B&R Spare Parts Identification and Compatible Hardware Reference

Overview

When you inherit a B&R CP1584-based machine from a defunct OEM with zero documentation, the first challenge is knowing what parts are installed and how to replace them. This guide covers practical methods for identifying B&R hardware from physical inspection alone, decoding the B&R order code system, finding compatible replacements for discontinued parts, building a spare parts inventory from scratch, and sourcing components from third-party channels.

B&R’s part numbering system is highly structured — once you understand the conventions, you can determine the exact specifications, power ratings, and compatibility of any module from the label alone.

1. Identifying B&R Part Numbers from Physical Inspection

1.1 Label Locations

B&R modules have their order number printed on a label affixed to the side or front face of every component. Look in these locations:

1.2 What You’ll Find on the Label

Every B&R module label contains at minimum:

• Order number — the full part number for ordering (e.g., X20DI9371, 8V1016.00-2)
• Revision — a letter+number code (e.g., H0, J0). Higher letters are newer hardware revisions
• Serial number — a 12-digit alphanumeric code unique to that individual unit
• B&R ID code — a 4-digit hexadecimal hardware identifier used by the controller (e.g., 0xC370 for X20CP1584)

1.3 Using the Serial Number

B&R assigns a unique serial number to every hardware unit. The format is a 12-character alphanumeric string printed on the module label. You can:

• Look up serial numbers on the B&R website at https://www.br-automation.com/en/search/ — enter the serial number to find manufacturing date, warranty status, and firmware compatibility
• Read serial numbers via software using Automation Studio’s HWInfo function, which returns both the 4-digit module ID and 8-digit serial number for every module in the X2X tree
• Use SDM (System Diagnostics Manager) to retrieve serial numbers of all connected modules through the web interface — see cp1584-forensics.md for SDM access procedures

1.4 Using Module ID Codes for Recognition

The B&R ID code is a 4-digit hex value (0x prefix) burned into every module’s firmware. The controller reads this at startup to identify what hardware is present. Key IDs:

Use the HWInfo function block or browse the SDM web UI to dump the full module ID table from a running system. This is critical when labels are damaged or missing.

2. Reading B&R Order Codes

2.1 General Principles

B&R order codes follow a systematic naming convention. While the exact structure varies by product family, these rules hold across all B&R hardware:

• Prefix digits (e.g., 8V, 8AC, X20) identify the product family
• Middle digits identify the specific model, power rating, or channel count
• Suffix after a dot (.00-2) identifies options, accessories, and version
• Coated variants are prefixed with c (e.g., X20cCP1584 = coated X20CP1584)

2.2 X20 System Order Codes

The X20 system uses a prefix-based structure. Each I/O module is actually three separate parts stacked together:

  +-------------------+
  | Terminal Block     |  <- X20TB06 or X20TB12 (field wiring)
  +-------------------+
  | Electronic Module  |  <- X20DI9371, X20AO4622, etc. (the "smart" part)
  +-------------------+
  | Bus Module         |  <- X20BM11, X20BM31, X20BM01 (backplane)
  +-------------------+

X20 I/O Module Naming Convention

Format: X20 + TT + CC + SS + [-N]

X20 CPU Module Naming Convention

Format: X20 + [c] + CP + N + G + PP

Key cross-compatibility note: X20CPx58x and X20CPx68x are not drop-in replacements for each other. You must update the hardware configuration in Automation Studio. Similarly, the new X20EM series requires different firmware and is not a direct replacement for the CP series.

2.3 ACOPOS Drive Order Codes (8V1 Series)

Format: 8V1 + RRR + . + OO + - + V

ACOPOS 8V1 Drive Range

The number after 8V1 roughly correlates with current: 010 ~1.5A, 016 ~3.6A, 022 ~4A, 045 ~8A, 090 ~16A, 132 ~34A, 180 ~48A.

2.4 ACOPOS P3 Drive Order Codes (8EI Series)

Format: 8EI + ccc + d + e + f + g + h + i + kk + -1

2.5 ACOPOSmotor Order Codes (8DI Series)

Format: 8DI + c + d + e + . + ff + ggg + h + i + k + -1

2.6 Bus Module and Power Supply Order Codes

2.7 Accessory Order Codes

3. Finding Compatible Replacement Modules

3.1 I/O Module Hot-Swap Compatibility

X20 I/O modules support hot-swap in most configurations. The key compatibility rules:

Terminal blocks are universal within their pin-count class:

• All X20TB06 blocks interchange with any 6-pin X20 electronic module
• All X20TB12 blocks interchange with any 12-pin X20 electronic module

Bus modules must match the voltage class:

• X20BM01/X20BM11/X20BM31 for 24 VDC I/O modules
• X20BM12 for 240 VAC I/O modules
• Mixing voltage classes on the same bus segment will cause faults

Electronic modules are independent of bus/terminal:

• Any X20 electronic module (DI, DO, AI, AO, AT, etc.) plugs into any matching-width bus module
• You can swap a X20DI9371 for a X20DI6371 as long as the application mapping is updated in Automation Studio
• The controller detects the new module type via the B&R ID code automatically

3.2 CPU Upgrade Path from CP1584

If your CP1584 fails or needs replacement:

Migration from CPx48x to CPx58x requires Automation Studio V3.0.90.20 or later and firmware upgrades for some interface modules. Refer to B&R’s migration guide (see table in Section 12).

3.3 ACOPOS Drive Replacement

When replacing an ACOPOS drive:

1. Match the current rating — use the same or next-higher 8V1 model number
2. Match the mains voltage — 8V1016 (low voltage) is NOT interchangeable with 8V1045 (high voltage) without rewiring
3. Transfer plug-in modules — remove encoder interface, I/O, and communication modules from the failed drive and install in the replacement
4. Re-download acp10sys — the controller will automatically push configuration to the new drive on startup. See acopos-drives.md for details on the acp10sys configuration file
5. Re-configure node addressing — if using CAN, set the node number on the replacement drive’s hex switches to match the original

Critical: A new ACOPOS drive ships with factory defaults and NO configuration. Without a valid acp10sys download from the controller, it will not operate.

3.4 CompactFlash Card Replacement

The CP1584 stores its application on a CompactFlash card. CF cards are consumable items with finite write cycles.

Compatible CF cards for X20CP158x:

Important: Use only B&R-branded SLC (Single-Level Cell) CF cards. Commercial MLC cards will fail prematurely under industrial write patterns. Extended temperature variants (0CFCRD.0512E.01) are available for extreme environments.

For CF card backup and cloning procedures, see cf-card-boot.md.

4. Cross-Referencing Discontinued Parts

4.1 How B&R Manages Product Lifecycle

B&R (as part of ABB since 2017) follows a structured product lifecycle with four phases:

Last-Time-Buy (LTB) Process:

• During the Classic phase, B&R notifies customers of the upcoming phase-out
• Customers must place a binding LTB order specifying annual quantities for the Limited phase
• If B&R accepts the order, quantities are binding — cancellation fees apply (50% for standard, 85% for customized)
• Prices are staggered per delivery year during the Limited phase
• After the Limited phase ends, the product becomes Obsolete

Checking Lifecycle Status:

• Online: https://www.br-automation.com — product pages show lifecycle status
• Customer portal: Log in to view lifecycle status of purchased products
• B&R support: Contact for lifecycle matrix queries
• SDM: Connected modules show hardware revision; cross-reference with B&R lifecycle database

Source: B&R Lifecycle Policy

X20 System Longevity Note: The X20 system celebrated its 20th anniversary in 2024 with B&R confirming continued development and long-term availability. B&R Product Manager Andreas Hager stated the X20 “will remain crucial to the success of machine builders in the future.” This means X20 IO modules, bus controllers, and interface modules are likely to remain available for the foreseeable future, reducing spare-parts risk for the IO layer even as individual CPU models cycle through the lifecycle.

Source: B&R Press Release, October 2024

4.2 Common Discontinued Parts and Replacements

4.3 Interrogating the Controller for Installed Hardware

When you have no documentation, use these methods to discover exactly what hardware is installed:

Method 1: SDM Web Interface

1. Connect to the CP1584 via Ethernet
2. Open a browser to http://<PLC-IP>/sdm/
3. Navigate to Hardware > Modules to see every module in the X2X tree with its order number, revision, and serial number

Method 2: Automation Studio Online Connection

1. Create a new project in Automation Studio
2. Add a generic X20CP1584 to the hardware tree
3. Connect online via Ethernet or RS232
4. Use “Upload from target” to pull the actual hardware configuration

Method 3: ANSL Discovery + Telnet/SSH

1. Use Wireshark to capture ANSL packets (UDP ports 30303, 11169) to find the PLC
2. Telnet to the PLC’s IP and use B&R diagnostic commands to query the module table
3. See cp1584-forensics.md for detailed procedures

Method 4: Physical Walkdown

1. Photograph every module label in the cabinet
2. Record the position (DIN rail slot number) and order number
3. Note the wiring connections on each terminal block
4. Build a physical inventory spreadsheet

4.4 Checking B&R ID Codes Against Known Values

The controller’s hardware tree uses B&R ID codes internally. When you read these via HWInfo, you can cross-reference against the known ID table. If you encounter an unknown ID code, search the B&R Automation Help system or post on the B&R Community forum (https://community.br-automation.com).

5. Building a Spare Parts Inventory for Defunct OEM Machines

5.1 Prioritization Framework

When building a spare parts inventory with limited budget, prioritize by criticality x difficulty of sourcing x lead time:

Tier 1 — Keep on Hand (immediate failure = machine down):

• CP1584 CPU unit or equivalent upgrade
• CompactFlash card with known-good backup image
• Backup batteries (CR2477N) — at least 2 per machine
• Most-commonly-used I/O modules (digital inputs, digital outputs)
• ACOPOS drives (at least one spare per unique current rating in use)
• Power supply modules (X20PS series)

Tier 2 — Source Within 48 Hours (failure degrades capability):

• Less-common I/O modules (analog, temperature, special function)
• Interface modules (IFxxxx for fieldbus communication)
• Terminal blocks (X20TB06, X20TB12)
• Bus modules (X20BM11, X20BM31)
• End cover plates (X20AC0SR1)
• ACOPOS plug-in modules (encoder interfaces, I/O modules)

Tier 3 — Source Within 2 Weeks (failure reduces functionality):

• HMI panels and touch screens
• Network cables and connectors
• Additional CompactFlash cards
• Mounting hardware and DIN rail accessories

5.2 Minimum Recommended Spares for a CP1584 Machine

5.3 Creating the Inventory from an Undocumented Machine

Step-by-step procedure:

1. Network discovery — Follow cp1584-forensics.md to connect to the PLC and pull the hardware tree via SDM

2. Capture the hardware configuration via brwatch — Use the brwatch GUI tool (github.com/hilch/brwatch) to browse the PLC’s variable tree and extract module info. brwatch is a Windows-only GUI application that requires B&R PVI to be installed. It cannot be pip-installed and has no CLI/JSON mode. To capture hardware info:

   • Download brwatch.exe from github.com/hilch/brwatch/releases
   • Configure BRWATCH.ini with ANSL=1 (or leave as INA for older AR)
   • Click the TCP device node to scan for PLCs on the network
   • Browse the CPU node to see all connected hardware
   • Use File > Save to preserve the watch configuration
   • See pvi-api.md and access-recovery.md for alternatives using PVI Python or OPC-UA

3. Create a system dump for full inventory — The systemdump.py tool (github.com/hilch/systemdump.py) can generate an inventory from a dump file:

pip install systemdumpy

## Create and download a system dump from the PLC
py -m systemdumpy 192.168.1.10 -cuv -p Inventory_

## Extract hardware inventory as .xlsx spreadsheet
py -m systemdumpy Inventory_BuR_SDM_Sysdump_2026-07-10_14-30-55.tar.gz -iv

The resulting .xlsx file contains a complete inventory of all modules with order numbers, serial numbers, firmware versions, and status — ready to paste into your spare parts BOM spreadsheet.

4. Physical walkdown — Walk every cabinet and photograph every module. Record position, order number, revision, and wiring connections. Pay special attention to:

   • ACOPOS drives in the drive cabinet
   • Bus couplers and remote I/O nodes
   • Any non-B&R components (relays, contactors, fuses)

5. Build a BOM spreadsheet with columns:

   • Position/location in cabinet
   • Order number
   • Description
   • Revision
   • Serial number
   • B&R ID code (from SDM)
   • Quantity installed
   • Spare quantity on hand
   • Supplier / last price
   • Lead time
   • Priority tier

6. Identify unique vs. common parts — Group parts by order number. Parts used in only one position are highest risk (no redundancy)

7. Determine obsolescence status — For each unique order number, check:

   • B&R website product lifecycle
   • Third-party distributor stock levels
   • Community forums for replacement discussions

8. Order critical spares — Start with Tier 1 items, then Tier 2 based on budget

5.4 Backup Strategy

Beyond physical spare parts, maintain these digital backups:

See cf-card-boot.md for CF card imaging procedures and project-reconstruction.md for project recovery.

6. Third-Party Sources for B&R Parts

6.1 Authorized B&R Channels

6.2 Third-Party Distributors (New and Surplus)

6.3 Repair Services

For drives and modules that can be repaired rather than replaced:

6.4 Online Marketplaces (Use with Caution)

Warning when buying from marketplaces:

• Always verify the full order number including suffix (.00-2 matters)
• Check hardware revision — older revisions may not be compatible with your firmware
• Request photos of the actual label, not stock photos
• Prefer sellers who test before shipping
• Budget for potential returns — some marketplace sellers charge restocking fees

6.5 B&R Community Forum

The B&R Community (https://community.br-automation.com) is an invaluable resource for:

• Asking about discontinued parts and replacements
• Confirming compatibility between module revisions
• Getting help with order code interpretation
• Finding migration guides for older hardware
• B&R engineers actively participate in discussions

7. Lead Times and Availability Considerations

7.1 Typical Lead Times

7.2 Factors Affecting Availability

• Active vs. obsolete — Active B&R parts are available through B&R and distributors. Obsolete parts require surplus channels or repair
• Voltage variants — Low-voltage ACOPOS drives (8V1016 series) are less common than high-voltage (8V1045/1090 series) and may have longer lead times
• Coated modules — X20c (conformal-coated) variants are less common than standard X20 and may need to be ordered from B&R directly
• CF cards — B&R-branded SLC CF cards are becoming harder to source as CompactFlash is being phased out industry-wide. Stock up while available
• Battery (CR2477N) — Standard lithium cell, available from battery suppliers. Not B&R-specific, but must be the Renata CR2477N to avoid fire/explosion risk
• Global chip shortages — Since 2020, industrial semiconductors have experienced intermittent shortages. Active B&R parts may have extended lead times during shortage periods

7.3 Emergency Sourcing Strategy

When a critical part fails and no spare is available:

1. Check all third-party distributors simultaneously — Use the order number to search EU Automation, Wake Industrial, CJS, and Allaoui in parallel
2. Check eBay with exact order number — Sort by “Buy It Now” for fastest procurement
3. Consider repair — Send the failed unit to a repair service (Wake Industrial, Omega Electronics). Even a 2-week repair is better than a 2-month new-part wait
4. Consider upgrade — If the exact part is obsolete, a newer compatible part may be in stock. Check B&R’s migration guides
5. Contact B&R support — Even if you have no direct relationship, B&R support can check global inventory across their distribution network
6. Cross-post on the B&R Community — Other engineers may have spare units they are willing to sell

8. Practical Walkdown Checklist

Use this checklist when doing a first-time physical inspection of an undocumented B&R machine:

Cabinet 1 — Main Control Cabinet

• Photograph every DIN rail with all modules installed
• Record CPU module order number, revision, serial number (typically X20CPxxxx)
• Record all I/O module order numbers (DI, DO, AI, AO, AT)
• Record all bus module order numbers (X20BMxx)
• Record power supply modules (X20PSxxxx)
• Record interface modules (X20IFxxxx)
• Note bus couplers (X20BC0087, X20BC0088) if present
• Record terminal block types (X20TB06, X20TB12)
• Check battery compartment — is a battery installed? Note replacement date
• Check CF card — is one installed? Note capacity marking
• Photograph the interior wiring layout

Cabinet 2 — Drive Cabinet (if separate)

• Record all ACOPOS drive order numbers (8V1xxx.xx-x)
• Record all ACOPOS plug-in modules (8AC110.xx-x)
• Note the plug-in module installed in each drive slot
• Record motor nameplates (8DI, 8LS, 8LVA, 8WSA series)
• Record drive node addresses from hex switches
• Photograph the DC bus and power wiring
• Note any fusing and their ratings

Cabinet 3 — Field I/O (if remote nodes exist)

• Record bus couplers at each remote node
• Record all I/O modules at each node
• Record bus receiver/transmitter modules (X20BR9300, X20BT9100)
• Photograph cable routing and node addresses

Network Configuration

• Record all Ethernet station addresses (hex switches on CPUs and interfaces)
• Record POWERLINK node numbers
• Capture the network diagram from the physical cable routing
• Note any managed switches or network infrastructure

10. Migration Checklist for CPx48x to CPx58x

When upgrading from X20CPx48x generation to X20CPx58x (e.g., from CP1484 to CP1584), the following interface modules require specific hardware revisions or firmware upgrades:

Modules not listed require no upgrade — they are compatible as-is.

Requires Automation Studio V3.0.90.20 minimum.

11. Quick Reference: Order Number to Specification Lookup

Digital Input Modules

Digital Output Modules

Analog Input Modules

Analog Output Modules

Temperature Modules

Bus Controllers

Key Findings

1. Every B&R module label follows a structured order code — once you learn the convention for each product family (X20, 8V1, 8EI, 8DI), you can determine specifications, power ratings, and compatibility from the part number alone without any documentation.

2. The X20 system’s three-part module design (terminal block + electronic module + bus module) means individual components can be replaced independently. Terminal blocks and bus modules are universal within their class; only the electronic module is specific to the I/O function. See io-card-hardware.md for signal processing details.

3. CPU upgrades within the CP158x family are generally compatible (CP1583/1584/1585/1586 share the same platform), but crossing generations (CPx48x → CPx58x → X20EM) requires Automation Studio project changes and firmware upgrades for interface modules. See cp1584-hardware-ref.md for hardware specifications and firmware-version-mgmt.md for version compatibility.

4. ACOPOS drives require acp10sys download from the controller — a replacement drive will not operate until the controller pushes its configuration on startup. Always verify your controller has the correct acp10sys before replacing a drive. See acopos-drives.md for the complete drive management procedures.

5. B&R serial numbers can be looked up on the B&R website (https://www.br-automation.com/en/search/) to determine manufacturing date and compatibility. The B&R ID code (4-digit hex) can be read via HWInfo or SDM to identify modules even when labels are missing or damaged.

6. Third-party distributors are the primary sourcing channel for machines from defunct OEMs. EU Automation, Wake Industrial, CJS, Allaoui, and Xindustra all maintain significant B&R stock with 12-month warranties. Budget 1-4 weeks for standard delivery and keep critical Tier 1 spares on hand.

7. CompactFlash cards are the most critical consumable — use only B&R-branded SLC cards. Stock multiple cards and maintain verified backup images. CF card failure is the most common cause of unplanned downtime on CP1584 machines. See cf-card-boot.md for imaging and backup procedures.

8. The backup battery (Renata CR2477N) must be replaced every 4 years and is the only permitted battery type. Using a different battery is a fire and explosion hazard per B&R’s safety documentation. This item should always be in your spares inventory. See retentive-data.md for battery replacement procedures.

9. The B&R Community forum is an active and valuable resource — B&R engineers participate, and the community collectively maintains institutional knowledge about part compatibility, migration, and sourcing that is not available in official documentation.

10. When sourcing from the surplus/used market, verify firmware compatibility before purchasing. An X20IF1082 Modbus module requires upgrade version 1.2.2.0 for CP1584 compatibility. See remanufacturing.md for evaluation criteria and network-architecture.md for network topology planning.

11. The awesome-B-R community repository (github.com/br-automation-community/awesome-B-R) is the single best resource for finding compatible alternatives, migration tools, and community-maintained compatibility lists. It includes the as6-migration-tools for AR version upgrades, links to B&R part number databases, and user-reported compatibility experiences for third-party hardware substitutions.

12. brwatch can read module serial numbers and firmware versions without Automation Studio. When inventorying a machine, use brwatch (github.com/hilch/brwatch) to extract the hardware tree from the running PLC — this gives you module IDs, serial numbers, and firmware versions for every device in the X2X chain. See access-recovery.md §12 for the procedure.

13. systemdump.py (github.com/hilch/systemdump.py) can generate Excel hardware inventories from a system dump file, saving hours of manual transcription. Run py -m systemdumpy <dump_file> -iv to produce a ready-to-use .xlsx inventory spreadsheet. See diagnostics-sdm.md §11.7 for full CLI usage.

14. brsnmp (github.com/hilch/brsnmp) can scan entire subnets to find all B&R devices, even those you don’t know the IP of. This is useful when a machine has multiple PLCs or network segments:

pip install brsnmp

# Discover all B&R PLCs on the subnet with full details
brsnmp --details

# Output example:
# [
#   {"targetType": "X20CP1584", "serialNumber": "C37012345678",
#    "arVersion": "B04.73", "ipAddress": "192.168.1.10"},
#   {"targetType": "X20CP1586", "serialNumber": "C3B00009876",
#    "arVersion": "B04.93", "ipAddress": "192.168.1.11"}
# ]

Cross-References