ETHERNET Powerlink: User's Manual
ETHERNET Powerlink: User's Manual
ETHERNET Powerlink: User's Manual
User's Manual
We reserve the right to change the contents of this manual without warning. The information
contained herein is believed to be accurate as of the date of publication, however, Bernecker +
Rainer Industrie-Elektronik Ges.m.b.H. makes no warranty, expressed or implied, with regards
to the products or the documentation contained within this book. In addition, Bernecker + Rainer
Industrie-Elektronik Ges.m.b.H. shall not be liable in the event of incidental or consequential
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products. The software names, hardware names and trademarks used in this document are
registered by the respective companies.
Chapter 2: Hardware
Table Index
Index
General Information
Chapter 1
Chapter 1 • General Information
1. Manual History
2. Introduction
2.2.2 Properties
Table 3: Properties
2.2.3 Cabling
Particularly:
• Cables
• System installation
ETHERNET Powerlink topology guidelines should be adhered to: See Section 7
"Recommended Topology", on page 22 in this handbook.
Table 4: Cabling
• Cyclic
• Acyclic
General Information
Chapter 1
Figure 1: Powerlink cycle
A Powerlink cycle begins with a Start of Cycle (SoC) which is used by the controllers for
synchronization. After this happens, the manager sends a poll request to the first station which
then answers with a poll response etc. All cS stations (cyclic Station) are addressed in each
cycle.
One station, Powerlink Manager, assigns the send time for the rest of the stations. All available
stations in the network must be configured on the manager.
Only the manager itself is active. All other stations, the Powerlink Controller, are only allowed to
send, if they are prompted by the manager. Each configured station is cyclically addressed by
the manager. That means that data is sent from the manager to the controller (Frame:
PollRequest), which then sends data as a broadcast in the network (Frame: PollResponse).
General Information
Chapter 1
Controllers are passive bus stations. These are only allowed to be sent when prompted by the
manager.
Each controller receives data from the manager in the Powerlink cycle (Frame: PollRequest) and
sends data back to this (Frame: PollResponse). PollRequests can only be received from the
addressed controller. However, PollResponse frames are sent by the controller as a broadcast.
As a result of this, it is possible for all other controllers to monitor the data being sent.
3. Firmware Update
Firmware can be updated for all Powerlink modules. See also the hardware description for the
module and the online help in B&R Automation Studio™: Powerlink - Firmware Update.
All Powerlink modules which support manager mode, can also be operated in controller mode
(e. g. IF686 and IF78x). The user must make certain configurations when operating in the
controller mode.
68k systems are all Powerlink modules which are based on Motorola (68k) (e. g. CP260, IF260,
CP476). The intelligent controller is configured with these 68k targets using the structure
PLSYSCONF_typ and PLSYSCONF_RS_typ (see online help in B&R Automation Studio™:
Powerlink - Library help).
x86 systems are all Powerlink modules which are based on the x86 (e. g. CP360, IPC). The user
configuration, e. g. for a CP360 (or another x86 target) operated in the controller mode, is
described in the online help for B&R Automation Studio: Powerlink - Controller mode.
The memory capacity of manager modules must be taken into consideration with very large
Powerlink applications. Memory size for manager modules: See the technical data for the
respective modules.
The memory requirements on the manager module are calculated from the sum of in/out data
for all controllers.
5.2.1 AC112
The memory requirements for the ACOPOS AC112 plug-in module is always the same size.
5.2.2 EX48x
The memory requirements for a 2003 EX48x bus controller depend on the system configuration.
General Information
Chapter 1
In this section, recommendations for Powerlink cycle times are given. The examples will show
how these can be determined.
The number for the maximum amount of stations is a B&R recommended value. More stations
can be used depending on the network topology or fewer, depending on the amount of data.
For 1 - 3 hub levels, B&R recommends the following maximum number of stations:
1) Sum of all stations located in a line structure. A maximum of 10 hubs in series is allowed. See also Section 7
"Recommended Topology", on page 22.
The following formula gives the maximum required total cycle time in µs depending on the
number of stations, the data to be transferred, and the number of hub levels:
T total = T con + T B + TL
max max
TL = ( n L2 – n L ) ⋅ T HL
max
Legend
Bytes Sum of the bytes sent from the manager to all controllers and back again (see Section "Sum of the Bytes sent",
on page 19)
n total Number of all controllers on the network
E Number of hub levels
nL Number of controllers in the longest line structure
General Information
Chapter 1
The sum of the bytes sent per station is computed from IN net data + overhead (28 bytes) and
OUT net data + overhead (28 bytes), but amounts to at least 64 bytes (minimum frame length
with Fast ETHERNET).
Configuration Phase
• What is the minimum Powerlink cycle time that should be set with the given hardware
configuration?
• Can a desired Powerlink cycle time be set with predefined hardware configuration?
• Which maximum configuration is achievable with a predefined Powerlink cycle time?
Example
In the following example, four PLC stations and four ACOPOS stations are integrated into one
Powerlink network. The minimum Powerlink cycle time to be set should be determined.
• 8 controllers
• 2 hub levels
• 4 controllers in the longest line structure
• Each station transfers the minimum amount of data
Network Topology
Note: The example is designed so that the tree topolgy comes before the line topology.
Conversely, all hubs in the line should be added to the hub levels. This avoids
delays in the cycle time (see also Section 7 "Recommended Topology", on
page 22).
Specification
General Information
n total = 8
Chapter 1
E = 2
nL = 4
T HT = 460 ns
T HL = 500 ns
T total = T con + T B + TL
max max
TL = ( n L2 – n L ) ⋅ T HL = ( 4 2 – 4 ) ⋅ 0.5 = 6 µs
max
The calculated total cycle time is 321.48 µs. The minimum Powerlink cycle time can therefore be
set to e. g. 400 µs.
7. Recommended Topology
In the Powerlink network (seen from the manager), the tree structure should always come first
followed then by the line structure. Otherwise the line structure delay affects the entire tree
beneath it.
Information:
Please note that a maximum of 10 hubs in series is permitted in a line structure.
Example
The following example contains three hub levels in a tree structure (E = 3). The longest line
structure contains seven hubs in series (nL = 7).
General Information
Chapter 1
It is possible in Automation Studio™ to have tasks run synchronous to the Powerlink cycle. Here,
there is a differentiation made between 68k (Motorola based systems) and x86 targets (x86
based systems).
Target Description
x86 All task classes run synchronously.
68k Only one task class (Timer#2) can run synchronously
Tasks which run synchronously with Powerlink are executed once every Powerlink cycle *
prescale factor.
Using the prescale factor, it is possible to start task classes in all Powerlink cycles rather than
only in each Powerlink cycle (see Figure 5 "Prescale factor"). The CPU load can then be
considerably reduced if actions do not have to be executed in each Powerlink cycle, .
General Information
Chapter 1
All task classes can operate synchronously to the Powerlink cycle on i386 targets (i. e. CP360).
For this purpose, it is necessary that all task classes cycle times are an integer multiple of the
Powerlink cycle time (e. g. Powerlink cycle = 400 µs -> Task1 = 4 ms, Task2 = 8 ms).
The desired Powerlink module must be selected as system timer under CPU -> Properties ->
Timing.
In the log book, a note is made whether the system is running synchronously or asynchronously .
On m68k targets (i. e. CP260, CP476, PP41), only one task class (Timer#2) can operate
synchronously.
The number of timer resources must be set to 2, in B&R Automation Studio™ under CPU ->
Properties -> Resources:
The task classes, which should run synchronously, must be added in the Timer#2 resource. The
General Information
trigger source can then be selected for the Timer#2 class (right mouse click -> Properties).
Chapter 1
Figure 10: Selecting the trigger source
The B&R SYSTEM 2003 bus can be operated synchronously with the Powerlink cycle. This
means that data is accepted at each new Powerlink cycle by the B&R SYSTEM 2003 bus.
After starting the EX481 or EX484, the default setting is asynchronous. This bus can be
configured as synchronous via Powerlink and using the asynchronous channel 251 (see also
online help in B&R Automation Studio™: Powerlink - Library).
Value Description
0 Selector = 7 = I/O bus mode request
1 Reserved 1
2 Reserved 2
3 Reserved 3
4 Mode
Table 13: Operating the B&R SYSTEM 2003 bus synchronous with the Powerlink cycle
Mode
Mode Description
0 Asynchronous mode
1 Synchronous mode
General Information
Chapter 1
Value Description
0 Selector = 8 = I/O bus mode response
1 Reserved 1
2 Reserved 2
3 Reserved 3
4 Mode (see Section "Mode", on page 28)
5 Reserved 1
6 Reserved 2
7 Reserved 3
8
9
Error number (0 for OK, see also Appendix A "Error Numbers")
10
11
Chapter 2 • Hardware
1. General Information
Chapter 2
Hardware
This chapter is in preparation.
1. Overview
Module Description
7EX481.50-1 2003 ETHERNET Powerlink bus controller, 1 ETHERNET Powerlink interface, 24 VDC, electrically isolated. Order TB704
terminal block separately.
7EX484.50-1 2003 ETHERNET Powerlink bus controller, 4 ETHERNET Powerlink interfaces, 24 VDC, electrically isolated. Order TB704
terminal block separately.
Modules
2. EX481
The EX481 module is a Powerlink bus controller module. It is equipped with an RJ45 connection.
Product ID EX481
General Information
C-UL-US Listed In preparation
Module Type B&R 2003 controller
Module Slot 1
Number of Modules that can be Used See Section 2.8 "Number of Modules that can be Used", on page 41
Peripherals
Diagnosis LEDs Yes
I/O Bus Interface 9 pin DSUB socket
Station Number Dial For setting the Powerlink station number
Product ID EX481
Power Supply
Design Switching power supply with reverse polarity diode
Input Voltage
Minimum 18 VDC
Nominal 24 VDC
Maximum 30 VDC
Power Consumption Max. 20 W
Output Power for I/O Modules and 13.4 W
Screw-in Modules
ETHERNET Powerlink Interface
Standard (Compliance) ANSI/IEEE 802.3
Data Rate 100 Mbps
Signal 100 Base-T
Port Design Shielded RJ45 port
Line Length Between Two Stations Max. 100 m
Chapter 3
Modules
Mechanical Characteristics
Dimensions B&R 2003 single width
Status LED
Boot Phase
The red LED is lit during the booting procedure. After selecting the boot block, the LED indicates
which block is being booted from:
The red LED goes out and the green LED is switched on after the initialization routines are
carried out with no errors.
Operation
Status LED
Green Red Status of the Powerlink Station
On Off The Powerlink station is running with no errors.
Off On A fatal system error has occurred. The error type can be read using the PLC log book. It concerns an
irreparable problem. The system cannot properly carry out its tasks. This status can only be changed
by resetting the module.
Blinking Alternately Powerlink Manager failed
Off Blinking System Failure. The red LED blinks an error code (see Section "System Failure Error Codes", on
page 37).
The error is displayed via the red status LED using four switch-on phases. The switch-on phases
are either 150 ms or 600 ms long. Error code outputs are repeated cyclically every 2 seconds.
Legend:
• 150 ms
− 600 ms
Pause 2 s delay
Chapter 3
• • − − • • − −
Modules
Invalid Memory Access During Instruction Fetch (e. g. UINT access of an uneven Pause Pause
address).
Data Access Memory Abort:
• − • • Pause • − • • Pause
Invalid Memory Access During Data Access (e. g. UINT access of an uneven address).
Error when Programming the FPGA. • − − • Pause • − − • Pause
Invalid Station Number (e. g. $00 for controller stations, and $FE, $FF) • − − − Pause • − − − Pause
Terminal Assignment
1 +24 VDC
2 +24 VDC
3 GND
4 GND
The station number for the Powerlink station is set using both number switches. Station numbers
are permitted between $01 and $FD.
Chapter 3
$01 - $FD Station number for Powerlink station.
Modules
$FE Reserved, switch position is not permitted.
$FF Reserved, switch position is not permitted.
Pin Assignment
1 RXD
2 RXD\
3 TXD
4 Termination
5 Termination
6 TXD\
7 Termination
8 Termination
Information:
The type (digital/analog) and number of modules determines the possible cycle
times for the nodes.
Modules
actual space required on the module rack. A module can also occupy several
module addresses (see technical data for the module).
The firmware update takes place via Powerlink (using the IF686 in an m68K target). The
firmware is contained in the .br module plfex481.br. The update is described in the online help
in B&R Automation Studio™: Powerlink - Firmware Update
3. EX484
The EX484 module is a Powerlink bus controller module. It is equipped with an internal hub with
four RJ45 connectors.
Product ID EX484
General Information
C-UL-US Listed In preparation
Module Type B&R 2003 controller
Module Slot 1
Number of Modules that can be Used See Section 3.8 "Number of Modules that can be Used", on page 49
Peripherals
Diagnosis LEDs Yes
I/O Bus Interface 9 pin DSUB socket
Station Number Dial For setting the Powerlink station number
Product ID EX484
Power Supply
Design Switching power supply with reverse polarity diode
Input Voltage
Minimum 18 VDC
Nominal 24 VDC
Maximum 30 VDC
Power Consumption Max. 20 W
Output Power for I/O Modules and Screw- 10.4 W
in Modules
ETHERNET Powerlink Interface
Standard (Compliance) ANSI/IEEE 802.3
Data Rate 100 Mbps
Signal 100 Base-T
Port Design Internal 4x hub
4 x shielded RJ45 port
Chapter 3
Modules
Mechanical Characteristics
Dimensions B&R 2003 single width
Status LED
Boot Phase
The red LED is lit during the booting procedure. After selecting the boot block, the LED indicates
which block is being booted from:
The red LED goes out and the green LED is switched on after the initialization routines are
carried out with no errors.
Operation
Status LED
Green Red Status of the Powerlink Station
On Off The Powerlink station is running with no errors.
Off On A fatal system error has occurred. The error type can be read using the PLC log book. It concerns an
irreparable problem. The system cannot properly carry out its tasks. This status can only be changed
by resetting the module.
Blinking Alternately Powerlink Manager failed
Off Blinking System Failure. The red LED blinks an error code (see Section "System Failure Error Codes", on
page 37).
The error is displayed via the red status LED using four switch-on phases. The switch-on phases
are either 150 ms or 600 ms long. Error code outputs are repeated cyclically every 2 seconds.
Legend:
• 150 ms
− 600 ms
Pause 2 s delay
Chapter 3
• • − − • • − −
Modules
Invalid Memory Access During Instruction Fetch (e. g. UINT access of an uneven Pause Pause
address).
Data Access Memory Abort:
• − • • Pause • − • • Pause
Invalid Memory Access During Data Access (e. g. UINT access of an uneven address).
Error when Programming the FPGA. • − − • Pause • − − • Pause
Invalid Station Number (e. g. $00 for controller stations, and $FE, $FF) • − − − Pause • − − − Pause
Terminal Assignment
1 +24 VDC
2 +24 VDC
3 GND
4 GND
The station number for the Powerlink station is set using both number switches. Station numbers
are permitted between $01 and $FD.
Chapter 3
$01 - $FD Station number for Powerlink station.
Modules
$FE Reserved, switch position is not permitted.
$FF Reserved, switch position is not permitted.
The four RJ45 ports are located on the bottom of the module.
Pin Assignment
1 RXD
2 RXD\
3 TXD
4 Termination
5 Termination
6 TXD\
7 Termination
8 Termination
Information:
The type (digital/analog) and number of modules determines the possible cycle
times for the nodes.
Modules
actual space required on the module rack. A module can also occupy several
module addresses (see technical data for the module).
The firmware update takes place via Powerlink (using the IF686 in an m68K target). The
firmware is contained in the .br module plfex484.br. The update is described in the online help
in B&R Automation Studio™: Powerlink - Firmware Update
1. Overview
Module Description
3IF686.9 2005 interface module, 1 ETHERNET Powerlink interface, manager or controller function, electrically isolated
3IF786.9 aPCI interface module, 1 ETHERNET Powerlink interface, manager or controller function, 1 RS232 interface
3IF787.9 aPCI interface module 1 ETHERNET Powerlink interface, manager or controller function, 1 CAN interface , max. 500 kbps,
object buffer in send and receive direction, network capable, electrically isolated. Order TB704 terminal blocks separately.
3IF789.9 aPCI interface interface module, 1 ETHERNET Powerlink Schnittstelle, manager or controller function, 1 X2X Link Master
interface, electrically isolated. Order TB704 terminal block separately.
1.1 Use
Chapter 4
Standard Interface Module IF686 e. g. CP260, IF260, IF060
Modules
aPCI Interface Module IF786, IF787, IF789 e. g. CP360, PP200
2. IF686
The module IF686 is a Powerlink interface module. It can be used as a manager or bus controller
module. The connection is made via an RJ45 port.
Product ID IF686
General Information
C-UL-US Listed In preparation
Slot Insert e.g. in CP260, IF260, IF060
Interface 1 x ETHERNET Powerlink
Power Consumption
5V Max. 1.76 W
24 V ---
Total Max. 1.76 W
ETHERNET Powerlink Interface
Standard (Compliance) ANSI/IEEE 802.3
In/Out Buffer 11 KByte
Data Rate 100 Mbps
Signal 100 Base-T
Port Design Shielded RJ45 port
Line Length Between Two Stations Max. 100 m
(Segment Length)
Modules
Boot Phase
The red LED is lit during the booting procedure. After selecting the boot block, the LED indicates
which block is being booted from:
The red LED goes out and the green LED is switched on after the initialization routines are
carried out with no errors.
Operation
Status LED
Green Red Status of the Powerlink Station
On Off The Powerlink station is running with no errors.
Off On A fatal system error has occurred. The error type can be read using the PLC log book. It concerns an
irreparable problem. The system cannot properly carry out its tasks. This status can only be changed
by resetting the module.
Blinking Alternately Powerlink Manager failed. This error code can only occur in bus controller operation. i.e. the set station
number lies within the range $01 - $FD.
Off Blinking System Failure. The red LED blinks an error code (see Section "System Failure Error Codes", on
page 55).
The error is displayed via the red status LED using four switch-on phases. The switch-on phases
are either 150 ms or 600 ms long. Error code outputs are repeated cyclically every 2 seconds.
Legend:
• 150 ms
− 600 ms
Pause 2 s delay
Chapter 4
Modules
The station number for the Powerlink station is set using both number switches. Station numbers
are permitted between $00 and $FD.
Pin Assignment
1 RXD
2 RXD\
3 TXD
4 Termination
5 Termination
6 TXD\
7 Termination
Chapter 4
Modules
Table 46: IF686 pin assignment for ETHERNET Powerlink interface
The firmware update takes place automatically via the CPU (see online help in B&R Automation
Studio™: Powerlink - Firmware Update). If an IF686 is operated in controller mode, then it can
only be updated locally and not via the Powerlink network.
3. IF786
The interface module IF786 is an aPCI module and can be installed in every corresponding
interface module slot e. g. in the CP360.
The IF786 is a Powerlink interface module. It can be used as a manager or bus controller
module. The connection is made via an RJ45 port.
Product ID IF786
General Information
C-UL-US Listed In preparation
Slot aPCI insert
Interfaces 1 x RS232
1 x ETHERNET Powerlink
Power Consumption
5V Max. 2.5 W
24 V ---
Total Max. 2.5 W
Application Interface IF1
Type RS232
Controller UART Type 16C550 compatible
FIFO 16 bytes in send and receive direction
Design 9 pin DSUB plug
Electrical Isolation No
Input Filter / Protective Circuit Yes
Maximum Distance 15 m / 19200 Baud
Maximum Baud Rate 115.2 kBaud
Handshake Lines RTS, CTS
Network Capable No
Chapter 4
Modules
Data Bits 5 to 8
Parity Yes / No / Even / Odd
Stop Bits 1/2
Application Interface IF2
Type ETHERNET Powerlink interface
Standard (Compliance) ANSI/IEEE 802.3
In/Out Buffer 20 KByte 1)
Data Rate 100 Mbps
Signal 100 Base-T
Port Design Shielded RJ45 port
Line Length Between Two Stations Max. 100 m
(Segment Length)
Status LED
Boot Phase
During booting the red LED is lit. The red LED goes out and the green LED is switched on after
the initialization routines are carried out with no errors.
Operation
Chapter 4
Modules
On Off The Powerlink station is running with no errors.
Off On A fatal system error has occurred. The error type can be read using the PLC log book. It concerns an
irreparable problem. The system cannot properly carry out its tasks. This status can only be changed
by resetting the module.
Blinking Alternately Powerlink Manager failed. This error code can only occur in bus controller operation. i.e. the set station
number lies within the range $01 - $FD.
Off Blinking System Failure. The red LED blinks an error code (see Section "System Failure Error Codes", on
page 62).
The error is displayed via the red status LED using four switch-on phases. The switch-on phases
are either 150 ms or 600 ms long. Error code outputs are repeated cyclically every 2 seconds.
Legend:
• 150 ms
− 600 ms
Pause 2 s delay
The station number for the Powerlink station is set using both number switches. Station numbers
are permitted between $00 and $FD.
Modules
Pin Assignment
1 RXD
2 RXD\
3 TXD
4 Termination
5 Termination
6 TXD\
7 Termination
8 Termination
Table 54: IF786 pin assignment for ETHERNET Powerlink interface (IF2)
The firmware is loaded from the x86 target during each start (e. g. CP360). To carry out a
Chapter 4
Modules
4. IF787
The interface module IF787 is an aPCI module and can be installed in every corresponding
interface module slot e. g. in the CP360.
The IF787 is a Powerlink interface module. It can be used as a manager or bus controller
module. The connection is made via an RJ45 port.
The module is also equipped with a CAN interface, with its own object buffers in send and
receive direction.
Information:
The 4 pin terminal block TB704 is not contained in the delivery!
Product ID IF787
General Information
C-UL-US Listed In preparation
Slot aPCI insert
Interfaces 1 x CAN
1 x ETHERNET Powerlink
Power Consumption
5V Max. 3 W
24 V ---
Total Max. 3 W
Application Interface IF1
Type CAN
Controller Controller SJA 1000
Design 4 pin multipoint connector
Electrical Isolation Yes
Maximum Distance 1,000 m
Maximum Baud Rate
Bus Length ≤60 m 500 kBit/s
Bus Length ≤200 m 250 kBit/s
Bus Length ≤1,000 m 50 kBit/s
Network Capable Yes
Bus Termination Resistor Optional (externally wired)
Chapter 4
Modules
Type ETHERNET Powerlink interface
Standard (Compliance) ANSI/IEEE 802.3
In/Out Buffer 20 KByte 1)
Data Rate 100 Mbps
Signal 100 Base-T
Port Design Shielded RJ45 port
Line Length Between Two Stations Max. 100 m
(Segment Length)
Status LED
Boot Phase
During booting the red LED is lit. The red LED goes out and the green LED is switched on after
the initialization routines are carried out with no errors.
Operation
Chapter 4
Modules
On Off The Powerlink station is running with no errors.
Off On A fatal system error has occurred. The error type can be read using the PLC log book. It concerns an
irreparable problem. The system cannot properly carry out its tasks. This status can only be changed
by resetting the module.
Blinking Alternately Powerlink Manager failed. This error code can only occur in bus controller operation. i.e. the set station
number lies within the range $01 - $FD.
Off Blinking System Failure. The red LED blinks an error code (see Section "System Failure Error Codes", on
page 70).
The error is displayed via the red status LED using four switch-on phases. The switch-on phases
are either 150 ms or 600 ms long. Error code outputs are repeated cyclically every 2 seconds.
Legend:
• 150 ms
− 600 ms
Pause 2 s delay
The station number for the Powerlink station is set using both number switches. Station numbers
are permitted between $00 and $FD.
Modules
Pin Assignment
1 RXD
2 RXD\
3 TXD
4 Termination
5 Termination
6 TXD\
7 Termination
8 Termination
Table 63: IF787 pin assignment for ETHERNET Powerlink interface (IF2)
The node number for the CAN interface (IF1) is set with the two hex switches.
The CAN node number can also be set by the software (in preparation).
A 120 Ω bus terminating resistor is included with delivery. The resistor can be inserted between
pin 1 and pin 3.
Chapter 4
4 Shield
Modules
500 kBit/s Bus Length: ≤60 m
250 kBit/s Bus Length: ≤200 m
50 kBit/s Bus Length: ≤1,000 m
The firmware is loaded from the x86 target during each start (e. g. CP360). To carry out a
firmware update on the CP360, see online help in B&R Automation Studio™: CP360 Firmware
Update.
5. IF789
The interface module IF789 is an aPCI module and can be installed in every corresponding
interface module slot e. g. in the CP360.
The IF789 is a Powerlink interface module. It can be used as a manager or bus controller
module. The connection is made via an RJ45 port.
Information:
The 4 pin terminal block TB704 is not contained in the delivery!
Product ID IF789
General Information
C-UL-US Listed In preparation
Slot aPCI insert
Interfaces 1 x X2X Link
1 x ETHERNET Powerlink
Power Consumption
5V Max. 2.8 W
24 V ---
Total Max. 2.8 W
Application Interface IF1
Type X2X Link - Master
Design 4 pin multipoint connector
Electrical Isolation Yes
Number of Stations Max. 253
Distance between Two Stations Max. 100 m
Network Topology Line
Internal Bus Supply No
Bus Termination Resistor Internal
Application Interface IF2
Type ETHERNET Powerlink interface
Chapter 4
Modules
In/Out Buffer 20 KByte 1)
Data Rate 100 Mbps
Signal 100 Base-T
Port Design Shielded RJ45 port
Line Length Between Two Stations Max. 100 m
(Segment Length)
Status LED
Boot Phase
During booting the red LED is lit. The red LED goes out and the green LED is switched on after
the initialization routines are carried out with no errors.
Operation
Chapter 4
Modules
On Off The Powerlink station is running with no errors.
Off On A fatal system error has occurred. The error type can be read using the PLC log book. It concerns an
irreparable problem. The system cannot properly carry out its tasks. This status can only be changed
by resetting the module.
Blinking Alternately Powerlink Manager failed. This error code can only occur in bus controller operation. i.e. the set station
number lies within the range $01 - $FD.
Off Blinking System Failure. The red LED blinks an error code (see Section "System Failure Error Codes", on
page 78).
The error is displayed via the red status LED using four switch-on phases. The switch-on phases
are either 150 ms or 600 ms long. Error code outputs are repeated cyclically every 2 seconds.
Legend:
• 150 ms
− 600 ms
Pause 2 s delay
The station number for the Powerlink station is set using both number switches. Station numbers
are permitted between $00 and $FD.
Modules
Pin Assignment
1 RXD
2 RXD\
3 TXD
4 Termination
5 Termination
6 TXD\
7 Termination
8 Termination
Table 72: IF789 pin assignment for ETHERNET Powerlink interface (IF2)
The firmware is loaded from the x86 target during each start (e. g. CP360). To carry out a
firmware update on the CP360, see online help in B&R Automation Studio™: CP360 Firmware
Update.
Modules
1. Overview
Module Description
8AC112.60-1 ACOPOS plug-in module, ETHERNET Powerlink interface
ACOPOS Powerlink
Chapter 5
Modules
The AC112 plug-in module can be used in an ACOPOS slot. The module is equipped with an
ETHERNET Powerlink interface. This fieldbus interface is used for communication and setting
parameters on the ACOPOS servo drive for complex and time critical applications.
The plug-in module is set up as a 2x hub. This makes it easy to establish a device to device
connection (line topology).
Product ID 8AC112.60-1
General Information
C-UL-US Listed Yes
Module Type ACOPOS plug-in module
Slot Currently limited to slot 1
Power Consumption Max. 2.5 W
Powerlink Interface
Connection, Module Side 2 x RJ45 socket
Indications Status LEDs
Electrical Isolation Yes
ETHERNET - ACOPOS
Maximum Distance per Segment 100 m 1)
Baud Rate 100 Mbit/s
Network Capable Yes
Hub, 2x Yes
Operational Conditions
Environment Temperature during 0 to 50 °C
Operation
Relative Humidity during Operation 5 to 95 %, non-condensing
Storage and Transport Conditions
Storage Temperature -25 to +55 °C
Relative Humidity for Storage 5 to 95 %, non-condensing
Transport Temperature -25 to +70 °C
Relative Humidity for Transport 95 % at 40 °C, non-condensing
1) With a cycle time of 400 µs and 10 ACOPOS servo drives, the maximum total cable length is 200 m. ACOPOS Powerlink
Modules
The Powerlink node number can be set using two HEX code switches:
Table 77: Setting the Powerlink node number with the two HEX code switches
Changing the node number becomes active the next time the ACOPOS servo drive is switched
on.
The status is indicated on the AC112 using one green and one red LED.
LED Test
Immediately after resetting the module, both LEDs are switched off for 0.5 s, then switched on
for 1.5 s.
Then the green LED is cleared for one second and the following boot procedure. After proper
initialization, the red LED is switched off and the green LED is switched on.
1) This is a problem which cannot be repaired, the system can no longer carry out tasks correctly. This status can only be changed by
resetting the module.
2) The red LED blinks an error code, the output of the error code occurs in 4 short (150 ms) or long (600 ms) phases.
Pause: 2000 ms
Error Display
Stack Overflow
RAM Error
Undefined Address 1)
Instruction Fetch Memory Abort 2)
Data Access Memory Abort 3)
Assertion Failed 4)
Programming Failed 5)
The firmware is part of the operating system for the ACOPOS servo drives.
ACOPOS Powerlink
Chapter 5
Modules
1. General Information
1) The base error number (Error) specifies the actual error. It is entered into the PLC log book.
2) The error number (Information) is an extension of the base error number and describes it
more exactly.
Example: The manager loses connection to the controllers (carrier lost) -> log book entry:
Figure Index
Figure 3: Topology for the calculation example ....................................................................... 20
Figure 4: Recommended topology........................................................................................... 22
Figure 5: Prescale factor.......................................................................................................... 23
Figure 6: Set the cycle time and the prescale factor................................................................ 24
Figure 7: Selecting the desired Powerlink module................................................................... 25
Figure 8: The system status can be checked in the log book.................................................. 25
Figure 9: Setting timer resources............................................................................................. 26
Figure 10: Selecting the trigger source.................................................................................... 27
Figure 11: EX481 power supply............................................................................................... 38
Figure 12: EX481 station number dial ..................................................................................... 39
Figure 13: EX481 RJ45 port .................................................................................................... 40
Figure 14: EX484 power supply............................................................................................... 46
Figure 15: EX484 station number dial ..................................................................................... 47
Figure 16: EX484 RJ45 port .................................................................................................... 48
Figure 17: IF686 operational and connection elements........................................................... 53
Figure 18: IF686 station number switch................................................................................... 56
Figure 19: IF686 ETHERNET Powerlink interface................................................................... 57
Figure 20: IF786 operational and connection elements........................................................... 60
Figure 21: IF786 station number switch................................................................................... 63
Figure 22: IF786 ETHERNET Powerlink interface (IF2) .......................................................... 64
Figure 23: IF787 operational and connection elements........................................................... 68
Figure 24: IF787 ETHERNET Powerlink station number switch.............................................. 71
Figure 25: IF787 ETHERNET Powerlink interface (IF2) .......................................................... 72
Figure 26: IF787 CAN node number switch............................................................................. 73
Figure 27: IF789 operational and connection elements........................................................... 76
Figure 28: IF789 station number switch................................................................................... 79
Figure 29: IF789 ETHERNET Powerlink interface (IF2) .......................................................... 80
Figure 30: Status LEDs AC112................................................................................................ 86
Figure 31: The error number is entered into the log book ....................................................... 89
Table Index
Table 11: Minimum data amount depending on the station type ............................................. 19
Table 12: Task classes synchronous to the Powerlink cycle................................................... 23
Table 13: Operating the B&R SYSTEM 2003 bus synchronous with the Powerlink cycle ...... 28
Table 14: Asynchronous or synchronous mode for 2003 bus ................................................. 28
Table 15: Read-back data ....................................................................................................... 29
Table 16: Overview of B&R2003 Powerlink modules .............................................................. 33
Table 17: EX481 order data..................................................................................................... 34
Table 18: EX481 technical data............................................................................................... 34
Table 19: EX481 status display ............................................................................................... 35
Table 20: EX481 boot block indicator ...................................................................................... 36
Table 21: EX481 status LED ................................................................................................... 36
Table 22: EX481 system failure error codes............................................................................ 37
Table 23: EX481 terminal assignment 24 VDC supply............................................................ 38
Table 24: EX481 station number ............................................................................................. 39
Table 25: EX481 pin assignments for RJ45 port ..................................................................... 40
Table 26: EX481 number of modules that can be used........................................................... 41
Table 27: EX484 order data..................................................................................................... 42
Table 28: EX484 technical data............................................................................................... 42
Table 29: EX484 status display ............................................................................................... 43
Table 30: EX484 boot block indicator ...................................................................................... 44
Table 31: EX484 status LED ................................................................................................... 44
Table 32: EX484 system failure error codes............................................................................ 45
Table 33: EX484 terminal assignment 24 VDC supply............................................................ 46
Table 34: EX484 station number ............................................................................................. 47
Table 35: EX484 pin assignments for RJ45 port ..................................................................... 48
Table 36: EX484 number of modules that can be used........................................................... 49
Table 37: Overview of B&R2005 Powerlink modules .............................................................. 51
Table 38: Using B&R2005 Powerlink modules ........................................................................ 51
Table 39: IF686 order data ...................................................................................................... 52
Table 40: IF686 technical data ................................................................................................ 53
Table 41: IF686 status display................................................................................................. 54
Table 42: IF686 boot block indicator........................................................................................ 54
Table 43: IF686 status LED ..................................................................................................... 54
Table 44: IF686 system failure error codes ............................................................................. 55
Table 45: IF686 station number............................................................................................... 56
Table 46: IF686 pin assignment for ETHERNET Powerlink interface ..................................... 57
Table 47: IF786 order data ...................................................................................................... 58
A L
AC112.........................................................84 Line Topology ............................................. 17
B M
B&R SYSTEM 2003 Bus ............................28 Manager ..................................................... 14
Bus Controller Module Manager Module
AC112 .....................................................84 IF686 ....................................................... 52
EX481......................................................34 IF786 ....................................................... 58
EX484......................................................42 IF787 ....................................................... 66
IF686 .......................................................52 IF789 ....................................................... 74
IF786 .......................................................58 Manual History............................................ 11
IF787 .......................................................66
IF789 .......................................................74
N
C Number of Powerlink Stations .................... 17
Number of Stations..................................... 17
Cabling........................................................12
Index
Calculating the Memory Size ......................16
Controller ....................................................15
P
Cycle...........................................................13 Powerlink
B&R SYSTEM 2003 Bus......................... 28
E Cabling .................................................... 12
Calculating the Memory Size .................. 16
Error Numbers ............................................89 Controller................................................. 15
EX481 .........................................................34 Cycle ....................................................... 13
EX484 .........................................................42 Definition ................................................. 11
Diagram................................................... 14
Error Numbers......................................... 89
F
Firmware Update..................................... 15
Firmware Update ........................................15 Function Principle.................................... 12
Function Principle .......................................12 Line Topology.......................................... 17
Manager .................................................. 14
Network ................................................... 14
H Number of Stations ................................. 17
History.........................................................11 Prescaler: ................................................ 23
Properties................................................ 12
Synchronizing Task Classes ................... 23
I Synchronous B&R SYSTEM 2003 Bus... 28
Synchronous Task Classes..................... 23
IF686...........................................................52
Technical Data ........................................ 11
IF786...........................................................58
Tree Topology ......................................... 17
IF787...........................................................66
Powerlink Definition .................................... 11
IF789...........................................................74
Powerlink Network Diagram ....................... 14
Prescaler: ................................................... 23
S T
Synchronizing Task Classes.......................23 Topology
Synchronous B&R SYSTEM 2003 Bus ......28 Line Topology.......................................... 17
Synchronous Task Classes ........................23 Tree Topology ......................................... 17
Tree Topology ............................................ 17
3 7
3IF686.9 ....................................................52 7EX481.50-1 ............................................. 34
3IF786.9 ....................................................58 7EX484.50-1 ............................................. 42
3IF787.9 ....................................................66
3IF789.9 ....................................................74
8
8AC112.60-1 ............................................. 84