1 IRQ0 AUTO_RESDIP_DIS reserved Output

D7 D6 D5 D4 D3 D2 D1 D0

T_OK

OFF

"C" (ASCII)

"X" (ASCII)

"11" (DEC)

"90" (DEC)

AUTO_RES = 1 : auto reboot (shutdown after short power failure)

The AUTO_RES bit must be reset before system shutdown to "0" !

Attention

Meaning of STATE-Nibble:

Value State

0 no function

1 charging

2 full charged

3 discharged

4 discharging and restart

5 output off

6 overload

7 not used

8 not used

9 not used

Version: 1.4

CX1100-09xx26

Commissioning

5.5 Settings in the System Manager

The CX1100-0900 UPS module is inserted as a "Box" under the CX1100 module. You will find a detailed
explanation of how to add hardware in the documentation for the TwinCAT System Manager.

The UPS is added automatically when TwinCAT scans automatically for boxes in its configuration mode.

"General" tab:

Displays general device information on the selected device. The inputs and outputs of the UPS module can
be displayed on the left browser window. This can be used to manipulate the UPS from the PLC.

A detailed description of the setting options will be found in the documentation for the TwinCAT System
Manager.

There are fundamentally two different methods of controlling the UPS module. The first way is to make the
operating settings directly in the TwinCAT System Manager. In this case it is not necessary for any other
control to be exercised from the PLC program. The status signals from the UPS can, however, be evaluated
in the program. As an alternative, the control can be exercised from the PLC program. This is described

exhaustively in the section entitled "Controlling the UPS from the PLC [
TwinCAT System Manager, however, is described below.

}31]". Operation through the

Operating the UPS with the TwinCAT System Manager

Two configurations for operating the UPS are available in the System Manager:

Configuration 1:

"Enable Automatic Shutdown" is active, but "No Abort" however is not:

CX1100-09xx 27

Version: 1.4

Commissioning

"CX1190 UPS" tab:

Enable Automatic Shut Down:

If this switch is selected, then TwinCAT is stopped after an adjustable retention time, and "Windows XPe" is
shut down. Device 1 (here the CX1100) is switched off after the retention time has elapsed. Even when the
power fails for very short periods (<<10s) the system shuts down and the CX is switched off.

Problem: If the voltage returns after TwinCAT has stopped but while "Windows XPe" is still in the process of
shutting down, the CX remains on, but "Windows XPe" remains stopped.

The UPS is fully charged again. The voltage must remain switched off for long enough for the UPS to switch
off, and only after this will reboot take place.

Configuration 2:

"Enable Automatic Shutdown" and "No Abort" are active:

Version: 1.4

CX1100-09xx28

"CX1190 UPS" tab:

Commissioning

Enable Automatic Shut Down:

If this switch is selected, then TwinCAT is stopped after an adjustable retention time, and "Windows XPe" is
shut down. Device 1 (here the CX1100) is switched off after the retention time has elapsed. Even when the
power fails for very short periods (<<10s) the system shuts down and the CX10x0 is switched off.

No Abort:

If the power voltage returns after TwinCAT has stopped, but while "Windows XPe2" is still shutting down, the
CX10x0 will still reboot.

The problem of staying stuck in OFF, as above (option 1) does not occur. As soon as the UPS is fully
charged again, the CX switches on once more.

Problem: The CX10x0 boots in every case, even when power failures are extremely short

Using the System Manager to set the retention time

The retention time of the UPS is set through the rotary switch on the front panel of the UPS. Details on this
can be consulted in the technical description [

set the retention time of the UPS through the System Manager. This is done by selecting the "Override DIP
Switch" dialog box. The "DIP Switch" check box is activated here. A value from 0 to 9 can be chosen. This
value corresponds to the setting of the rotary switch. The position of the rotary switch no longer has any
effect.

}25] of the switch. It is possible to ignore this setting, and to

CX1100-09xx 29

Version: 1.4

Commissioning

Activating the settings

Once all the desired settings have been made, the configuration must be activated through the System
Manager. You will find further explanations in the documentation for the TwinCAT System Manager.

Version: 1.4

CX1100-09xx30

Commissioning

5.6 Controlling theUPS from the PLC

It is possible to control the UPS module from the PLC. There are two TwinCAT blocks that permit this
control. This allows the PLC program to deal with a power failure. It is, however, first necessary to make
some settings in the TwinCAT System Manager, so that the UPS can be properly included. The UPS module

is integrated in the TwinCAT System Manager, as described under Commissioning [
however, for a few important settings to be made so that the PLC can obtain control. The controller must be
switched off in the System Manager. It is also necessary for the hardware inputs and outputs of the UPS to
be linked to the corresponding variables in the PLC program. The inputs and outputs must be declared in the
program as GLOBAL variables. (Further details are given below.) First the settings of the System Manager
are described.

NecessarySystem Manager settings:

-Everything must be set to OFF! In other words, on the CX1190 UPS tab, neither "Enable Automatic
Shutdown" nor "No Abort" may be activated.

-In addition, both inputs (24V State and Charge State) and both outputs (Control and DIP Control) of the
System Manager must be linked in the PLC to the UPS block in the corresponding variables.

The illustration shows the UPS being incorporated in the System Manager. The inputs and outputs of the
UPS will be found both in the process image and in the hardware image in the hierarchy browser.

}27]. It is necessary,

The signals are associated by a double-click. This association is required in order for the function block in
the PLC program to operate properly. The PLC process image will, however, not be available until after the
program has been compiled. This means that it must be linked into a PLC program before being linked with
the UPS control block.

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Version: 1.4

Commissioning

Details of linking signals are given in the documentation for the TwinCAT System Manager.

Linking the UPS control block into a PLC program:

The UPS is controlled from the PLC, with the aid of the FB_CX1000SimpleUps function block which is in the
TC CX1000System.lib. This must, however, be linked by 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_UPS
VAR
UPS : FB_CX1000SimpleUps;
END_VAR

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

• bDIPDisable : BOOL;

• iDischargeLevel : USINT;

• tDelay : TIME;

"tDelay" sets the maximum retention time for which the power may be absent before the UPS switches the
PLC off. The permitted entries here are between 0 and 10 seconds. The boolean expression "bDIPDisable"
allows the setting of the rotary switch on the UPS to be ignored. If the value is "TRUE" then the value set by
"iDischargeLevel" is used as the valid retention time. The call then looks like this:

UPS(
bDIPDisable := TRUE, (* TRUE for DIP switch override *)
iDischargeLevel := 30, (* Values from 0.1, ... 9 *)
tDelay := t#5s (* Retention time before shutdown t#0s .. t#10s *)
);

In order for the function block to operate, the signals that are to be linked in TwinCAT's System Manager
must be created as variables. This is done automatically when the process image is read into the System
Manager. The linking process stores the addresses in the "TwinCAT_Configuration" file, and they are
introduced during the next call to the compiler. (A more precise description can be read in the description of
TwinCAT.) Alternatively it is possible to assign the addresses by hand. After compilation, warnings about the

Version: 1.4

CX1100-09xx32

Commissioning

missing configuration for the signals are displayed. The signals are inserted into the
"Variablen_Konfiguration" file through the "Insert -> All instances" menu item. It is possible to enter the
addresses for the signals here. (E.g. MAIN.UPS.Li24VState AT %IB0 : BYTE for memory address 0).

VAR
MAIN.UPS.Ii24VState AT %IB0 : BYTE;
MAIN.UPS.IiChargeState AT %IB1 : BYTE;
MAIN.UPS.QiControl AT %QB0 : BYTE;
MAIN.UPS.QiDipControl AT %QB1 : BYTE;
END_VAR

The block supplies a few status signals for evaluating the program environment. These can then be used for
control, e.g. saving the process data in NOVRAM, or for setting defined states or positions for axes. In detail,
the block supplies the following signals:

• bPowerFailure : BOOL;

• bShutdownActive : BOOL;

• bUpsReady : BOOL;

• b24VInOK : BOOL;

• bHolding : BOOL;

• tTimeUntilShutdown : TIME;

• eUpsState : E_UPS_STATE

"bPowerFailure" returns "TRUE" when a failure in the power supply voltage is detected . The signal goes
back to "FALSE" when the input voltage returns.

"bShutdownActive" indicates that a stop or shutdown is being executed.

"bUpsReady" indicates that the UPS is providing the output voltage.

"b24VInOK" reports that the UPS is being supplied with 24 V input voltage.

"bHolding" returns "TRUE" when a failure in the supply voltage has been detected, and the retention time
has not yet elapsed.

"tTimeUntilShutdown" indicates the retention time remaining until shutdown.

"eUpsState" displays the status of the UPS [UNDEF | CHARGING | CHARGED | DISCHARGE |
DISCHARGE_RESTART | OUTPUT_OFF | OVERLOAD

The function block bridges short supply voltage drop-outs without generating a shutdown,
while longer supply failures cause TwinCAT to be stopped and the operating system to be
shut down.The CX10x0 is switched off by the UPS when it has reached it is discharge limit,

Note

even if the current returns during the shutdown.The CX10x0 is switched on again by the
UPS once the UPS is fully charged.

If it is necessary for the UPS to behave in a different way, e.g. with a longer retention time, resetting the bus,
or definitely restarting the PLC even when the power failure was short, then the FB_CX1000UPSHANDLING
function block from TC CX1000System.lib can be used as an alternative. This 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_UPS
VAR
UPS : FB_CX1000UPSHANDLING;
END_VAR

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

• bAutoReset : BOOL;

• bDIPDisable : BOOL;

CX1100-09xx 33

Version: 1.4

Commissioning

• bShutdown24V : BOOL;

• bShutdown5V : BOOL;

• iDischargeLevel : USINT;

• bTcStopOnly : BOOL;

• tDelay : TIME;

"bAutoReset" does not switch the CX10x0 system off if the supply voltage returns in time (this is set under
"tDelay"). If this behaviour is wanted, the input must be set to "TRUE". As in the case of the other module,
"bDIPDisable" can be used to ignore the setting of the rotary switch (by setting the input to "TRUE"). In that
case again, the value set under "iDischargeLevel" is used. "bShutdown24V" switches off the 24V voltage.
Warning! "bShutdown5V" is not used at present. This input must always be set to "FALSE"! It is, however,
only necessary to ignore it, as it is initialised with "FALSE". "iDischargeLevel" indicates the discharge
capacity of the UPS. The range of values extends from 0 to 9, whereby, for instance, 3 corresponds to switch
setting 3 and means that the UPS will switch off after losing 30% of its capacity. "TDelay" indicates the
retention time before a stop or shutdown is initiated. The "bTcStopOnly" switch is required for writing the
persistent data under the "Microsoft Windows CE" operating system. Shutdown causes the system to reboot.
It is necessary, however, to stop TwinCAT in order to write the persistent data. This stop signal is set through
the "bTCStopOnly" input ("bTcStopOnly" := "TRUE"). Under "Microsoft Windows XP embedded" shutting
down causes the persistent data to be written. The switch is therefore not necessary (bTcStopOnly =
FALSE).

The call then looks like this:

UPS(
bAutoReset := TRUE; (* TRUE if operation is to continue when the supply returns)
bDIPDisable := TRUE;(* TRUE for DIP switch override *)
bShutdown24V := FALSE;(* Only TRUE if switching off is desired -> everything OFF !!! *)
bShutdown5V := FALSE;(* DO NOT USE ---> reserved function *)
iDischargeLevel := 3; (* Values from 0.1, ... 9 *)
bTcStopOnly := TRUE;(* Under WINDOWS CE in order to save the persistent data, otherwise
FALSE*)
tDelay := t#5s; (* Retention time before shutting down *)
);

This function block also needs further variables for its operation. They are linked in TwinCAT's System
Manager with signals from the UPS. These variables still have to be created. This is done automatically
when the process image is read into the System Manager. The linking process stores the addresses in the
"TwinCAT_Configuration" file, and they are introduced during the next call to the compiler. (A more precise
description can be referred to in the description of TwinCAT.) Alternatively it is possible to assign the
addresses by hand. After compilation, warnings about the missing configuration for the signals are displayed.
The signals are inserted into the "Variablen_Konfiguration" file through the "Insert -> All instances" menu
item. It is possible to enter the addresses for the signals here. (E.g. MAIN.UPS.Li24VState AT %IB0 : BYTE
for memory address 0).

VAR
MAIN.UPS.Ii24VState AT %IB0 : BYTE;
MAIN.US.IiChargeState AT %IB1 : USINT;
MAIN.UPS.QiControl AT %QB0 : BYTE;
MAIN.UPS.QiDipControl AT %QB1 : USINT;
MAIN.UPS.IbPowerFault AT %I : BOOL;

END_VAR

The block supplies a few status signals for evaluating the program environment. These can then be used for
control, e.g. saving the process data in NOVRAM, or for setting defined states or positions for axes. In detail,
the block supplies the following signals:

• bPowerFailure : BOOL;

• bShutdownActive : BOOL;

• bUpsReady : BOOL;

• b24VInOK : BOOL;

"bPowerFailure" returns "TRUE" when a failure in the power supply voltage is detected . The signal goes
back to "FALSE" when the input voltage returns.

Version: 1.4

CX1100-09xx34

"bShutdownActive" indicates that a stop or shutdown is being executed.

"bUpsReady" indicates that the UPS is providing the output voltage.

"b24VInOK" reports that the UPS is being supplied with 24 V input voltage.

The function block gives the PLC program full control over the behaviour of the UPS. De­pending on the operating mode, the developer must see to it that the system is in the de­sired state when switched off, and/or that the system behaves correctly when it restarts.

Note

Problems that can occur include, for instance:The system has halted, the UPS however
provides voltage again -> the system remains inert, even though a power supply is
present.The system starts again, but the UPS is still in the discharge phase, and does not
switch off until fully discharged -> the system starts up, but then is powered down without
warning.

Commissioning

CX1100-09xx 35

Version: 1.4

Error handling and diagnostics

6 Error handling and diagnostics

6.1 LEDs CX1100-09xx

The UPS-Modules show their state of operating via status LEDs. The LEDs reside on the front of the
module. The following table shows the possible states and their meaning.

Display LED Meaning

24 V IN power supply (in) The LED glows

green if input power supply ( >21,5
V) is connected , otherwise it glows
red.

24 V OUT power supply (out) The LED glows

green if a consuming unit is
connected to the power output
( >21,5 V), otherwise it glows red.In
case of short circuit the LED start
blinking red.

CHARGE (Charge status) - charging: yellow - full charged:

green

- discharging: red

Version: 1.4

CX1100-09xx36

Decomissioning

7 Decomissioning

7.1 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 top-hat rail:

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

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

First remove any wiring from power supply unit and then from the first terminal on the top-hat 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 top-hat rail.

CX1100-09xx 37Version: 1.4

Decomissioning

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
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.

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

Attention

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.

Version: 1.4

CX1100-09xx38

Appendix

8 Appendix

8.1 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 at www.beckhoff.com

FCC Approvals for the United States of America

FCC: Federal Communications Commission Radio Frequency Interference
Statement

This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to
Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful
interference when the equipment is operated in a commercial environment. This equipment generates, uses,
and can radiate radio frequency energy and, if not installed and used in accordance with the instruction
manual, may cause harmful interference to radio communications. Operation of this equipment in a
residential area is likely to cause harmful interference in which case the user will be required to correct the
interference at his own expense.

.

FCC Approval for Canada

FCC: Canadian Notice

This equipment does not exceed the Class A limits for radiated emissions as described in the Radio
Interference Regulations of the Canadian Department of Communications.

CX1100-09xx 39

Version: 1.4

Appendix

8.2 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's branch offices and representatives

Please contact your Beckhoff branch office or representative for local support and service
products!

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.

on Beckhoff

Beckhoff Headquarters

Beckhoff Automation GmbH & Co. KG

Huelshorstweg 20
33415 Verl
Germany

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

Beckhoff Support

Support offers you comprehensive technical assistance, helping you not only with the application of
individual Beckhoff products, but also with other, wide-ranging services:

• support

• design, programming and commissioning of complex automation systems

• and extensive training program for Beckhoff system components

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

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

Version: 1.4

CX1100-09xx40