BECKHOFF CX9000 User Manual
Hardware documentation
for CX90x0 Ethernet controller
CX900x-xxxx
CX901x-xxxx
CX90x0-Nxxx
version:2.4
date:2008-06-11
Table of contents
Table of contents
1. Foreword
Notes on the documentation
Safety instructions 4
Documentation issue status 6
2. Product overview 7
Appropiate use 7
System overview 8
Basic modules 9
Technical data 9
CX900x-0xxx (E-bus) 10
CX900x-1xxx (K-bus)
CX9010-0xxx (E-bus)
CX9010-1xxx (K-bus) 13
Configurations CX9000 14
Configurations CX9010 15
Connections 16
Battery compartment 20
DIP switch settings 21
11
12
System interfaces 24
Technical data 24
Connections CX9000-N010 25
Connections CX9000-N030 27
Connections CX9000-N031 28
3. Transport 31
Unpacking, installation and transport 31
4. Assembly and connecting 32
Mechanical assembly 32
Dimensions 32
Mechanical assembly of basic module 35
Mechanical assembly of UPS module 37
Start-up procedure 40
Start-up procedure 40
5. Error handling and diagnostics 41
CPU basic module 41
LED basic module E-Bus 41
LED basic module K-Bus 42
K-Bus diagnosis with TwinCAT 44
6. Decomissioning 46
Removal and disposal 46
Embedded PC
Table of contents
7. Appendix 48
Update image 48
Accessories 57
Certifications 58
Support and service 59
2 Embedded PC
Foreword
1. Foreword
Notes on the Documentation
This description is only intended for the use of trained specialists in control and automatio n engineering who are
familiar with the applicable national standards. It is essential that the following notes and explanati ons 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.
© This documentation is copyrighted. Any reproduction or third party use of this publication, whether in whole or in
part, without the written permission of Beckhoff Automation GmbH, is forbidden.
Embedded PC 3
Foreword
Safety Instructions
Safety Rules
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.
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 automatio n 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.
Operator's obligation to exercise diligence
The operator must ensure that
· the product is only used for its intended purpose.
· the product is only operated in sound condition and in working order.
· the instruction manual is in good condition and complete, and always available for reference at the location where
the products are used.
· the product is operated only by suitably qualified and authorised personnel.
· the personnel is instructed regularly about relevant occupational safety and environmental protection aspects, and is
familiar with the operating manual and in particular the safety notes contained herein.
National regulations depending on the machine type
Depending on the type of machine and plant in which the product is used, national reg ulations governing the
controllers of such machines will apply, and must be observed by the operator. These regulations cover, amongst
4 Embedded PC
Foreword
other things, the intervals between inspections of the controller. The operator must initiate such inspections in good
time.
Operator requirements
Read the operating instructions
All users of the product must have read the operating instructions for the system they work with.
System know-how
All users must be familiar with all accessible functions of the product.
Embedded PC 5
Foreword
Documentation Issue Status
Version Changes
2.4 system interfaces CX1200-xxxx removed
2.3 new installation positions are added
2.2 changes in names of system interfaces CX90x0-N070 and CX90x0-N080 inserted
2.1 notes on new system interfaces CX90x0-N070 and CX90x0-N08 0 added
2.0 notes on UL added
1.9 order information changed
1.8 notes on K-Bus diagnosis added
1.7 notes on USV and CF card handling added title picture changed
1.6 Notes on software image update
1.5 cable length for DVI cable corrected
1.4 consumption value for CX1020-A001 added
1.3 notes on dip switches and image update added
1.2 information for CF-cards changed, errors in product numbers corrected
1.1 notes for system interface N010 added
1.0 revised version
0.0.1 preliminarily version
6 Embedded PC
Product overview
2. Product overview
Appropriate Use
The CX-SYSTEM 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.
Only switch the PC off after closing the software
Before the Embedded PC is switched off, the software currently running on it should be stopped properly in order to
avoid data loss on the hard disk. Please read the section on “Switching off”.
Switch off all system components and uncouple the Industrial PC from the system if the PC is not used for control
purposes, e.g. during a function test.
System components that have been switched off must be secured against being switched on again.
The power supply unit of the Embedded PC requires a 24 V DC supply.
Danger
Do not exchange any parts when under power!
When components are being fitted or removed, the supply voltage must be switched off.
Software knowledge
Warning
Mandatory software knowledge!
Every user must be familiar with any of the functions of the software installed on the PC that he can reach.
Embedded PC 7
Product overview
System overview
Ethernet-Controller CX9000
With the Ethernet controller CX9000, Beckhoff presents a further extension of the family of CX-type embedded
controllers. The CX9000 is a compact, high-performance yet cost-effective PLC and motion controller for 30 mm DIN
rail mounting. Within the Beckhoff control world it is positioned between the Bus Terminal Controller series BX and
the Embedded PC CX1000. The main feature of this devices is an energy-saving 266 MHz Intel® IXP420 CPU with
XScale® technology that runs under the Microsoft Windows CE operating system. It thus offers adequate computing
capacity even for complex automation tasks. The CX9000 requir es no external storage media – the device boots the
operating system from the internal fl ash. Due to the low power consumption, within the specified operating range no
fan is required. The CX9000 therefore requires no rotating components. As usual for the CX series, the device
features a modular mechanical design. In its basic configuration, the compact device only measures 58 x 100 x 91
mm.
EtherCAT as fast I/O-System / K-Bus as alternative I/O-System
The CX9000 is available in two versions: with K-bus for direct connection of Bus Terminals, and as a n E-bus version
for direct connection of EtherCAT Terminals. In the basic confi guration, two RJ 45 sockets that are internally
connected to an integrated switch are available as interfaces. This simplifies wiring of several CX9000 within a line
topology. No separate switch hardware is required. The t wo externally accessible Ether net ports are independent of
the EtherCAT interface, which is served by a second MAC (media access controller) provided by the CPU.
Basic module and Systeminterfaces
Further interfaces may be added ex works as required: A screen display can be realized using a CX9000-N001
device, i.e. a module combining DVI/ VGA + 2 x USB 2.0. The combination of DVI and USB enables all types of
Beckhoff Control Panel with DVI/USB interface to be used. Touch functionality is connected via USB. As a further
option, two RS232 modules or two RS422/RS485 modules can be configured as COM1 and COM2. All serial
interfaces feature opto-decoupling. Mass storage in form of a Compact Flash card can be used via the CX9000-A000
module, which offers physical storage capacity in the range of several gigabytes.
SPS, Motion Control and Visualization
Like for all Beckhoff controllers, TwinCAT is used for programming the CX9000 as an automation device. The device
itself contains the run-time environment for PLC and Motion Control. One of the two Ethernet interfaces is used as
programming interface.
Software
Microsoft Windows CE enables the creation of fully graphic user programs,which are able to satisf y high
expectationsthanks to the graphics chip integrated in the CX9000.
In summary, the CX9000 is a compact Ethernet controller, which in combination with EtherCAT I/O allows very fast
I/O control cycles. Windows CE and TwinCAT CE constitute the powerful software architecture for this controller.
8 Embedded PC
Product overview
Basic modules
Ethernet-Controller CX90x0
The CX9000 is a compact, top hat rail-mountable Ethernet Controller with direct connection to the Beckhoff I/O
systems in IP 20. The CX90x0 is available in four basic versions: two version for Bus Terminals with K-bus, the other
two for EtherCAT Terminals with E-bus. The CX90x0 comprises the CPU (available in 266 MHz an d 533 MHz), the
internal flash memory with two configuration options, the main memory (RAM) (available in two different sizes), and
NOVRAM as non-volatile memory. Two Ethernet RJ 45 interfaces are also part of the basic configuration. These
interfaces are connected to an internal switch and offer a simple option for creating a line topology without the need
for additional Ethernet switches. A memory medium in Compact Flash format I and II is available as an optional
module.(only in combination with system interface CX90x0-N010) The operating system is Microsoft W indows CE.
The TwinCAT automation software transforms a CX90x0 system into powerful PLC and Motion Control system that
can be operated with or without visualization. Further system interfaces can be connected to the CPU module ex
works. The CX9000-N010 option can be connected to Beckhoff Control Panels or standard monitors with DVI or VGA
input via the DVI and USB interfaces. Devices such as printer, scanner, mouse, keyboard, mass storage, CR-RW etc.
can be connected via the USB2.0 interfaces. The module CX90x0-N030 of fers two serial RS232 interfaces with a
maximum transfer speed of 115 kbaud. These two interfaces can be implemented as RS422/RS48 5, in which case
they are identified as CX90x0-N031.
The Ethernet-Controller CX90xx is offered in four versions:
• CX900x-0000 E-bus connection
• CX900x-1000 K-bus connection
• CX9010-0000 E-bus connection
• CX9010-1000 K-bus connection
Embedded PC 9
Product overview
Technical data – CX9000-0000 E-bus connection
Technical data CX9000-0000
Processor Intel® IXP420 with Xscale® Te chnology, 266-MHz clock rate
Internal flash memory 16 Mbyte Flash (internal, expandable up to 32 Mbyte)
Internal main memory 64 Mbyte RAM (internal, expandable up to 128 Mbyte)
interfaces 2 x RJ 45 (internal Switch), 10/100 Mbit
Diagnostics LEDs 1 x Power, 2 x LAN, 1 x L/A, 1 x flash access
Clock internal battery-backed clock for time and date
Operating system Microsoft Windows CE
Control software TwinCAT-CE-PLC-Runtime or TwinCAT-CE-NC-PTP-Runtime
Power supply 24 VDC (-15%/+20%) To meet the UL requirements use a 4 A fuse or a power
supply that has to satisfy NEC class 2!
Dielectric strength 500 V
I/O connection E-bus (EtherCAT Terminals)
NOVRAM 128 kByte
I/O-DPRAM Power supply I/O
terminals
Max. power loss 6 W (including CX9000-xxxx system interfaces)
Dimensions (W x H x D) 59 mm x 100 mm x 91 mm
weight ca. 250 g
Operating / storage
temperature
Relative humidity 95% no condensation
Vibration/shock
resistance
EMC resistance
burst/ESD
Protection class IP 20
2 A
0° C ... +50° 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
(supply/internal electronics)
rms
10 Embedded PC
Product overview
Technical data CX9000-1000 K-bus connection
Technical data CX9000-1000
Processor Intel® IXP420 with XScale® Technology, 266-MHz clock rate
Internal flash memory 16 MByte Flash (internal, expandable up to 32 MByte)
Internal main memory 64 MByte RAM (internal, expandable up to 128 MByte)
interfaces 2 x RJ 45 (internal Switch), 10/100 MBit
Diagnostics LEDs 1 x Power, 2 x LAN, 1 x K-Bus, 1 x Flash-Zugriff
Clock internal battery-backed clock for time and date
Operating system Microsoft Windows CE
Control software TwinCAT-CE-PLC-Runtime or TwinCAT-CE-NC-PTP-Runtime
Power supply 24 VDC (-15%/+20%) To meet the UL requirements use a 4 A fuse or a power
supply that has to satisfy NEC class 2!
Dielectric strength 500 V
(supply/internal electronics)
rms
I/O connection K-bus (Bus Terminals)
NOVRAM 128 kByte
I/O-DPRAM 4 kByte
Power supply I/O
2 A
terminals
Max. power loss 6 W (including CX9000-xxxx system interfaces)
Dimensions (W x H x D) 59 mm x 100 mm x 91 mm
weight ca. 250 g
Operating / storage
0° C ... +50° C / -25° C ... +85° C
temperature
Relative humidity 95% no condensation
Vibration/shock
conforms to EN 60068-2-6 / EN 60068-2-27/29
resistance
EMC resistance
conforms to EN 61000-6-2/EN 61000-6-4
burst/ESD
Protection class IP 20
Embedded PC 11
Product overview
Technical data – CX9010-0000 E-bus connection
Technical data CX9010-0000
Processor Intel® IXP420 with Xscale® Te chnology, 533-MHz clock rate
Internal flash memory 32 Mbyte Flash (internal)
Internal main memory 128 Mbyte RAM (internal)
interfaces 2 x RJ 45 (internal Switch), 10/100 Mbit
Diagnostics LEDs 1 x Power, 2 x LAN, 1 x L/A, 1 x flash access
Clock internal battery-backed clock for time and date
Operating system Microsoft Windows CE
Control software TwinCAT-CE-PLC-Runtime or TwinCAT-CE-NC-PTP-Runtime
Power supply 24 VDC (-15%/+20%) To meet the UL requirements use a 4 A fuse or a power
supply that has to satisfy NEC class 2!
Dielectric strength 500 V
I/O connection E-bus (EtherCAT Terminals)
NOVRAM 128 kByte
I/O-DPRAM Power supply I/O
terminals
Max. power loss 7 W (including CX9000-xxxx system interfaces)
Dimensions (W x H x D) 59 mm x 100 mm x 91 mm
weight ca. 250 g
Operating / storage
temperature
Relative humidity 95% no condensation
Vibration/shock
resistance
EMC resistance
burst/ESD
Protection class IP 20
2 A
0° C ... +50° 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
(supply/internal electronics)
rms
12 Embedded PC
Product overview
Technical data CX9010-1000 K-bus connection
Technical data CX9010-1000
Processor Intel® IXP420 with XScale® Technology, 533-MHz clock rate
Internal flash memory 32 MByte Flash (internal)
Internal main memory 128 MByte RAM (internal)
interfaces 2 x RJ 45 (internal Switch), 10/100 MBit
Diagnostics LEDs 1 x Power, 2 x LAN, 1 x K-Bus, 1 x Flash-Zugriff
Clock internal battery-backed clock for time and date
Operating system Microsoft Windows CE
Control software TwinCAT-CE-PLC-Runtime or TwinCAT-CE-NC-PTP-Runtime
Power supply 24 VDC (-15%/+20%) To meet the UL requirements use a 4 A fuse or a power
supply that has to satisfy NEC class 2!
Dielectric strength 500 V
(supply/internal electronics)
rms
I/O connection K-bus (Bus Terminals)
NOVRAM 128 kByte
I/O-DPRAM 4 kByte
Power supply I/O
2 A
terminals
Max. power loss 7 W (including CX90x0-xxxx system interfaces)
Dimensions (W x H x D) 59 mm x 100 mm x 91 mm
weight ca. 250 g
Operating / storage
0° C ... +50° C / -25° C ... +85° C
temperature
Relative humidity 95% no condensation
Vibration/shock
conforms to EN 60068-2-6 / EN 60068-2-27/29
resistance
EMC resistance
conforms to EN 61000-6-2/EN 61000-6-4
burst/ESD
Protection class IP 20
Embedded PC 13
Product overview
Configurations CX9000
The order identifier of the basic CPU module is derived as follows:
Following CX9000 configurations are available:
Ordering
information
CX9000-0000
CX9000-0001
CX9000-1000
CX9000-1001
CX9001-0000
CX9001-0001
CX9001-0002
CX9001-0100
16 MB Flash
64 MB RAM
32 MB Flash
128 MB RAM E-Bus K-Bus
X - x -
X - x -
X - - x
DVI,
2 x
USB
-
-
-
no
TwinCAT
X - -
- x -
x - -
TwinCATPLCRuntime
X - - x - - x -
- x x - - x - -
- x x - - - x -
- x x - - - x x
- x x - x x - -
TwinCATNCRuntime
CX9001-0101
CX9001-0102
CX9001-1000
CX9001-1001
CX9001-1002
CX9001-1100
CX9001-1101
CX9001-1102
- x x - x - x -
- x x - x - x x
- x - x - x - -
- x - x - - x -
- x - x - - x x
- x - x x x - -
- x - x x - x -
- x - x x - x x
14 Embedded PC
Product overview
Configurations CX9010
The order identifier of the basic CPU module is derived as follows:
Following CX9000 configurations are available:
Ordering
information E-Bus K-Bus
CX9010-0000
CX9010-0001
CX9010-0002
CX9010-0100
CX9010-0101
CX9010-0102
CX9010-1000
CX9010-1001
CX9010-1002
x - - x - -
x - - - x -
x - - - x x
x - x x - -
x - x - x -
x - x - x x
- x - x - -
- x - - x -
- x - - x x
DVI, 2 x
USB
no
TwinCAT
TwinCATPLCRuntime
TwinCATNCRuntime
CX9010-1100
CX9010-1101
CX9010-1102
- x x x - -
- x x - x -
- x x - x x
Embedded PC 15
Product overview
Connections
The system is supplied with power via the integrated power supply. This is wired as follows:
The basic module is powered via the upper connectors with 24 V DC. The terminal bus can be supplied via the lower
connections.
UL requirements
Danger
For the compliance of the UL requirements the CX-Controllers should only be supplied
• by a 24 V
fuse (in accordance with UL248), rated maximum 4 Amp.
• by a 24 V
supply voltage, supplied by an isolating source and protected b y means of a
DC
power source, that has to satisfy NEC class 2.
DC
A NEC class 2 power supply shall not be connected in series or parallel with another
(class 2) power source!
These UL requirements are valid for all supply voltages of the CX-Controllers!
16 Embedded PC
Product overview
CPU basic module with 2 Ethernet RJ 45 connectors:
RJ 45 interface (socket):
Assignment of the RJ45-interface, Port 1:
PIN Signal Desciption
1 TD + Transmit +
2 TD - Transmit 3 RD + Receive +
4
5
6 RD - Receive 7
8
TD & RD are exchanged at the hubs or between two PCs.
connected not used
connected not used
Assignment of the RJ45 interface, Port 2:
PIN Signal Description
1 TD + Transmit +
2 TD - Transmit 3 RD + Receive +
4
5
6 RD - Receive 7
8
TD & RD are exchanged at the hubs or between two PCs.
connected not used
connected not used
Connection of the Ethernet ports:
Warning
The two Ethernet ports of a basic CPU module must not be connected to the same external switch!
Note
Only for use in LAN, not for connection to telecommunication circuits.
Schematic structure of the network components:
The CX9000 features two MAC blocks. The first one (MAC1) operates the network interfaces for the Ethernet ports.
The two outputs are connected via a switch. In this way a line structure can be configured as described belo w. From
an operating system perspective this represents a single connection. The second block (MAC2) operates the
extended PC104 bus. The second physical network connection is used to run the E-bus connection. (in version
CX900x-0xxx) The signals are connected to and FPGA. This unit converts the Ethernet signals to E-bus signals. So
EtherCAT terminals can be connected to the system.
Embedded PC 17
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