B&R X20CP1584 Complete Hardware Reference
Overview
The B&R X20CP1584 is a mid-range PLC CPU module in the X20 system family, based on the Intel Atom E640T processor. It is a headless controller (no integrated display) designed for industrial automation applications requiring POWERLINK real-time networking, Gigabit Ethernet, and modular I/O expansion via the X2X Link bus. This document consolidates all hardware specifications, physical details, and practical information needed for physical inspection, spare parts procurement, and hardware configuration of a CP1584 in the field.
Key identifiers:
- Order number:
X20CP1584 - Coated variant:
X20cCP1584(identical electronics, conformal coating for harsh environments) - B&R ID code:
0xC370
CPU Specifications
| Parameter | Value |
|---|---|
| Processor | Intel Atom E640T |
| Clock frequency | 600 MHz (0.6 GHz) |
| L1 instruction cache | 32 kB |
| L1 data cache | 24 kB |
| L2 cache | 512 kB |
| Floating point unit | Yes (hardware FPU) |
| Integrated I/O processor | Yes (processes I/O data points in background) |
| Typical instruction cycle time | 0.0075 us |
| Shortest task class cycle time | 400 us |
| Cooling | Fanless |
Memory Architecture
| Memory Type | Size | Description |
|---|---|---|
| DDR2 SDRAM (main RAM) | 256 MB | Runtime memory for AR OS, tasks, libraries |
| SRAM (user RAM) | 1 MB total | Battery-backed; split between retentive vars and user data |
| Remanent variables max | 256 kB | Configurable in Automation Studio; deducted from SRAM |
| CompactFlash slot | 1 | Application memory (ordered separately) |
| Real-time clock | Nonvolatile | Resolution 1 s, -10 to +10 ppm accuracy at 25 C |
The SRAM is backed by a lithium battery (Renata CR2477N, 3V/950mAh). Actual usable user RAM = 1 MB minus configured remanent variable space. See retentive-data.md for battery management and data retention procedures.
Interfaces
IF1 - RS232 (Serial)
| Parameter | Value |
|---|---|
| Signal | RS232 (non-galvanically isolated) |
| Connector | 12-pin terminal block X20TB12 |
| Max distance | 900 m |
| Max transfer rate | 115.2 kbit/s |
| Default baud rate | 57600 bps (factory default) |
The RS232 interface shares the X20TB12 terminal block with the CPU/I/O power supply. The RS232 pins are on the bottom row (pins 7-12 area):
| Terminal | Function |
|---|---|
| I_r | I/O power supply input (shared) |
| S | I/O power supply input (shared) |
| TX | RS232 transmit data (output from PLC) |
| RX | RS232 receive data (input to PLC) |
| GND | RS232 signal ground |
Wiring for serial console (DB9 null-modem cable to PC):
- PLC TX → PC RX (pin 2 on DB9)
- PLC RX → PC TX (pin 3 on DB9)
- PLC GND → PC GND (pin 5 on DB9)
Note on “900 m max distance”: B&R rates the RS232 interface at 900 m. This exceeds the TIA-232 standard maximum of ~15 m at 115.2 kbit/s. B&R’s rating likely assumes RS422/RS485 line driver/receiver equipment is used at the far end. For standard RS232 point-to-point wiring, observe the standard limits. See grounding-emc.md for serial cable EMC considerations.
Important: The factory default baud rate is 57600 bps. While rates up to 115.2 kbit/s are supported, the default must be assumed when connecting to an unknown PLC. See bootloader-recovery.md for serial console usage.
IF2 - Ethernet (Gigabit)
| Parameter | Value |
|---|---|
| Physical layer | 10BASE-T / 100BASE-TX / 1000BASE-T |
| Connector | 1x RJ45 shielded |
| Max segment length | 100 m between 2 stations |
| Transfer rate | 10/100/1000 Mbit/s |
| Auto-negotiation | Yes |
| Auto-MDI/MDIX | Yes |
| Half-duplex | Yes |
| Full-duplex | Yes |
This is the primary interface for:
- Automation Studio online connection (ANSL/PVI)
- OPC-UA server
- FTP server
- Web server (SDM)
- SNMP
- General TCP/IP communication
The INA2000 station number is set using the two hex switches on the front panel.
IF3 - POWERLINK (Real-Time Ethernet)
| Parameter | Value |
|---|---|
| Physical layer | 100BASE-TX |
| Connector | 1x RJ45 shielded |
| Max segment length | 100 m between 2 stations |
| Transfer rate | 100 Mbit/s |
| Protocol | ETHERNET Powerlink V1/V2 |
| Role | Managing Node (MN) or Controlled Node (CN) |
| MN node number (V1) | Fixed 0x00 |
| MN node number (V2) | Fixed 0xF0 |
| CN node number range (V1) | 0x01 - 0xFD |
| CN node number range (V2) | 0x01 - 0xEF |
| Half-duplex | Yes (POWERLINK mode) |
| Full-duplex | No (POWERLINK mode) / Yes (Ethernet mode) |
Important: POWERLINK mode only operates in half-duplex. The interface cannot be used for POWERLINK and standard Ethernet simultaneously. When POWERLINK is active, IF2 (Ethernet) must not use an IP address in the POWERLINK address range (192.168.100.x). See powerlink-internals.md for protocol details.
IF4 and IF5 - USB
| Parameter | Value |
|---|---|
| Type | USB 1.1 / 2.0 |
| Connector | Type A |
| Max output current | 0.5 A per port |
| Galvanic isolation | No |
Critical limitations:
- USB interfaces CANNOT be used for online communication (no ANSL/PVI over USB)
- Only ground-isolated USB devices are permitted
- B&R only guarantees functionality of B&R-branded USB devices
IF6 - X2X Link (I/O Bus)
| Parameter | Value |
|---|---|
| Fieldbus | X2X Link (master) |
| Galvanic isolation | Yes (isolated from Ethernet, POWERLINK, and other interfaces) |
The X2X Link connects to X20 bus couplers and base modules for I/O expansion. See x2x-protocol.md for protocol details.
Electrical Isolation
All three network interfaces are galvanically isolated from each other and from the PLC:
- Ethernet (IF2) - isolated
- POWERLINK (IF3) - isolated
- X2X Link (IF6) - isolated
RS232 (IF1) and USB (IF4/IF5) are NOT galvanically isolated.
Power Supply
CPU and X2X Link Power Supply
| Parameter | Value |
|---|---|
| Input voltage | 24 VDC -15% / +20% (20.4 - 28.8 VDC) |
| Input current | Max. 1.5 A |
| Fuse | Integrated, non-replaceable |
| Reverse polarity protection | Yes |
| Power consumption (no interface/USB) | 8.6 W |
X2X Link Power Output
| Parameter | Value |
|---|---|
| Nominal output power | 7 W (derated to 5 W above 55 C) |
| Parallel connection | Yes (75% of nominal power per supply) |
| Redundant operation | Yes |
I/O Power Supply
| Parameter | Value |
|---|---|
| Input voltage | 24 VDC -15% / +20% |
| Required line fuse | Max. 10 A, slow-blow |
| Nominal output voltage | 24 VDC |
| Permissible contact load | 10 A |
Terminal Block Pinout (X20TB12)
The 12-pin terminal block provides power connections and RS232:
| Pin | Function |
|---|---|
| 1 | RS232 RXD |
| 2 | RS232 TXD |
| 3 | RS232 GND |
| 4-6 | Reserved |
| 7 | +24V I/O supply |
| 8 | GND I/O supply |
| 9 | +24V I/O supply (output) |
| 10 | GND I/O supply |
| 11 | +24V CPU/X2X Link supply |
| 12 | GND CPU/X2X Link supply |
Wiring specifications:
- Wire type: copper only (no aluminum)
- Solid wire: 0.08 - 2.50 mm2 (28-14 AWG)
- Stranded wire: 0.25 - 2.50 mm2 (24-14 AWG)
- Strip length: 7-9 mm
Physical Specifications
| Parameter | Value |
|---|---|
| Width | 150 mm |
| Height | 99 mm |
| Depth | 85 mm |
| Weight | 750 g |
| IP rating | IP20 |
| Mounting | 35 mm DIN rail (top-hat rail) |
| Mounting orientation | Horizontal or vertical |
Operating Conditions
| Condition | Range |
|---|---|
| Operating temperature (horizontal) | -25 to 60 C |
| Operating temperature (vertical) | -25 to 50 C |
| Storage/transport temperature | -40 to 85 C |
| Relative humidity | 5-95%, non-condensing |
| Max altitude (no derating) | 2000 m |
| Above 2000 m | Derate 0.5 C per 100 m |
Overtemperature Shutdown
| Condition | Temperature | Result |
|---|---|---|
| Processor overtemperature | 110 C | PLC enters reset state |
| Board overtemperature | 95 C | PLC enters reset state |
Logbook errors:
- Error 9204: PLC restart triggered by CPU temperature monitoring
- Error 9210: Warning: Halt/Service after watchdog or manual reset
Certifications
- CE, UKCA
- ATEX Zone 2 (II 3G Ex nA nC IIA T5 Gc IP20)
- UL/cULus E115267 (Industrial control equipment)
- HazLoc cCSAus 244665 (Class I, Div 2, Groups ABCD, T5)
- DNV (maritime: Temperature B, Humidity B, Vibration 4g, EMC B)
- ABS, BV, CCS, KR, EAC
Front Panel Layout
[1] [2] [3] [4]
| | | |
| Top-hat rail latch
| Select application memory (CF card select switch)
| Slot for CompactFlash
| LED status indicators (R/E, RDY/F, S/E, PLK, ETH, CF, DC)
|
[5] [6] [7]
| | |
| IF6 - X2X Link
| IF1 - RS232 (via terminal block)
| Slot for interface module (1 slot on CP1584)
|
[8] [9] [10] [11] [12]
| | | | |
| Terminal block (power + RS232)
| IF5 - USB
| IF4 - USB
| Reset button
| Battery compartment
|
[13] [14]
| |
| IF3 - POWERLINK (RJ45)
| IF2 - Ethernet (RJ45)
|
[15]
|
Ethernet station address (hex switches)
LED Status Indicators
CPU Status LEDs
| LED | Color | State | Meaning |
|---|---|---|---|
| R/E | Green | On | Application running |
| R/E | Green | Blinking | System startup (initializing app, bus systems, I/O) |
| R/E | Green | Double flash | System startup during firmware update |
| R/E | Red | On | Mode SERVICE or BOOT |
| R/E | Red | Blinking | License violation (when RDY/F also blinks yellow) |
| R/E | Red | Double flash | Installation error (AR 4.93+: USB install aborted) |
| RDY/F | Yellow | On | Mode SERVICE or BOOT |
| RDY/F | Yellow | Blinking | License violation (when R/E also blinks red) |
| S/E | Green/Red | Dual | POWERLINK interface status (see below) |
| PLK | Green | On | POWERLINK link established |
| PLK | Green | Blinking | POWERLINK link active with Ethernet traffic |
| ETH | Green | On | Ethernet link established |
| ETH | Green | Blinking | Ethernet link active with traffic |
| CF | Green | On | CompactFlash inserted and detected |
| CF | Yellow | On | CompactFlash read/write access |
| DC | Green | On | CPU power supply OK |
| DC | Red | On | Backup battery empty |
S/E LED - POWERLINK Interface States
Ethernet mode:
| Green | Red | Meaning |
|---|---|---|
| On | Off | Interface operated as Ethernet |
POWERLINK V1 mode:
| Green | Red | Meaning |
|---|---|---|
| On | Off | Node running, no errors |
| Off | On | System error (check PLC logbook) |
| Blinking alt. | - | MN has failed (CN only) |
| Off | Blinking | System stop with error code |
| Off | Off | Not active / startup / misconfigured / defective |
POWERLINK V2 mode - Blink patterns:
| Pattern | Green | Red | State |
|---|---|---|---|
| Flicker (~10 Hz) | Off | - | BASIC_ETHERNET (timeout expired before EPL detected) |
| Single flash (~1 Hz) | On | Off | PRE_OPERATIONAL_1 (CN: waiting for SoC from MN) |
| Single flash (~1 Hz) | On | On | PRE_OPERATIONAL_1 with MN failure (CN only) |
| Double flash (~1 Hz) | On | Off | PRE_OPERATIONAL_2 (CN: configured, waiting for READY_TO_OPERATE command) |
| Double flash (~1 Hz) | On | On | PRE_OPERATIONAL_2 with MN failure (CN only) |
| Triple flash (~1 Hz) | On | Off | READY_TO_OPERATE (CN: cyclic + async comm, PDO data not yet evaluated) |
| Triple flash (~1 Hz) | On | On | READY_TO_OPERATE with MN failure (CN only) |
| Blinking (~2.5 Hz) | On | Off | OPERATIONAL (full cyclic data exchange, PDO mapping active) |
| Off | On | - | Error mode (failed Ethernet frames, collisions, etc.) |
| Off | - | Off | NOT_ACTIVE (off, startup, misconfigured, or defective) |
POWERLINK V2 state transition for CN (controlled node):
BASIC_ETHERNET ──(EPL detected)──→ PRE_OPERATIONAL_1 ──(SoC received)──→
PRE_OPERATIONAL_2 ──(command)──→ READY_TO_OPERATE ──(command)──→
OPERATIONAL
Key diagnostic note: If the S/E LED is off with no green or red, and the R/E LED shows green (application running), the POWERLINK interface may be configured as Ethernet-only (not POWERLINK) in Automation Studio. Check the interface module configuration or the CPU’s IF3 settings.
Power Supply LEDs
| LED | Color | State | Meaning |
|---|---|---|---|
| r (green) | Green | On | Mode RUN |
| r (green) | Green | Blinking | Mode PREOPERATIONAL |
| r (green) | Green | Single flash | Mode RESET |
| e (red) | Red | On | Module not supplied or everything OK |
| e (red) | Red | Double flash | X2X Link overloaded / I/O power too low |
| e (red) | Red | Solid + green flash | Invalid firmware |
| S (yellow) | Yellow | On | RS232 data transfer active |
| l (red) | Red | On | X2X Link power supply overloaded |
System Stop Error Codes
When S/E blinks red, the error code is a sequence of 4 phases (150 ms = short, 600 ms = long), repeated every 2 seconds:
| Code (phases) | Error |
|---|---|
| Short Short Short Long | RAM error - device defective, replace |
| Short Short Long Long | Hardware error - device or component defective, replace |
Operating Mode Switch
The CP1584 has a three-position operating mode switch:
| Position | Mode | Description |
|---|---|---|
| BOOT | BOOT | Starts Boot AR; runtime installable via online interface (AS). User flash erased only when download begins. |
| RUN | RUN | Normal runtime operation |
| DIAG | DIAGNOSE | CPU boots in diagnostic mode. Program sections in User RAM and Flash are NOT initialized. Always warm restart after DIAG mode. |
Important: Any switch position other than the three listed is not permitted.
Reset Button
The reset button is located below the USB interfaces on the bottom of the housing. It can be pressed with a small pointed object (paper clip, etc.).
Pressing the reset button causes a hardware reset:
- All application programs are stopped
- All outputs are set to zero
- The PLC starts up in SERVICE mode by default (configurable in AS)
Ethernet Station Address (Hex Switches)
Two hex rotary switches set the INA2000 station number for Ethernet (IF2) and optionally the POWERLINK node number (IF3).
| Switch Range | Usage |
|---|---|
| 0x00 | Reserved (not permitted) |
| 0x01 - 0xEF | POWERLINK controlled node (CN) |
| 0xF0 | POWERLINK managing node (MN) |
| 0xF1 - 0xFF | Reserved (not permitted) |
When used for Ethernet (IF2), the station number maps to the default IP address formula: 192.168.1.<station_number> in some configurations. For POWERLINK, the switch directly sets the node number.
CompactFlash Card
The CF card slot accepts industrial-grade CompactFlash cards. CF cards are ordered separately and are not included with the CPU.
Supported CF Cards (B&R part numbers)
| Order Number | Capacity |
|---|---|
| 0CFCRD.0512E.02 | 512 MB |
| 0CFCRD.1024E.02 | 1 GB |
| 0CFCRD.2048E.02 | 2 GB |
| 0CFCRD.4096E.02 | 4 GB |
| 0CFCRD.8192E.02 | 8 GB |
| 0CFCRD.016GE.02 | 16 GB |
All cards are extended temperature rated. Only B&R-approved CF cards should be used; consumer CF cards may fail in industrial conditions.
See cf-card-boot.md for CF card contents, boot sequence, and imaging procedures.
Battery
| Parameter | Value |
|---|---|
| Type | Lithium (Renata CR2477N, button cell) |
| Voltage | 3 V |
| Capacity | 950 mAh |
| B&R order number (single) | 4A0006.00-000 |
| B&R order number (4-pack) | 0AC201.91 |
| Storage temperature | -40 to 85 C |
| Max storage time | 3 years at 30 C |
| Recommended replacement interval | Every 4 years |
| Min. runtime at 23 C | 2 years |
The battery buffers:
- Remanent variables
- User RAM
- System RAM
- Real-time clock
Battery replacement:
- Discharge ESD at top-hat rail or ground (do not touch power supply)
- Slide battery cover down and away
- Push empty battery out of holder
- Insert new battery “+” side up on right part of holder
- Press battery into holder (use plastic tweezers, never metal)
- Replace cover
- Must complete within 1 minute if PLC is voltage-free
Warning: Only Renata CR2477N batteries are permitted. Other batteries may present fire or explosion hazard. See retentive-data.md for full procedures.
Interface Module Slot
The X20CP1584 has 1 slot for modular X20 interface modules. This allows adding:
- Additional fieldbus interfaces (Modbus TCP/RTU, PROFINET, EtherCAT, CANopen)
- Serial interfaces (RS485, additional RS232)
- Other communication modules
Compatible Interface Modules (selected)
| Order Number | Description | Min HW Rev | Min Upgrade Version |
|---|---|---|---|
| X20IF1020 | Ethernet interface | H0 | 1.1.5.1 |
| X20IF1030 | Ethernet switch | I0 | 1.1.5.1 |
| X20IF1041-1 | 2x RS485 | - | - |
| X20IF1043-1 | 2x RS485 | - | - |
| X20IF1051-1 | RS485/RS422 | - | - |
| X20IF1053-1 | RS485/RS422 | - | - |
| X20IF1061 | CAN bus | E0 | - |
| X20IF1063 | CAN bus (X2X + CAN hybrid) | - | 1.1.5.0 |
| X20IF1072 | PROFIBUS DP | - | 1.0.5.1 |
| X20IF1082 | Modbus TCP/RTU | - | 1.2.2.0 |
| X20IF1086-2 | Modbus TCP/RTU | - | 1.1.1.0 |
| X20IF1091 | EtherCAT | - | 1.0.5.1 |
| X20IF2772 | CANopen (CiA 301) | - | 1.0.6.1 |
| X20IF2792 | DeviceNet | - | 1.0.5.1 |
| X20IF10E1-1 | PROFINET RT | - | - |
| X20IF10E3-1 | PROFINET RT | - | - |
| X20IF10G3-1 | CC-Link IE | - | - |
Important: Some interface modules require a hardware upgrade when migrating from X20CPx48x to X20CPx58x CPUs. Check the minimum hardware revision column above. See firmware-version-mgmt.md Section 4.4 for the complete migration compatibility table.
Interface Module Upgrade Requirements (CPx48x to CPx58x)
When upgrading from X20CP1484 to X20CP1584 (or from CPx48x to CPx58x generation), these interface modules require specific firmware or hardware revisions:
| Interface Module | Min Upgrade Version | Min HW Revision | Notes |
|---|---|---|---|
| X20IF1020 (Ethernet) | 1.1.5.1 | H0 | Required |
| X20IF1030 (Ethernet Switch) | 1.1.5.1 | I0 | Required |
| X20IF1041-1 (2x RS485) | – | – | Compatible as-is |
| X20IF1043-1 (2x RS485) | – | – | Compatible as-is |
| X20IF1051-1 (RS485/422) | – | – | Compatible as-is |
| X20IF1053-1 (RS485/422) | – | – | Compatible as-is |
| X20IF1061 (CAN) | – | E0 | HW revision required |
| X20IF1063 (CAN+X2X) | 1.1.5.0 | – | Upgrade required |
| X20IF1072 (PROFIBUS DP) | 1.0.5.1 | – | Upgrade required |
| X20IF1082 (Modbus TCP/RTU) | 1.2.2.0 | – | Upgrade required |
| X20IF1091 (EtherCAT) | 1.0.5.1 | – | Upgrade required |
| X20IF2772 (CANopen) | 1.0.6.1 | – | Upgrade required |
| X20IF2792 (DeviceNet) | 1.0.5.1 | – | Upgrade required |
Modules not listed are compatible as-is without any upgrade. Requires Automation Studio V3.0.90.20 minimum. See spare-parts.md Section 10 for the full migration checklist.
See if2772-canopen.md for CANopen details and modbus-gateway.md for Modbus configuration.
X2X Link and I/O Station Architecture
X2X Link Bus Interface (IF6)
The X2X Link is B&R’s proprietary deterministic I/O bus connecting the CPU to I/O stations. On the CP1584, the X2X interface uses a dedicated connector on the bottom of the housing.
| Parameter | Value |
|---|---|
| Protocol | X2X Link (B&R proprietary) |
| Physical layer | Differential signaling (LVDS-like) |
| Topology | Multi-drop daisy chain |
| Maximum nodes per segment | 253 |
| Cable type | B&R X2X bus cable (shielded, proprietary connector) |
| Baud rate | 12 Mbit/s (fixed) |
| Cycle time | 200 us (typical for full I/O update) |
| Galvanic isolation | Yes (isolated from all other interfaces) |
| Power over bus | Yes (7 W max for station power) |
X2X Link Connector Details
The X2X Link connectors on the X20 system use a proprietary push-pull connector with two ports per module (IN and OUT) for daisy chaining. The connectors are keyed to prevent incorrect insertion.
X2X cable pin assignments:
| Signal | Description |
|---|---|
| X2X_DATA+ | Differential data positive |
| X2X_DATA- | Differential data negative |
| X2X_CLK+ | Differential clock positive |
| X2X_CLK- | Differential clock negative |
| X2X_GND | Ground reference |
| Power +24V | Bus power input (supplied by CPU or upstream module) |
| Shield | Cable shield (connected to module ground) |
The X2X bus uses synchronous communication with a dedicated clock line. Each I/O module receives timing from the upstream module and re-transmits to the downstream module. This creates a deterministic timing chain where all modules in a station sample inputs and update outputs synchronously.
X2X Bus Timing and Configuration
| Parameter | Default | Configurable Range | Notes |
|---|---|---|---|
| Bus cycle time | 200 us | 100-1000 us | Must be a multiple of the system tick |
| Station response time | < 100 us | Determined by module count | More modules = longer response |
| Cable length per segment | Up to 100 m | Total bus length | Longer cables increase propagation delay |
| Baud rate | 12 Mbit/s | Fixed | Not user-configurable |
Practical impact on machine performance: The X2X cycle time directly affects I/O response time. A 200 us X2X cycle means a minimum of 200 us between an input changing and the CPU seeing that change. For high-speed applications, reduce the X2X cycle time, but be aware that shorter cycles increase CPU interrupt load.
See x2x-protocol.md for wire-level frame format and io-sniffing.md for sniffing techniques.
X2X Bus Couplers and Base Modules
The CPU connects to X20 I/O stations via X2X Link through bus couplers:
| Order Number | Description |
|---|---|
| X20BC0083 | X20 bus controller, CP1583 compatible |
| X20BC0087 | X20 Modbus TCP/UDP bus controller (standalone gateway) |
| X20BC0088 | X20 POWERLINK V2 bus controller |
| X20BB82 | X20 bus base, 2 expansion slots |
| X20BB88 | X20 bus base, 8 expansion slots |
| X20BM01 | Bus module, 24 VDC, single-width (standard) |
| X20BM11 | Bus module, 24 VDC, single-width (updated) |
| X20BM31 | Bus module, 24 VDC, double-width |
| X20BM12 | Bus module, 240 VAC |
Station Structure
A typical X20 I/O station consists of:
- Bus coupler/base module (X20BC or X20BB series) - connects to CPU via X2X Link
- Power supply module (X20PS series) - provides I/O power
- I/O modules (X20DI, X20DO, X20AI, X20AO, X20AT, X20PT series) - signal processing
Each station is a daisy chain on the X2X Link bus. See network-architecture.md for topology details and x2x-protocol.md for bus protocol internals.
Three-Part Module Architecture
Every X20 I/O slot is actually three separate physical components stacked together:
+-------------------+
| Terminal Block | <- X20TB06 or X20TB12 (field wiring)
| (removable) |
+-------------------+
| Electronic Module | <- X20DI9371, X20AO4622, etc.
| (hot-swappable) | The "smart" part with FPGA/MCU
+-------------------+
| Bus Module | <- X20BM01, X20BM31
| (fixed to rail) | Backplane connector
+-------------------+
Key practical points:
- Terminal blocks are universal within their pin-count class (all X20TB06 work with all 6-pin modules)
- Bus modules must match the voltage class (24V vs 240V)
- Electronic modules are independent of bus/terminal – any module plugs into any matching-width slot
- The controller identifies modules via the B&R ID code (0x hex) automatically
- Electronic modules are hot-swappable in most configurations
Maximum I/O Capacity
The X20CP1584 supports:
- Multiple X2X stations per controller
- Up to 253 X2X nodes per link segment
- Power budget: 7 W X2X Link output (derated to 5 W above 55 C)
- I/O power: separate supply via terminal block (10 A max)
- Total I/O points: limited by X2X cycle time and CPU memory, not a hard count
The practical limit depends on the number of I/O modules, their power consumption, and X2X Link timing. See io-card-hardware.md for module power specifications.
Interface Module Slot Details
The X20CP1584 has 1 slot for modular X20 interface modules. This slot is located on the right side of the CPU housing and accepts any single-width X20 interface module.
Slot mechanics:
- The interface module slides into a guide rail on the CPU housing
- A latch mechanism secures the module
- The module connects to the CPU’s internal PCI Express or local bus
- Hot-swap is NOT supported for interface modules – power cycle required
Electrical isolation: The interface module slot is galvanically isolated from the CPU core and from the X2X Link. This means faults on the fieldbus side of an interface module cannot propagate to the CPU logic.
X20CP158x Family Comparison
| Feature | X20CP1583 | X20CP1584 | X20CP1585 | X20CP1586 |
|---|---|---|---|---|
| Processor | Atom E620T (333 MHz compat) | Atom E640T (600 MHz) | Atom E680T (1 GHz) | Atom E680T (1.6 GHz) |
| RAM | 128 MB DDR2 | 256 MB DDR2 | 256 MB DDR2 | 512 MB DDR2 |
| SRAM | 1 MB | 1 MB | 1 MB | 1 MB |
| Max retentive | 64 kB | 256 kB | 256 kB | 1 MB |
| Min cycle time | 800 us | 400 us | 200 us | 100 us |
| L2 cache | - | 512 kB | 512 kB | 512 kB |
| Interface slots | 1 | 1 | 1 | 1 |
| B&R ID | 0xD45B | 0xC370 | 0xC3AE | 0xC3B0 |
| Power consumption | 8.2 W | 8.6 W | 8.8 W | 9.7 W |
The X20CP358x series is identical but has 3 interface module slots instead of 1.
Firmware and Software Compatibility
Supported Software Versions
| Software | Minimum Version | Maximum Version | Notes |
|---|---|---|---|
| Automation Studio | 3.0.90.20 | 4.12.x | AS 6.x does NOT target CP1584 hardware |
| Automation Runtime | 3.x | 4.93 (final AR 4.x) | AR 6.x does NOT run on CP1584 |
| OPC-UA Server | AR 4.0+ | AR 4.93 | Requires OPC-UA license on target |
| POWERLINK MN | AR 3.x+ | AR 4.93 | POWERLINK V1 and V2 supported |
| SDM Web Interface | AR 3.08+ | AR 4.93 | SDM enabled by default in AR 4.x |
| FTP Server | AR 3.x+ | AR 4.93 | FTPS available in AR 4.x |
| mappView HMI | AR 4.x | AR 4.93 | HTML5 HMI in browser; NOT supported in AR 6.x on this hardware |
Automation Studio Version Requirements by Feature
| Feature | Min AS Version | Notes |
|---|---|---|
| CP1584 hardware support | 3.0.90.20 | First AS version to recognize CP1584 |
| AR 4.x runtime targeting | 4.0 | Cannot use AS 3.x to target AR 4.x |
| AR 4.93 (latest) | 4.3.5+ SP | Use AS 4.12 for best compatibility |
| OPC-UA configuration | 4.0+ | Built-in OPC-UA server configuration |
| POWERLINK V2 (EPL V2) | 3.0.90.20 | POWERLINK V2 requires compatible bus controller |
| PVI Transfer Tool | Any 4.x | For transferring projects without full AS IDE |
| Hardware migration from CP1484 | 3.0.90.20 | HW upgrade required; see spare-parts.md |
| mapp Framework components | 4.x | mapp not available in AS 3.x |
| Profiler (Long Profiler) | Any 4.x | Works without project source code |
Interface Module Compatibility by AR Version
Not all interface modules work with all AR versions on the CP1584. The table below shows minimum requirements for common modules:
| Interface Module | Min AR Version | Min HW Revision | Notes |
|---|---|---|---|
| X20BC0088 (POWERLINK V2) | 3.x | Any | Most common bus controller |
| X20IF1063 (Modbus TCP) | 3.x | Any | Firmware 1.2.2.0+ for CP1584 |
| X20IF1020 (POWERLINK) | 3.x | H0 | Firmware 1.1.5.1+ for CP1584 |
| X20IF2772 (CANopen) | 3.x | Any | Firmware 1.0.6.1+ for CP1584 |
| X20IF1082 (EtherCAT) | 4.x | Any | Not available on older AR |
| X20IF1082-2 (EtherNET/IP) | 4.x | Any | Firmware 1.2.1.0+ for CP1584 |
| X20IF1091 (PROFINET) | 4.x | Any | Firmware 1.0.5.1+ for CP1584 |
| X20IF1072 (VARAN) | 4.x | Any | Firmware 1.0.5.1+ for CP1584 |
Key point: If you add an interface module to a CP1584 running older firmware, and the module requires a newer minimum AR version, you may need to upgrade the AR before the module will be recognized. This is a chicken-and-egg problem if you only have one CPU and no spare — always upgrade AR first, then add new modules.
CP1584 Upgrade Paths to Newer Hardware
| From | To | Required AS Version | Migration Complexity |
|---|---|---|---|
| X20CP1584 (AR 4.93) | X20CP1684 (AR 4.x/6.x) | AS 4.7+ or AS 6.0+ | Medium — same form factor, different CPU core |
| X20CP1584 (AR 4.93) | X20CP3484 (AR 4.x) | AS 4.x | Medium — different form factor, 3 slots |
| X20CP1584 (AR 4.93) | X20CP3586 (AR 4.x/6.x) | AS 4.x or AS 6.0+ | Medium — different form factor, 3 slots, faster |
| X20CP1584 (AR 4.93) | X20EM (ARM-based) | AS 6.x only | High — different CPU architecture entirely |
X20CP1684 specific note (from B&R Community): The X20CP1684 requires Automation Studio 4.7 minimum (or AS 6.0). It is NOT yet supported in AS 4.3. When upgrading from CP1584 to CP1684, the new CPU must appear in the Hardware Catalog under Tool_Box before you can configure it. See remanufacturing.md for the full migration workflow.
See firmware.md and firmware-version-mgmt.md for detailed firmware download and installation procedures.
Practical Inspection Checklist
When encountering an unknown X20CP1584 in the field:
- Verify the model: Read the label on the side of the module. Order number should be
X20CP1584orX20cCP1584. - Check battery LED (DC): Red = battery depleted. Replace immediately before power loss.
- Check CF card: Green LED = card present. No CF card = PLC will not boot to RUN.
- Check mode switch: Should be in RUN position for normal operation.
- Note hex switch settings: Record the station address values for network documentation.
- Check interface module: Identify any module in the expansion slot (look up order code).
- Note LED states: All status LEDs provide diagnostic information (see tables above).
- Check X2X link: Verify daisy chain connections to I/O stations.
- Check power wiring: Verify 24 VDC on both CPU/X2X and I/O supply terminals.
- Record serial numbers: Found on the module label, useful for license tracking and spare parts.
Common Replacement Scenarios
Replacing a Failed CP1584
- Record all settings (hex switches, mode switch, battery date)
- Image the CF card before removal:
dd if=/dev/sdX of=cp1584-backup.img bs=4M - Replace CPU on DIN rail
- Insert CF card
- Set hex switches and mode switch to match original
- Apply power and verify boot sequence
- See project-reconstruction.md if configuration is unknown
Upgrading from X20CP1484
The CP1584 is the direct upgrade path from the older X20CP1484 (Celeron-based). Migration requires:
- Automation Studio 3.0.90.20 or later
- Hardware upgrade for some interface modules (see compatibility table above)
- CF card with compatible AR version
- Project reconfiguration for the new CPU target
Key Findings
- The X20CP1584 is headless - no integrated display, no panel functionality. It is purely a CPU controller.
- The RS232 interface runs at 57600 bps factory default, not 115200 bps. Always try 57600 first.
- Only 1 interface module slot (not 3 like the CP3584). Plan fieldbus needs accordingly.
- The hex switches serve dual purpose: Ethernet INA2000 station number AND POWERLINK node number.
- POWERLINK is half-duplex only on IF3. Ethernet mode on IF3 supports full-duplex.
- Battery must be replaced within 1 minute of power loss to prevent SRAM data loss.
- Integrated fuse is non-replaceable - if the fuse blows, the entire CPU must be replaced.
- B&R ID code 0xC370 is useful for SNMP discovery and software identification.
- The CP1584 supports both POWERLINK V1 (node 0x00 = MN) and V2 (node 0xF0 = MN) with different node ranges.
- Operating temperature derating above 55 C reduces X2X Link power output from 7 W to 5 W.
- Fanless design with overtemperature protection at 110 C (CPU) and 95 C (board) — the PLC enters reset state, not a graceful shutdown. Logbook error 9204 indicates temperature-triggered restart.
- 256 MB DDR2 SDRAM is split between AR OS, task execution, and libraries. If memory usage approaches capacity, task cycle times will degrade. Monitor via system-variables.md and hardware-monitoring.md.
- Shortest achievable task class cycle time is 400 µs (CP1584 with Atom E640T at 0.6 GHz). For comparison: CP1583 = 800 µs, CP1585 = 200 µs, CP1586 = 100 µs. This determines the minimum POWERLINK cycle time the CP1584 can sustain as MN. Typical instruction cycle time is 0.0075 µs per the official datasheet. The integrated I/O processor handles I/O data point processing in the background, offloading this from the main CPU.
- Overtemperature shutdown thresholds are 110°C (processor) and 95°C (board) — the CPU enters reset state (not graceful). Logbook errors 9204 (temperature restart) and 9210 (halt/service after watchdog) indicate thermal events. No fan is present — rely on cabinet ventilation and ambient temperature control. See hardware-monitoring.md for temperature monitoring procedures.
Practical Hardware Diagnostic Commands
Via FTP (if enabled)
# Connect to the CP1584 FTP server
ftp 192.168.10.1
# Username: (varies, may be anonymous or empty)
# Password: (varies, may be empty or set by OEM)
# Useful directories:
# /System/ - AR system files, firmware, logs
# /Card/ - CF card contents (user application)
# /Temp/ - Temporary files
# /Log/ - Logbook and diagnostic files
# Download the AR logbook for error analysis
get /System/Log/Logbook.txt
Via SNMP (if enabled)
# Query the CP1584 via SNMP for hardware health
snmpwalk -v2c -c public 192.168.10.1 1.3.6.1.2.1.1
# B&R enterprise OID for hardware-specific data
snmpwalk -v2c -c public 192.168.10.1 1.3.6.1.4.1.28639
# Check interface status (IF2 Ethernet)
snmpget -v2c -c public 192.168.10.1 ifDescr.2 ifOperStatus.2
Via OPC-UA (if configured)
# Connect to OPC-UA server on the CP1584 to read system variables
# See [opcua.md](opcua.md) and [system-variables.md](system-variables.md)
# for the full variable list and connection details
Via Serial Console (Bootloader)
# Serial console settings for bootloader mode:
# Baud: 57600 (factory default)
# Data: 8 bits
# Parity: None
# Stop: 1 bit
# Flow: None
# Connect with minicom or picocom:
picocom -b 57600 /dev/ttyUSB0
# After connecting, press Enter to get the bootloader prompt
# Available commands depend on AR version:
# help - list available commands
# dir - list files
# mem - memory dump
# info - hardware info
# See [bootloader-recovery.md](bootloader-recovery.md) for full procedure
Physical Inspection Quick-Reference Card
When walking up to an unknown CP1584 in a cabinet:
[ ] Label side: read order number (X20CP1584 or X20cCP1584)
[ ] Coated variant? X20cCP1584 = conformal coating for harsh environments
[ ] Read serial number from label (for spare parts and license tracking)
[ ] Read B&R ID code (0xC370) if visible
[ ] Check DC LED: green = power OK, red = battery depleted
[ ] Check CF LED: green = card present, yellow = card access
[ ] Check R/E LED: green solid = running, red = BOOT/SERVICE
[ ] Check ETH LED: green = Ethernet link active
[ ] Check PLK LED: green = POWERLINK link active
[ ] Check mode switch: should be RUN for normal operation
[ ] Record hex switch positions (station address for network documentation)
[ ] Identify interface module in expansion slot (read its order code)
[ ] Count X2X stations connected (daisy chain physical trace)
[ ] Verify 24 VDC on both CPU/X2X (pin 11-12) and I/O (pin 7-8) power terminals
[ ] Check battery compartment: is battery present? date code?
[ ] Check for corrosion or physical damage on terminals
References
- B&R X20CP1584 Product Page: https://www.br-automation.com/en-us/products/plc-systems/x20-system/x20-plc/x20cp1584/
- X20CP158x Data Sheet V1.56: https://www.multiwaycontrol.com/multiway/X20CPx58x-en_V1.56.pdf
- X20(c)CP158x and X20(c)CP358x Technical Manual: https://www.all4sps.com/mediafiles/Sonstiges/X20CP1586.pdf
- X20TB12 Terminal Block Data Sheet: https://www.nexinstrument.com/assets/images/pdf/X20TB06__X20TB12-ENG_V266.pdf
- X20 System User’s Manual: https://www.br-automation.com/en-us/downloads/control-and-io-systems/x20-system/x20-system-users-manual/
- B&R Community Forum: https://community.br-automation.com/
- B&R X20CP1684 Product Page: https://www.br-automation.com/en-us/products/plc-systems/x20-system/x20-plc/x20cp1684/
Successor: X20CP1684
B&R has released the X20CP1684 as the direct in-family successor to the CP1584. This is a drop-in compatible replacement with significant hardware improvements:
| Parameter | X20CP1584 | X20CP1684 |
|---|---|---|
| Processor | Intel Atom E640T @ 600 MHz | Intel Atom @ 400 MHz (newer architecture) |
| RAM | 256 MB DDR2 | 512 MB LPDDR4 |
| User RAM (SRAM) | 1 MB (battery-backed) | 1 MB (battery-backed) |
| Storage | CompactFlash (removable) | 1 GB internal flash |
| Ethernet | 10/100/1000 Mbps (1 port) | Gigabit Ethernet |
| Interface slots | 1 (X20) | 1 (X20) |
| Min Automation Studio | 3.0.90.20 | 4.7 (recommended: 6.0+) |
| Min AR version | 4.x (B04.xx) | 5.x+ (G05.xx) |
| Cooling | Fanless | Fanless |
| Power consumption | 8.6 W | ~8 W |
| B&R ID code | 0xC370 | (varies by revision) |
| CF card required | Yes (5CFCRD series) | No (internal flash) |
Key migration notes for CP1584 to CP1684:
-
All X20 IO modules, bus modules, and terminal blocks are fully compatible. The X2X bus, POWERLINK, and interface module slot are identical. No IO hardware changes needed.
-
No more CompactFlash. The CP1684 uses 1 GB internal flash instead of removable CF cards. This eliminates CF card failures (the most common failure mode on CP1584) but means backup must be done via FTP, Automation Studio transfer, or mapp Backup. See ftp-web-interface.md for FTP backup procedures.
-
Minimum AS version is 4.7. B&R recommends Automation Studio 6.0+ for the CP1684. If you have an AS4 project, you may need to open it in AS4.7 first, verify it compiles, then optionally migrate to AS6 for CRA compliance. See remanufacturing.md for the full AS4→AS6 migration guide.
-
AR 5.x/6.x runtime. The CP1684 runs AR 5.x or later. Some AS4-era libraries may need updates for AR 5+ compatibility. Use the community
as6-migration-toolsto check your project. -
Hardware tree update only. In Automation Studio, the migration is straightforward: replace the CPU module in the hardware tree from X20CP1584 to X20CP1684, re-address if needed (usually automatic), recompile, and download. The IO mapping remains unchanged.
-
Production deployment: See firmware-version-mgmt.md for the production deployment checklist when changing CPU hardware. Estimated downtime: 4-8 hours for a direct CPU swap with the same IO configuration.
Order code: X20CP1684 (standard), X20cCP1684 (conformal-coated variant for harsh environments).
Beyond CP1684: X20EM ARM Edge Controllers
B&R has introduced the X20EM series as the next-generation X20 controller platform. These use ARM-based processors instead of Intel Atom, and represent B&R’s long-term direction for the X20 ecosystem. The X20EM is relevant for CP1584 maintainers planning long-term migration.
What we know about X20EM:
| Aspect | X20CP1584 (current) | X20CP1684 (successor) | X20EM (next gen) |
|---|---|---|---|
| CPU architecture | Intel Atom E640T (x86) | Intel Atom (x86) | ARM / RISC-V |
| Automation Studio | AS 3.x–4.x | AS 4.7+ (recommended AS 6.0+) | AS 6.x only |
| Automation Runtime | AR 4.x only | AR 5.x/6.x | AR 6.x only |
| Multicore support | No | No | Yes |
| X20 IO compatible | Yes | Yes | Yes |
| Form factor | 1-slot X20 | 1-slot X20 | X20 slice (details vary) |
| Storage | CompactFlash | Internal flash | Internal flash |
| Release timeline | Discontinued (SN 2022/54) | Current production | Available (as of 2025) |
Migration implications for CP1584 maintainers:
-
X20EM requires AS 6.x exclusively — if you migrate to X20EM, you MUST also migrate the project to AS 6. There is no AS 4.x support for ARM targets.
-
X20 IO modules are compatible — the X2X bus is unchanged, so all your existing IO modules, bus modules, terminal blocks, and interface modules work with X20EM.
-
Compiled code is architecture-specific —
.BRfiles compiled for Intel x86 will NOT run on ARM. You must recompile the entire project from source. If you only have compiled code (no project file), X20EM migration requires full project reconstruction first (see project-reconstruction.md). -
Multicore is a significant advantage — AR 6.5 on X20EM allows assigning cyclic task classes to specific CPU cores, eliminating cycle time contention between motion control and logic processing.
-
Not a direct drop-in replacement — unlike CP1684, the X20EM has a different CPU architecture and requires a complete software rebuild. Plan for full bench testing before production deployment.
-
When to consider X20EM over CP1684: When the machine has complex multi-axis motion that hits cycle time limits, when you need OPC UA over TSN, or when CRA compliance requires AR 6.x with multicore isolation for security domains.
Status: X20EM specifications are evolving. Check B&R’s product page at https://www.br-automation.com/en-us/products/plc-systems/x20-system/ for the latest models and specifications. The X20 system user’s manual (January 2025 revision) covers System Generation 4 controllers including ARM-based options.
New Apollo Lake I Generation (2025)
B&R has expanded the X20 PLC family with new controllers based on Intel Apollo Lake I processors. These controllers add OPC UA over TSN support and can function as field-level masters in TSN networks — a capability the CP1584 cannot provide.
| Model | Key Feature | Relevance to CP1584 Migration |
|---|---|---|
| X20CP3687X | “Power of a PC” in X20 form factor | High-performance AR 6.x target for complex machines |
| X20CP0484-1 | 512 MB RAM, 2 GB internal flash | Budget-friendly AR 6.x entry point |
Why this matters for CP1584 maintainers: If you are planning a migration to meet CRA 2027 compliance (see cybersecurity-hardening.md §9.3), these new controllers provide a modern, patchable AR 6.x platform with TSN capabilities — while maintaining X20 IO bus compatibility.
Source: B&R “Expanded X20 PLC generation” — https://www.br-automation.com/en/products/plc-systems/innovations/
Related Documents
- ar-rtos.md — Automation Runtime (VxWorks-based) that runs on this CPU
- memory-map.md — CPU memory layout including SRAM, DDR2, and IO mapping
- firmware.md — AR firmware architecture and boot process
- firmware-version-mgmt.md — Firmware versions, downgrade paths, compatibility
- cf-card-boot.md — CF card contents and boot sequence details
- retentive-data.md — Battery-backed SRAM management and data retention
- x2x-protocol.md — X2X Link wire-level protocol details
- powerlink-internals.md — POWERLINK protocol on IF3
- if2772-canopen.md — CANopen via X20IF2772 interface module
- modbus-gateway.md — Modbus TCP/RTU via X20IF1082 interface module
- io-card-hardware.md — X20 I/O module signal processing and diagnostics
- network-architecture.md — Network topology and device enumeration
- spare-parts.md — Replacement hardware identification and ordering
- bootloader-recovery.md — Serial console bootloader and firmware recovery
- access-recovery.md — Password recovery and admin access restoration
- system-variables.md — AR system variables for runtime monitoring
- hardware-monitoring.md — Temperature, voltage, and hardware health monitoring
- grounding-emc.md — Grounding and EMC considerations for installation
- ftp-web-interface.md — Remote file access via FTP and web server
- diagnostic-workstation.md — Building a diagnostic workstation for CP1584 systems
- remanufacturing.md — Repair vs. replace evaluation and migration paths
- license-mgmt.md — License management tied to this hardware’s B&R ID code