BECKHOFF CX1000 Industrial Control PC Complete Manual

BECKHOFF CX1000 Embedded PC Complete Manual

Product positioning and applicable scenarios

In the field of industrial automation, control tasks that are cost sensitive but require PC level computing power often face a dilemma: traditional embedded controllers have insufficient performance, while complete industrial computers exceed budgets. The Beckhoff CX1000 series embedded PC was born for this purpose - it is installed in a modular DIN rail form, providing processing capabilities compatible with Pentium MMX level, while supporting Microsoft Windows CE.net or Windows XP Embedded operating systems, and can run TwinCAT PLC and NC PTP real-time software. This series is particularly suitable for "headless mode" (no display keyboard) operation, and remote programming and monitoring can be completed only through Ethernet and RS232 interfaces.

This article is aimed at automation system integration engineers and on-site maintenance personnel, providing a complete set of engineering deployment and troubleshooting guidelines around the hardware selection, module combination, mechanical installation, power configuration, system interface expansion, LCD display usage, LED status diagnosis, common troubleshooting, and final disassembly and disposal of CX1000. Especially suitable for replacing outdated controllers (such as Woodward, Honeywell, and other discontinued modules) or adding local intelligence to distributed IO systems.

Overview of System Composition and Modules

The CX1000 system adopts PC104 (16 bit ISA) bus as the interconnection standard between modules, and all components are installed side by side on DIN rails. A complete system should include at least two types of modules:

CPU base module (CX1000-0000): Core computing unit, built-in processor compatible with Pentium MMX, with a clock speed of 266 MHz. Equipped with 32 MB RAM (expandable up to 128 MB) and 64 MB Compact Flash (CF) card as non-volatile storage. The basic interface includes one RJ45 Ethernet port (10/100 Mbit) and one 9-pin D-Sub RS232 serial port (COM1). There is a CF card slot (Type II) at the front, which supports hot swapping (but must be operated in a power-off state). Module size 57 × 100 × 91 mm, equipped with passive heat sink (CX1000-COOL). If equipped with DVI/USB function, the weight increases to 435 g.

Power module (CX1100-000x): Provides power to the entire system and offers different I/O expansion capabilities depending on the model. There are three variants in total:

CX1100-0001: Pure power supply, no I/O interface, width 45 mm.

CX1100-0002: Integrated K-Bus interface, can directly connect to Beckhoff Bus Terminals, with a width of 39mm.

CX1100-0003: It integrates both K-Bus and IP Link interfaces and can be connected to an expansion box (IExxxx series fieldbus box) with a width of 58 mm.

All power modules are equipped with 8 kByte NOVRAM for storing process data during power outages; And equipped with a 2-line x 16 character FSTN LCD display screen (with backlight), which can display system and user-defined messages.

System interface module (CX1000-N00x): It is installed on the left side of the CPU at the factory and cannot be added or deleted on site. There are four types in total:

N001: Provides 1 DVI-I (VGA compatible) and 2 USB 1.1 Type A interfaces. DVI-Isupports both analog and digital signals, and can be connected to a regular CRT monitor through a DVI to VGA adapter (CX1900-0101). The maximum resolution is related to the transmission distance: 1024 × 768 @ 5 m, 800 × 600 @ 6 m, 640 × 480 @ 7 m.

N002: Provides two RS232 serial ports (COM2, COM3), 9-pin D-Sub, with a maximum baud rate of 115 k.

N003: Provides audio interfaces: Line In, Mic In (mono), Line Out (stereo, maximum 200 mW, suitable for headphones), and built-in PC buzzer. Using a 3.5mm stereo socket.

N005: Provides two RS422/RS485 interfaces (COM2, COM3), 9-pin D-Sub, optoelectronic isolation, maximum baud rate of 115 k. Terminal resistance and echo mode can be configured through DIP switches.

Fieldbus module (CX1500 xxxx): optional master or slave interface, including Beckhoff Lightbus, Profibus DP, CANopen, DeviceNet, SERCOS interface, etc., with a width of 38 mm.

CPU selection and software configuration

The order number for the CX1000 CPU module encodes the memory size, whether it comes with DVI/USB, operating system, and pre installed TwinCAT level. The following are typical models:

Model Memory (Flash/RAM) DVI/USB Operating System TwinCAT

CX1000-0010 16/32 MB without CE.net

CX1000-0011 16/32 MB without CE.net PLC Runtime

CX1000-0012 16/32 MB without CE.net NC PTP Runtime

CX1000-0110 64/128 MB with XPE None

CX1001-0000 64/128 MB without CE.net (Extended Memory Edition)

Note: Running Windows XP Embedded requires a 64/128 MB configuration and a CF card capacity of at least 128 MB. Please refer to the CX1000 software documentation for a list of all software images.

Mechanical installation and DIN rail fixation

The CX1000 module has a height of 100 mm and is identical to the Beckhoff bus terminals. It can be installed in a standard 120 mm high junction box.

Installation steps

Prepare the guide rail: Fix the DIN guide rail inside the control cabinet, ensuring a ventilation gap of 30mm above and below. The CPU module must be installed vertically to allow cooling air to flow through the heat dissipation holes from bottom to top (see manual figures 8 and 9 for allowable positions, figure 10 for prohibited positions).