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 Especially suitable for replacing outdated controllers (such as Woodward, Honeywell, and other discontinued modules) or adding local intelligence to distributed IO systems.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).

Pull the white strap: There is a white strap at the bottom of each module. Use a straight screwdriver to gently pull it downwards (Figure 4) to release the locking mechanism.

Hanging the guide rail: First, hang the CPU module (connected to the system interface) onto the upper edge of the guide rail, and then press down to clamp the tension strap into the lower edge of the guide rail (Figure 5). Release the tension strap and allow it to bounce back to its initial position (Figure 6, 7).

Splicing other modules:

If you need to add a fieldbus module, first hang it on the guide rail, then align it with the PC104 interface of the CPU module from the side and push it tightly to ensure no gaps (Figure 3).

Finally, install the power module (also hang the rail and tighten it). Attention sequence: The power module should be installed on the right side of the CPU; The fieldbus module is on the left side (if any).

Remove the protective cover: If you need to connect the fieldbus module, first remove the gray protective cover on the left side of the CPU (Figure 1, 2), and then reinstall it.

Disassembly steps

Power off: Turn off the 24V power supply and disconnect all connections.

Remove the guide rail: Pull down the white strap at the bottom of all modules to release the lock. If the power module is connected to the bus terminal, the first terminal needs to be pried open from the guide rail first (Figure 2).

Separation module: Use a 1.0 × 5.5 × 150 mm flathead screwdriver to insert into the separation slot on the back of the module (Figure 4), rotate about 90 ° to create a 2-3 mm gap between the modules, and then carefully unplug the PC104 connector (Figure 5).

Warning: Forcefully prying open modules without separation slots can damage the casing.

Detailed explanation of power module and use of NOVRAM

CX1100-0001 (pure power supply)

Wiring: 5-pin open plug, pin definitions: 1=+24 V, 2=0 V, 3=GND, 4=+UPS (+24 V), 5=- UPS (0 V). Suggest using a 2A fuse (24V).

LED: PWR green - normal; Red - short circuit.

LCD: It can be controlled through the ADS port (0x000005000+DeviceID), including switch display, cursor, backlight, and writing two lines of text. The specific index offset can be found on page 31 of the manual.

CX1100-0002 (with K-Bus)

Features: The top spring terminal (24 V/0 V) supplies power to the system and K-Bus. PE power contacts cannot be used for other potentials.

I/O indicator light:

I/O RUN (green): K-Bus communication is normal.

I/O ERR (red): Flashing indicates an error. The flashing mode consists of "fast flashing start → slow sequence (error code) → slow sequence (parameter)".

Common K-Bus error codes:

Continuous flashing: EMC issue (check for power spikes, grounding).

Pulse parameter 0/1: EEPROM checksum error or code buffer overflow - restore factory settings or reduce the number of bus terminals.

2 pulse parameters 2/0: Unknown data type - update power firmware or check configuration.

3 pulse parameter n (n>0): Bus terminal n table entry error - check if the model of terminal n matches.

Pulse parameter 0: K-Bus command error - may not have been inserted into the terminal or the terminal is damaged, use binary method to locate the faulty terminal.

3 pulse parameters 0/n: K-Bus data disconnection - check if the (n+1) th terminal is connected properly and if the KL9010 terminal is connected at the end.

5 pulse parameter n: Communication error with the register of the nth terminal - replace this terminal.

14 pulse parameter n: The format of the nth terminal is incorrect - power on again, if it still occurs, replace it.

15 pulse parameter n: Change in terminal quantity - power on again.

16 pulse parameter n: K-Bus data length change - power on again.

Power off restart: Some errors will not automatically exit the flashing after clearing, and the power contact must be disconnected before powering on.

CX1100-0003 (with K-Bus+IP Link)

Similar to CX1100-0002, but with two additional fiber optic interfaces (IN x03, OUT x04) provided for connecting to Beckhoff expansion boxes (IExxxx). When wiring, the OUT of this module must be connected to the IN of the expansion box, and vice versa.

The width has increased to 58 mm.

Detailed pins and configuration of system interface

CX1000-N001（DVI + USB）

DVI-I socket: 29 pins, capable of transmitting both digital and analog signals simultaneously. The analog RGB signal is located at pins C1~C4 (C1=red, C2=green, C3=blue, C4=row sync). It can be converted to VGA through a passive adapter.

USB：Type A， Compliant with USB 1.1. Pin 1=VBUS (red), 2=D - (white), 3=D+(green), 4=GND (black).

CX1000-N002 (dual RS232)

COM2 and COM3 are both 9-pin male connectors, using only pins 2 (RxD), 3 (TxD), 5 (GND), and COM2's 4 (DTR). The highest baud rate is 115k.

CX1000-N003 (Audio)

Stereo Line In/Out: 3.5mm socket, tip=left channel, first ring=right channel, sleeve=ground.

Mic In: Mono, Tip=Signal, Sleeve=Ground.

CX1000-N005 (dual RS422/485, optical isolation)

9-pin male pins: 2=TxD+, 3=RxD+, 5=GND, 6=VCC (+5V), 7=TxD -, 8=RxD -.

RS485 mode: 2&3 need to be short circuited (Data+), 7&8 need to be short circuited (Data -).

DIP switch configuration (located on the left side of the module, visible when the gray cover is removed):

RS485 no echo, terminal resistance (default): Switch 1=off (echo on? The actual manual indicates confirmation: off=echo on? Clarification is required). According to pages 24-25 of the manual, there are four typical configurations:

No echo, terminal matching (endpoints): DIP 1=off, 2=on, 3=on, 4=off, 5=on, 6=off, 7=on, 8=on

There is echo, terminal matching: 1=on, 2=off, 3=on, 4=off, 5=off, 6=on, 7=on, 8=on

No echo, no terminal (Drop Point): 1=off, 2=on, 3=on, 4=off, 5=off, 6=on, 7=off, 8=off

There is echo, no terminal: 1=on, 2=off, 3=on, 4=off, 5=off, 6=on, 7=off, 8=off

RS422 full duplex endpoints: 1=on, 2=off, 3=off, 4=on, 5=off, 6=on, 7=on, 8=on

Compact Flash Card and Data Persistence

CF card is the main non-volatile storage medium of the system, and it is recommended to only use industrial grade CF cards supplied by Beckhoff (wide temperature up to+85 ℃, high read and write life). The order number includes CX1900-0015（128 MB）、0017（256 MB）、0021（512 MB）、0023（1 GB）、0025（2 GB）、0027（4 GB）。 The CF slot has an ejection mechanism: press down on the ejection rod with a screwdriver, the card will pop out by about 4 mm, and then it can be manually pulled out. When inserting, make sure that the card is about 1 mm lower than the front panel of the housing.

Note: This slot is a memory interface, not an I/O type CF slot. Replacing the CF card must be done in the event of a power outage, otherwise it may cause the system to crash.

Status LED diagnosis

CPU base module LED

Meaning of LED color

PWR green power supply is normal (powered through PC104 bus)

Link Green Network Link (10 or 100 Mbit)

When the green network speed is 100 Mbit, it lights up

Flashing when sending and receiving green network packets in HDD Act

Flashing when HDD green accesses CF card

Power module LED

PWR: green=normal power supply; Red=short circuit (applicable to CX1100-0001/2/3)

I/O RUN (CX1100-0002/3 only): Green=K-Bus communication is normal

I/O ERR (CX1100-0002/3 only): Red=K-Bus error (flashing code as above)

Programming interface for LCD display screen

The LCD of the CX1100 power module can be controlled through ADS (Automation Device Specification). The Device ID is: CX1100-0001=1, CX1100-0002=2, CX1100-0003=3. The ADS port number is 0x000005000+DeviceID. Common index offset (16 bits):

Offset operation instructions

0xFFF90FF Write cursor off

0xFFF91FF Write cursor enabled

0xFFF92FF Write cursor flashing off

0xFFF93FF Writing cursor flashing on

0xFFF94FF Write Display Off

0xFFF95FF write display enabled

0xFFF96FF write backlight off

0xFFF97FF write backlight on

0xFFFA0FF Write Text Line 1 (16 characters)

0xFFF00FF Write Text Line 2 (16 characters)

The action can be triggered by writing any value to these offsets (such as writing 0xFFFFA0FF with string data attached). Users can display system status, alarm information, etc. in real-time in the application.

Common troubleshooting table

Possible causes and solutions for the fault phenomenon

After powering on, there is no response at all. Check the 24V power supply, fuses, and plug pins (1=+24V, 2=0V) for missing power or wiring errors. The measured voltage must be within the range of 20.4~28.8 V.

The red power supply of the PWR LED is short circuited and all loads are disconnected. Check whether the peripheral devices or bus terminals are short circuited one by one.

CPU module PWR does not light up. PC104 bus power interruption check if the power module is tightly connected to the CPU module without any gap.

Unable to start (not boot) CF card damaged or boot configuration error, replace Beckhoff original CF card; Check BIOS settings (if any); Attempt to restore the factory image.

Network connection failure cable, hub or IP configuration error check RJ45 pin (1=TD+, 2=TD -, 3=RD+, 6=RD -); Attention should be paid when using a crossover line to directly connect to a PC.

DVI has no display distance that is too long, resolution that is too high, reduced resolution, or cable that is shortened to within 5 meters; Test the analog output using a DVI to VGA adapter.

USB devices do not recognize USB 1.1 compatibility issues and only support low-speed and full speed devices (up to 12 Mbit/s).

Touch screen signal cannot be read. Connect the touch screen to the wrong port. Ensure that the touch screen USB cable is connected to the USB port of the CPU module (not the USB port of the system interface)? The actual USB of N001 is an expansion port.

K-Bus I/O ERR flashes 3 times pulse n terminal n configuration error or disconnection check whether the actual terminal model is consistent with TwinCAT configuration; Check if terminal n+1 is securely plugged in; Confirm that there is a KL9010 terminal at the end.

K-Bus I/O ERR continuous flashing EMC interference check grounding and power filter; Separate the communication line from the power line for wiring.

System time loss, internal battery depletion, battery replacement (requires disassembly, executed by Beckhoff service).

Retirement and disposal

Software shutdown: Normal shutdown of the operating system (if running Windows XPE or CE).

Power outage: Cut off the 24V power supply.

Disassembly: Remove the entire module assembly from the DIN rail according to the previous disassembly steps, and use a separation groove tool to separate each module.

Environmental disposal: Electronic components must comply with national electronic waste regulations (such as WEEE). It is strictly prohibited to discard directly.

Accessories and Support

CF card: See the above order number.

DVI to VGA adapter: CX1900-0101, used to connect VGA displays.

Identification label: CX1900-0200, 1000 plastic labels per pack (15 × 5 mm), can be inserted into the preset slot of the module.

Technical support: Germany hotline+49 5246/963-157, or contact Beckhoff representative offices around the world.