ETHERNET Powerlink: User's Manual

ETHERNET Powerlink
User's Manual
Version: 1.0 (August 2002)

Mod. No.: MAPLINK-E
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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registered by the respective companies.
ETHERNET Powerlink User's Manual 1

2 ETHERNET Powerlink User's Manual
Chapter 1: General Information
Chapter 2: Hardware
Chapter 3: B&R 2003 Powerlink Modules
Chapter 4: B&R 2005 Powerlink Modules
Chapter 5: ACOPOS Powerlink Modules
Appendix A: Error Numbers

Figure Index
Table Index
Index
Model Number Index

Table of Contents
Chapter 1: General Information ..................................................... 11

1. Manual History .................................................................................................................... 11
2. Introduction ......................................................................................................................... 11
2.1 Powerlink Definition ....................................................................................................... 11
2.2 Technical Data .............................................................................................................. 11
2.2.1 General Information ................................................................................................ 11
2.2.2 Properties ................................................................................................................ 12
2.2.3 Cabling ................................................................................................................... 12
2.3 General Function Principle ............................................................................................ 12
2.3.1 Powerlink Cycle .................................................................................................... 13
2.3.2 Powerlink Network Diagram .................................................................................. 14
2.3.3 Powerlink Manager ................................................................................................. 14
2.3.4 Powerlink Controller ................................................................................................ 15
3. Firmware Update ................................................................................................................ 15
4. User Configuration for the Controller Mode ........................................................................ 15
4.1 General Information ....................................................................................................... 15
4.2 68k Systems .................................................................................................................. 15
4.3 x86 Systems .................................................................................................................. 15
5. Calculation of the Memory Size .......................................................................................... 16
5.1 Memory Requirements .................................................................................................. 16
5.2 Examples for In/Out Data Sizes .................................................................................... 16
5.2.1 AC112 ..................................................................................................................... 16
5.2.2 EX48x ..................................................................................................................... 16
6. Calculating the Cycle Time ................................................................................................. 17
6.1 Maximum Number of Stations ....................................................................................... 17
6.1.1 Tree Topology ......................................................................................................... 17
6.1.2 Line Topology ......................................................................................................... 17
6.2 Calculating the Cycle Time ............................................................................................ 18
6.2.1 Calculation Formula ................................................................................................ 18
6.2.2 Calculation Example ............................................................................................... 19
7. Recommended Topology .................................................................................................... 22
8. Synchronous Task Classes ................................................................................................ 23
8.2 x86 Targets ................................................................................................................... 25
8.3 68k Targets ................................................................................................................... 26
9. Synchronous B&R SYSTEM 2003 Bus .............................................................................. 28
Chapter 2: Hardware ....................................................................... 31

1. General Information ............................................................................................................ 31
Chapter 3: B&R 2003 Powerlink Modules ..................................... 33

1. Overview ............................................................................................................................. 33
2. EX481 ................................................................................................................................. 34
2.2 Order Data ..................................................................................................................... 34

Table of Contents
2.3 Technical Data .............................................................................................................. 34

2.4 Status Display ............................................................................................................... 35
2.5 Power Supply .............................................................................................................. 38
2.6 ETHERNET Powerlink Station Number ........................................................................ 39
2.7 RJ45 Port ...................................................................................................................... 40
2.8 Number of Modules that can be Used ......................................................................... 41
2.9 Firmware Update ........................................................................................................... 41
3. EX484 ................................................................................................................................. 42
3.2 Order Data ..................................................................................................................... 42
3.3 Technical Data .............................................................................................................. 42
3.4 Status Display ............................................................................................................... 43
3.5 Power Supply .............................................................................................................. 46
3.6 ETHERNET Powerlink Station Number ........................................................................ 47
3.7 RJ45 Ports ..................................................................................................................... 48
3.8 Number of Modules that can be Used ......................................................................... 49
3.9 Firmware Update ........................................................................................................... 49
Chapter 4: B&R 2005 Powerlink Modules ..................................... 51

1. Overview ............................................................................................................................. 51
1.1 Use ................................................................................................................................ 51
2. IF686 ................................................................................................................................... 52
2.2 Order Data ..................................................................................................................... 52
2.3 Technical Data .............................................................................................................. 53
2.4 Operational and Connection Elements .......................................................................... 53
2.5 Status Display ............................................................................................................... 54
2.5.1 Status LED .............................................................................................................. 54
2.6 ETHERNET Powerlink Station Number ...................................................................... 56
2.7 ETHERNET Powerlink Interface ................................................................................ 57
2.8 Firmware Update ........................................................................................................... 57
3. IF786 ................................................................................................................................... 58
3.2 Order Data ..................................................................................................................... 58
3.3 Technical Data .............................................................................................................. 59
3.5 Status Display ............................................................................................................... 60
3.5.1 RS232 Interface ...................................................................................................... 60
3.5.2 ETHERNET Powerlink Interface ............................................................................. 61
3.7 ETHERNET Powerlink Interface (IF2) ........................................................................ 64
3.8 RS232 Interface (IF1) .................................................................................................... 65
3.9 Firmware Update ........................................................................................................... 65
4. IF787 ................................................................................................................................... 66
4.2 Order Data ..................................................................................................................... 66

Table of Contents
4.3 Technical Data .............................................................................................................. 67

4.5 Status Display ............................................................................................................... 68
4.5.1 CAN Interface ......................................................................................................... 68
4.8 CAN Node Number ....................................................................................................... 73
4.9 CAN Interface (IF1) ....................................................................................................... 73
4.10 Firmware Update ......................................................................................................... 73
5. IF789 ................................................................................................................................... 74
5.2 Order Data ..................................................................................................................... 74
5.3 Technical Data .............................................................................................................. 75
5.5 Status Display ............................................................................................................... 76
5.5.1 X2X Link Interface ................................................................................................... 76
5.8 X2X Link Interface (IF1) ................................................................................................ 80
5.9 Firmware Update ........................................................................................................... 81
Chapter 5: ACOPOS Powerlink Modules ...................................... 83

1. Overview ............................................................................................................................. 83
2. AC112 - ETHERNET Powerlink Interface ........................................................................... 84
2.1 General Description ....................................................................................................... 84
2.2 Order Data ..................................................................................................................... 84
2.3 Technical Data .............................................................................................................. 85
2.4 Powerlink Node Number Setting ................................................................................... 85
2.5 Status LEDs .................................................................................................................. 86
2.6 Firmware Update ........................................................................................................... 87
Appendix A: Error Numbers .......................................................... 89

1. General Information ............................................................................................................ 89
2. Base Error Numbers (Error) .............................................................................................. 89
3. Error Numbers (Information) ............................................................................................. 90

Table of Contents

General Information • Manual History
General Information
Chapter 1
Chapter 1 • General Information
1. Manual History
Version Date Model No. and Product ID. Comments

1.0 August 2002 MAPLINK-E First Edition
ETHERNET Powerlink User's Manual
Table 1: Manual history
2. Introduction
2.1 Powerlink Definition
ETHERNET Powerlink is a strict, deterministic real-time protocol based on Fast ETHERNET

(100 MBit). Asynchronous communication between the network nodes is supported along with
time-isochronous transfer of cyclic PLC, I/O and Motion data. A part of network bandwidth is
reserved for this purpose.
2.2 Technical Data
2.2.1 General Information
Transfer Standard Fast ETHERNET, IEEE 802.3u, 100Base-TX

Data Transfer Rate 100 Mbps
Protocol Slot Communication Network Management (SCNM)
Communication Types Supported Cycle Class#1 cyclic (cS), non-cyclic
Minimum Net Data per Station 1 bytes
Minimum Net Data per Station 1500 bytes
Number of Stations per Powerlink Max. 253 (depends on the memory structure of the manager module)
Network
Cycle Times Can be configured (in 1 µs intervals up to a maximum of 65 ms)
Number of Stations when using 400 µs 8 cS cyclic stations (for 80 byte net data/station)
Cycle Time
Number of Stations when using 800 µs 22 cS cyclic stations (for 80 byte net data/station)
Cycle Time
Table 2: Technical data

General Information • Introduction
2.2.2 Properties
Possible Station Operating Modes Synchronous, asynchronous to Powerlink cycle

Hardware Watchdog Function Yes
Software Watchdog Function Yes
Electrical Isolation
Powerlink Interface - Network Yes
Table 3: Properties
2.2.3 Cabling
General recommendations for cabling ETHERNET in industrial environments should be adhered

to (see IAONA Europe: "Industrial ETHERNET Planning and Installation Guide", www.iaona-
eu.com).
Particularly:
• Cables
• System installation
ETHERNET Powerlink topology guidelines should be adhered to: See Section 7
"Recommended Topology", on page 22 in this handbook.
Segment Length (distance between Maximum 100 m

modules)
Maximum Hub Levels 10; See Section 7 "Recommended Topology", on page 22
Cabling Topology Star or tree with level 2 hubs
Cable Twisted pair, S/UTP, AWG26
Cable Type Category 5 patch cable (crossover cable), one cable type for all connections
Table 4: Cabling
2.3 General Function Principle
Two types of data traffic are possible on the Powerlink network:
• Cyclic
• Acyclic

2.3.1 Powerlink Cycle
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.
Cyclic communication terminates with an End of Cycle (EoC). Asynchronous communication

then follows. That means the manager sends data to a station or prompts it to send data.

2.3.2 Powerlink Network Diagram
Figure 2: Powerlink network diagram
2.3.3 Powerlink Manager
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).
Only one manager is allowed in a Powerlink network.

General Information • Firmware Update
2.3.4 Powerlink Controller
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.
4. User Configuration for the Controller Mode
4.1 General Information
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.
4.2 68k Systems
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).
4.3 x86 Systems
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.

General Information • Calculation of the Memory Size
5. Calculation of the Memory Size
5.1 Memory Requirements
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.
Data Memory Requirements on the Manager Remark

Module
In Data 28 bytes overhead + In data In data is rounded off to multiples of 4.
The minimum ETHERNET frame length is 64 bytes. If the sum of the
Header and In data is <64, it must be still calculated with 64 bytes.
Out Data 24 bytes overhead + Out data Out data is rounded off to multiples of 4.
The 64 byte rule should not be used with Out data.
Table 5: Memory requirements
5.2 Examples for In/Out Data Sizes
5.2.1 AC112
The memory requirements for the ACOPOS AC112 plug-in module is always the same size.
Data Memory Requirements on the Module

In Data 84 bytes
Out Data 56 bytes
Table 6: Memory requirements for an AC112 module
5.2.2 EX48x
The memory requirements for a 2003 EX48x bus controller depend on the system configuration.
Bytes In Bytes Out

Analog In per Channel 2 ---
Analog Out per Channel --- 2
Digital In per Module 2 ---
Digital Out per Module --- 1
Digital Mixed per Module: 8 In / 8 Out 2 1
Digital Mixed per Module: 16 In / 16 Out, e. g. DM465 4 2
Table 7: Memory requirements for an EX48x module

General Information • Calculating the Cycle Time
6. Calculating the Cycle Time
General Information
Chapter 1
In this section, recommendations for Powerlink cycle times are given. The examples will show
how these can be determined.
6.1 Maximum Number of Stations
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.
Basis for the Recommendation: 100 Byte data in each direction
6.1.1 Tree Topology
For 1 - 3 hub levels, B&R recommends the following maximum number of stations:
Cycle Time [µs] 400 800 1200 1600 2000

Maximum Number of Stations 9 26 42 56 72
Table 8: Maximum number of stations in tree topology
6.1.2 Line Topology
Cycle Time [µs] 400 800 1200 1600 2000

Maximum Number of Stations 9 19 1) 27 1) 35 1) 41 1)
Table 9: Maximum number of stations in tree topology
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.

6.2 Calculating the Cycle Time
6.2.1 Calculation Formula
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
Formulas for Section Times
T Con = ( T S + T A ) + 7.76 ⋅ n total + 0.08 ⋅ bytes

TB = ( 2 ⋅ E ⋅ n total ) ⋅ T HT
max
TL = ( n L2 – n L ) ⋅ T HL
max
Legend
Symbol Value Description

TS 45 µs Start latency
TA 90 µs Asynchronous slot
T HL 500 ns Hub delay in the line structure. For modules with two ports (e. g. AC112 and EX282).
T HT 460 ns Hub delay in the tree structure. For modules with more than two ports (e. g. EX484 and AC808).
T total Total maximum cycle time [µs]
T con Constant cycle time share for communication [µs]
TB Sum of the hub delay in the tree structure [µs]
max
TL Sum of the hub delay in the line structure [µs]

max
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
Table 10: Legend for calculating the cycle time

Sum of the Bytes sent
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).
Station Minimum Data Amount: In/Out Net Data + Overhead

PLC 128 bytes
ACOPOS 196 bytes
Table 11: Minimum data amount depending on the station type
6.2.2 Calculation Example
Configuration Phase
Generally, the following questions arise when configuring Powerlink applications:
• 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.
The network has the following technical data
• 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).
Figure 3: Topology for the calculation example

Specification
General Information
n total = 8
Chapter 1
E = 2
nL = 4
T HT = 460 ns
T HL = 500 ns
Sum of the Bytes sent
Bytes = 4 · PLC station + 4 · ACOPOS station = 4 · 128 + 4 · 196 = 1296
Total Cycle Time
T total = T con + T B + TL
max max
Constant Cycle Time Share
T con = ( T S + T A ) + 7.76 ⋅ n total + 0.08 ⋅ bytes

T con = ( 45 + 90 ) + 7.76 ⋅ 8 + 0.08 ⋅ 1296
T con = 300.76µs
Delay in the Tree Structure
TB = ( 2 ⋅ E ⋅ n total ) ⋅ T HT = ( 2 ⋅ 2 ⋅ 8 ) ⋅ 0.46 = 14.72µs

max
Delay in the Line Structure
TL = ( n L2 – n L ) ⋅ T HL = ( 4 2 – 4 ) ⋅ 0.5 = 6 µs
max
Total Cycle Time
T total = T con + T B + TL = 300.76 + 14.72 + 6 = 321.48µs

max max
The calculated total cycle time is 321.48 µs. The minimum Powerlink cycle time can therefore be
set to e. g. 400 µs.

General Information • Recommended Topology
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).
Figure 4: Recommended topology

General Information • Synchronous Task Classes
8. Synchronous Task Classes
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
Table 12: Task classes synchronous to the Powerlink cycle
Tasks which run synchronously with Powerlink are executed once every Powerlink cycle *
prescale factor.
Cycle Time: Period duration for the Powerlink cycle
Prescale Factor: Prescale factor for synchronous mode
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, .
Figure 5: Prescale factor

Set the cycle time and the prescale factor:
• Click on the Powerlink module in the hardware tree

• Click on the "Powerlink" tab in the right-hand window
• Set the cycle time and the prescale factor
Figure 6: Set the cycle time and the prescale factor

8.2 x86 Targets
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.
Figure 7: Selecting the desired Powerlink module
In the log book, a note is made whether the system is running synchronously or asynchronously .
Figure 8: The system status can be checked in the log book

8.3 68k Targets
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:
Figure 9: Setting timer 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

General Information • Synchronous B&R SYSTEM 2003 Bus
9. Synchronous B&R SYSTEM 2003 Bus
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).
The following values are to be transferred to the buffer
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
Table 14: Asynchronous or synchronous mode for 2003 bus

The following data is read back
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
Table 15: Read-back data
Example: See online help in B&R Automation Studio™:

Powerlink - Synchronous 2003 Bus


Hardware • General Information
Chapter 2 • Hardware
1. General Information
Chapter 2
Hardware
This chapter is in preparation.

Hardware • General Information

B&R 2003 Powerlink Modules • Overview •
Chapter 3 • B&R 2003 Powerlink Modules
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.
Table 16: Overview of B&R2003 Powerlink modules
B&R 2003 Powerlink

Chapter 3
Modules

B&R 2003 Powerlink Modules • EX481 • General Information
2. EX481
The EX481 module is a Powerlink bus controller module. It is equipped with an RJ45 connection.
2.2 Order Data
Model Number Short Description Image

7EX481.50-1 2003 ETHERNET Powerlink bus controller,
1 ETHERNET Powerlink interface, 24 VDC, electrically
isolated. Order TB704 terminal block separately.
0TB704.9 Accessory terminal block, 4 pin, screw clamp, 1.5 mm²
0TB704.91 Accessory terminal block, 4 pin, cage clamp, 2.5 mm²
Table 17: EX481 order data
2.3 Technical Data
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
Table 18: EX481 technical data

B&R 2003 Powerlink Modules • EX481 • Status Display
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
B&R 2003 Powerlink

(Segment Length)
Chapter 3
Modules
Mechanical Characteristics
Dimensions B&R 2003 single width
Table 18: EX481 technical data (cont.)
2.4 Status Display
Image LED Color Description

Status Red/Green See Section "Status LED", on page 36.
OK Orange The OK LED is controlled by the supply and is lit if the supply voltage
is over +18 VDC.
TX Orange The Powerlink station is sending data.
RX Orange The RX LED is always lit when Powerlink activity is present on the bus.
L/C Red/Green Green: Link
Red: Collision
Table 19: EX481 status display

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:
Red LED Boot Block

Blinking Slowly Twice A
Blinking Slowly Three Times B
Table 20: EX481 boot block indicator
The red LED goes out and the green LED is switched on after the initialization routines are
carried out with no errors.
Operation
During operation, the status LED indicate the following states:
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).
Table 21: EX481 status LED

System Failure Error Codes
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
Description of Error Error Code Displayed by Red Status LED

Stack Overflow • • • • Pause • • • • Pause
RAM Error • • • − Pause • • • − Pause
Undefined Address:
• • − • Pause • • − • Pause
Access to a Non-Existent Address.
B&R 2003 Powerlink

Instruction Fetch Memory Abort:
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
Table 22: EX481 system failure error codes

B&R 2003 Powerlink Modules • EX481 • Power Supply
2.5 Power Supply
Both '+' and − pins are connected to each other internally
Figure 11: EX481 power supply
Terminal Assignment
1 +24 VDC
2 +24 VDC
3 GND
4 GND
Table 23: EX481 terminal assignment 24 VDC supply

B&R 2003 Powerlink Modules • EX481 • ETHERNET Powerlink Station Number
2.6 ETHERNET Powerlink Station Number
Figure 12: EX481 station number dial
The station number for the Powerlink station is set using both number switches. Station numbers
are permitted between $01 and $FD.
Switch Position Description
B&R 2003 Powerlink

$00 Reserved for manager station, switch position is not permitted.
Chapter 3
$01 - $FD Station number for Powerlink station.
Modules
$FE Reserved, switch position is not permitted.
$FF Reserved, switch position is not permitted.
Table 24: EX481 station number

B&R 2003 Powerlink Modules • EX481 • RJ45 Port
2.7 RJ45 Port
The RJ45 port is located on the module.
Figure 13: EX481 RJ45 port
Pin Assignment
1 RXD
2 RXD\
3 TXD
4 Termination
5 Termination
6 TXD\
7 Termination
8 Termination
Table 25: EX481 pin assignments for RJ45 port
RXD ... Receive Data TXD ... Transmit Data

B&R 2003 Powerlink Modules • EX481 • Number of Modules that can be Used
2.8 Number of Modules that can be Used
Controller Maximum Number of Maximum Number of Possible Module Addresses

Logical Module Slots1) Analog Module Slots 1) for Analog Modules2)
EX481 16 8 1-8
Table 26: EX481 number of modules that can be used
1) Warning: Please take note of the power output table.

2) All analog modules and modules with logical analog sections must be operated directly next to the controller,
that means they must be inserted to the left of the first digital module. Module slot 1 is occupied by the
controller. The first slot to the right of a controller has module address 1 and the module addresses are
numbered in increasing order to the right.
Information:
The type (digital/analog) and number of modules determines the possible cycle
times for the nodes.
B&R 2003 Powerlink

Chapter 3
The module slot does not correspond to the module address, it only refers to the
Modules
actual space required on the module rack. A module can also occupy several
module addresses (see technical data for the module).
2.9 Firmware Update
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

B&R 2003 Powerlink Modules • EX484 • General Information
3. EX484
The EX484 module is a Powerlink bus controller module. It is equipped with an internal hub with
four RJ45 connectors.
3.2 Order Data

7EX484.50-1 2003 ETHERNET Powerlink bus controller,
4 ETHERNET Powerlink interfaces, 24 VDC, electrically
isolated. Order TB704 terminal block separately.
0TB704.9 Accessory terminal block, 4 pin, screw clamp, 1.5 mm²
0TB704.91 Accessory terminal block, 4 pin, cage clamp, 2.5 mm²
Table 27: EX484 order data
3.3 Technical Data
Product ID EX484
General Information
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
Table 28: EX484 technical data

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
Data Rate 100 Mbps
Signal 100 Base-T
Port Design Internal 4x hub
4 x shielded RJ45 port
B&R 2003 Powerlink

(Segment Length)
Chapter 3
Modules
Mechanical Characteristics
Dimensions B&R 2003 single width
Table 28: EX484 technical data (cont.)
3.4 Status Display

OK Orange The OK LED is controlled by the supply and is lit if the
supply voltage is over +18 VDC.
TX Orange The Powerlink station is sending data.
RX Orange The RX LED is always lit when Powerlink activity is present
on the bus.
L/C Red/Green Green:Link
Red:Collision
Table 29: EX484 status display

Status LED
Boot Phase
Red LED Boot Block

Table 30: EX484 boot block indicator
Operation
Status LED
Blinking Alternately Powerlink Manager failed
page 37).
Table 31: EX484 status LED

Legend:
• 150 ms
− 600 ms
Pause 2 s delay
Description of Error Error Code displayed by Red Status LED

Undefined Address:
• • − • Pause • • − • Pause
B&R 2003 Powerlink

Chapter 3
• • − − • • − −
Modules
Invalid Memory Access During Instruction Fetch (e. g. UINT access of an uneven Pause Pause
address).
• − • • Pause • − • • Pause
Invalid Station Number (e. g. $00 for controller stations, and $FE, $FF) • − − − Pause • − − − Pause
Table 32: EX484 system failure error codes

B&R 2003 Powerlink Modules • EX484 • Power Supply
3.5 Power Supply
Both '+' and − pins are connected to each other internally
Figure 14: EX484 power supply
Terminal Assignment
1 +24 VDC
2 +24 VDC
3 GND
4 GND
Table 33: EX484 terminal assignment 24 VDC supply

B&R 2003 Powerlink Modules • EX484 • ETHERNET Powerlink Station Number
Figure 15: EX484 station number dial
B&R 2003 Powerlink

$00 Reserved for manager station, switch position is not permitted.
Chapter 3
$01 - $FD Station number for Powerlink station.
Modules
Table 34: EX484 station number

B&R 2003 Powerlink Modules • EX484 • RJ45 Ports
3.7 RJ45 Ports
The four RJ45 ports are located on the bottom of the module.
Figure 16: EX484 RJ45 port
Pin Assignment
1 RXD
2 RXD\
3 TXD
4 Termination
5 Termination
6 TXD\
7 Termination
8 Termination
Table 35: EX484 pin assignments for RJ45 port

B&R 2003 Powerlink Modules • EX484 • Number of Modules that can be Used
3.8 Number of Modules that can be Used
Controller Maximum Number of Maximum Number of Possible Module Addresses

Logical Module Slots1) Analog Module Slots 1) for Analog Modules2)
EX484 16 8 1-8
Table 36: EX484 number of modules that can be used
1) Warning: Please take note of the power output table.

2) All analog modules and modules with logical analog sections must be operated directly next to the controller,
i.e. they must be inserted to the left of the first digital module. Module slot 1 is occupied by the controller. The
first slot to the right of a controller has module address 1 and the module addresses are numbered in increasing
order to the right.
Information:
The type (digital/analog) and number of modules determines the possible cycle
times for the nodes.
B&R 2003 Powerlink

Chapter 3
The module slot does not correspond to the module address, it only refers to the
Modules
actual space required on the module rack. A module can also occupy several
module addresses (see technical data for the module).
3.9 Firmware Update
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

B&R 2003 Powerlink Modules • EX484 • Firmware Update

B&R 2005 Powerlink Modules • Overview
Chapter 4 • B&R 2005 Powerlink Modules
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.
Table 37: Overview of B&R2005 Powerlink modules
1.1 Use
B&R SYSTEM 2005 Powerlink modules come in two versions:
B&R 2005 Powerlink

Design Modules Used as Insert in
Chapter 4
Standard Interface Module IF686 e. g. CP260, IF260, IF060
Modules
aPCI Interface Module IF786, IF787, IF789 e. g. CP360, PP200
Table 38: Using B&R2005 Powerlink modules

B&R 2005 Powerlink Modules • IF686
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.
2.2 Order Data

3IF686.9 2005 interface module, 1 ETHERNET Powerlink
interface, manager or controller function, electrically
isolated
Table 39: IF686 order data

2.3 Technical Data
Product ID IF686
General Information
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
In/Out Buffer 11 KByte
Data Rate 100 Mbps
Signal 100 Base-T
(Segment Length)
Table 40: IF686 technical data
2.4 Operational and Connection Elements
B&R 2005 Powerlink

Chapter 4
Modules
Figure 17: IF686 operational and connection elements

2.5 Status Display

St Red/Green See Section 2.5.1 "Status LED", on page 54.
Tx Orange The Powerlink station is sending data.
Rx Orange The Rx LED is always lit when Powerlink activity is present on the bus.
Red: Collision
Table 41: IF686 status display
2.5.1 Status LED
Boot Phase
Red LED Boot Block

Table 42: IF686 boot block indicator
Operation
Status LED
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.
page 55).
Table 43: IF686 status LED

Legend:
• 150 ms
− 600 ms
Pause 2 s delay

Undefined Address:
• • − • Pause • • − • Pause
Invalid Memory Access During Instruction Fetch (e. g. UINT access of an uneven • • − − Pause • • − − Pause
address).
• − • • Pause • − • • Pause
Invalid Station Number (e. g. $FE or $FF) • − − − Pause • − − − Pause
B&R 2005 Powerlink

Table 44: IF686 system failure error codes
Chapter 4
Modules

Figure 18: IF686 station number switch

$00 Operated as manager station.
$01 - $FD Station number for Powerlink station. Operated as controller station.
Table 45: IF686 station number

2.7 ETHERNET Powerlink Interface
Figure 19: IF686 ETHERNET Powerlink interface
Pin Assignment
1 RXD
2 RXD\
3 TXD
4 Termination
5 Termination
6 TXD\
7 Termination
B&R 2005 Powerlink

8 Termination
Chapter 4
Modules
Table 46: IF686 pin assignment for ETHERNET Powerlink interface
2.8 Firmware Update
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.
The firmware is contained in the .br module plfif686.br.

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
The module is also equipped with an RS232 interface.
3.2 Order Data

3IF786.9 aPCI interface module, 1 ETHERNET Powerlink
interface, manager or controller function, 1 RS232
interface
Accessories
0G0001.00-090 Cable PC <-> PLC/PW, RS232, online cable

3.3 Technical Data
Product ID IF786
General Information
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
B&R 2005 Powerlink

Data Formats
Chapter 4
Modules
Data Bits 5 to 8
Parity Yes / No / Even / Odd
Stop Bits 1/2
Type ETHERNET Powerlink interface
In/Out Buffer 20 KByte 1)
Data Rate 100 Mbps
Signal 100 Base-T
(Segment Length)
1) Beginning with firmware version V 50. Before that 11 KByte.

3.5 Status Display
3.5.1 RS232 Interface

RXD Orange The module receives data via the RS232 interface.
RS232
TXD Orange The module sends data via the RS232 interface.
Table 49: IF786 status display RS232 interface

3.5.2 ETHERNET Powerlink Interface

ETHERNET Powerlink
Red: Collision
Table 50: IF786 status display ETHERNET Powerlink interface
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
During operation, the status LED indicates the following states:
B&R 2005 Powerlink

Status LED
Chapter 4
Modules
page 62).

Legend:
• 150 ms
− 600 ms
Pause 2 s delay

Undefined Address:
• • − • Pause • • − • Pause
address).
• − • • Pause • − • • Pause


B&R 2005 Powerlink

Chapter 4
Modules

3.7 ETHERNET Powerlink Interface (IF2)
Figure 22: IF786 ETHERNET Powerlink interface (IF2)
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)

3.8 RS232 Interface (IF1)
Interface Description Pin Assignments

Application Interface The standard RS232 interface is not Pin RS232
RS232 electrically isolated.
1 NC
LEDs show on the interface whether data 2 RXD Receive Signal
is being received (RxD) or sent (TxD).
3 TXD Transmit Signal
The shield is connected to the DSUB
4 NC
connectors housing.
5 GND Ground
Max. baud rate: 115.2 kBaud
Max. cable length: 15 m 6 NC
7 RTS Request To Send
8 CTS Clear To Send
9 NC
9 pin DSUB plug
Table 55: IF786 RS232 Interface (IF1)
3.9 Firmware Update
The firmware is loaded from the x86 target during each start (e. g. CP360). To carry out a
B&R 2005 Powerlink

firmware update on the CP360, see online help in B&R Automation Studio™: CP360 Firmware
Update.
Chapter 4
Modules

4. IF787
The module is also equipped with a CAN interface, with its own object buffers in send and
receive direction.
4.2 Order Data

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.
0TB704.9 Accessory, terminal block, 4 pin, screw clamps, 1.5 mm²
0TB704.91 Accessory, terminal block, 4 pin, cage clamps, 2.5 mm²
Information:
The 4 pin terminal block TB704 is not contained in the delivery!

4.3 Technical Data
Product ID IF787
General Information
Slot aPCI insert
Interfaces 1 x CAN
Power Consumption
5V Max. 3 W
24 V ---
Total Max. 3 W
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)
B&R 2005 Powerlink

Chapter 4
Modules
Data Rate 100 Mbps
Signal 100 Base-T
(Segment Length)

4.5 Status Display
4.5.1 CAN Interface

RXD Orange The module receives data via the CAN interface.
CAN
TXD Orange The module sends data via the CAN interface.
Table 58: IF787 status display CAN interface


ETHERNET Powerlink
Red: Collision
Status LED
Boot Phase
Operation
B&R 2005 Powerlink

Status LED
Chapter 4
Modules
page 70).

Legend:
• 150 ms
− 600 ms
Pause 2 s delay

Undefined Address:
• • − • Pause • • − • Pause
address).
• − • • Pause • − • • Pause

Figure 24: IF787 ETHERNET Powerlink station number switch

Table 62: IF787 ETHERNET Powerlink station number
B&R 2005 Powerlink

Chapter 4
Modules

Pin Assignment
1 RXD
2 RXD\
3 TXD
4 Termination
5 Termination
6 TXD\
7 Termination
8 Termination

4.8 CAN Node Number
Figure 26: IF787 CAN node number switch
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).
4.9 CAN Interface (IF1)
A 120 Ω bus terminating resistor is included with delivery. The resistor can be inserted between
pin 1 and pin 3.

Application Interface The electrically isolated CAN interface is a Terminal CAN
CAN 4 pin multipoint connector.
1 CAN_H
LEDs show on the interface whether data 2 CAN_GND
B&R 2005 Powerlink

3 CAN_L
Max. baud rate:
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
4 pin multipoint connector
Table 64: IF787 CAN interface (IF1)
4.10 Firmware Update
Update.

5. IF789
The module is also equipped with an X2X Link interface.
5.2 Order Data

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.
0TB704.9 Accessory, terminal block, 4 pin, screw clamps, 1.5 mm²
0TB704.91 Accessory, terminal block, 4 pin, cage clamps, 2.5 mm²
Information:
The 4 pin terminal block TB704 is not contained in the delivery!

5.3 Technical Data
Product ID IF789
General Information
Slot aPCI insert
Interfaces 1 x X2X Link
Power Consumption
5V Max. 2.8 W
24 V ---
Total Max. 2.8 W
Type X2X Link - Master
Design 4 pin multipoint connector
Number of Stations Max. 253
Distance between Two Stations Max. 100 m
Network Topology Line
Internal Bus Supply No
Bus Termination Resistor Internal
B&R 2005 Powerlink

Chapter 4
Modules
Data Rate 100 Mbps
Signal 100 Base-T
(Segment Length)

5.5 Status Display
5.5.1 X2X Link Interface

RXD Orange The module receives data via the X2X Link interface.
X2X Link
TXD Orange The module sends data via the X2X Link interface.
Table 67: IF789 status display X2X Link interface


ETHERNET Powerlink
Red: Collision
Status LED
Boot Phase
Operation
B&R 2005 Powerlink

Status LED
Chapter 4
Modules
page 78).

Legend:
• 150 ms
− 600 ms
Pause 2 s delay
Description of Error Error Code Displayed by Red Status LED

Undefined Address:
• • − • Pause • • − • Pause
address).
• − • • Pause • − • • Pause


B&R 2005 Powerlink

Chapter 4
Modules

Pin Assignment
1 RXD
2 RXD\
3 TXD
4 Termination
5 Termination
6 TXD\
7 Termination
8 Termination
5.8 X2X Link Interface (IF1)

Application Interface The electrically isolated X2X Link is a 4 Terminal X2X Link
X2X Link pin multipoint connector.
1 X2X
LEDs show on the interface whether data 2 X2X⊥
3 X2X\
4 SHLD
SHLD .... Shield
4 pin multipoint connector
Table 73: IF789 X2X Link interface (IF1)

5.9 Firmware Update
Update.
B&R 2005 Powerlink

Chapter 4
Modules


ACOPOS Powerlink Modules • Overview
Chapter 5 • ACOPOS Powerlink Modules
1. Overview
Module Description
8AC112.60-1 ACOPOS plug-in module, ETHERNET Powerlink interface
Table 74: Overview of ACOPOS Powerlink modules
ACOPOS Powerlink
Chapter 5
Modules

ACOPOS Powerlink Modules • AC112 - ETHERNET Powerlink Interface
2. AC112 - ETHERNET Powerlink Interface
2.1 General Description
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).
2.2 Order Data

Plug-in Module
8AC112.60-1 ACOPOS plug-in module, ETHERNET Powerlink
interface
Table 75: Order data AC112

2.3 Technical Data
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
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
Table 76: Technical data AC112
1) With a cycle time of 400 µs and 10 ACOPOS servo drives, the maximum total cable length is 200 m. ACOPOS Powerlink
2.4 Powerlink Node Number Setting

Chapter 5
Modules
The Powerlink node number can be set using two HEX code switches:
Code Switch Powerlink Node Number

Top 16s position (high)
Bottom 1s position (low)
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.

2.5 Status LEDs
Figure 30: Status LEDs AC112
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.
Status of the LEDs
The following timing is used for the indication diagram:
Block size: 150 ms
Status LED Display

Green
Error Free Operation
Red
Green
Fatal System Error 1)
Red
Green
Master has Dropped Out
Red
Green
System Stop 2)
Red See System Stop Error Codes
Table 78: Indication diagram for the AC112 status LEDs
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.

System stop error codes
The following timing is used for the indication diagram:
Block size: 150 ms
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)
Table 79: System stop error codes
1) Access of non-existent address.

2) Invalid memory access during instruction fetch (e. g. WORD access of add numbered address).
3) Invalid memory access during data access (e. g. WORD access of add numbered address).
4) This system stop code only occurs in debug mode. The condition for a software assertion was not fulfilled.
5) Error during programming.
2.6 Firmware Update
The firmware is part of the operating system for the ACOPOS servo drives.
ACOPOS Powerlink
Chapter 5
Modules


Error Numbers • General Information
Appendix A • Error Numbers
1. General Information
The error codes in Powerlink are set as follows:
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 1: The error number is entered into the log book
Error: 20803 -> General base error
Information: $A -> No connection or connection lost
2. Base Error Numbers (Error)
Error Number Description

20800 Base error AC112.
20801 Station failure (information contains the station number).
20802 Base error IF686, IF78x, LS187 and LS189.
20803 General base error.
20804 Cycle time violation (information specifies the actual required time in µs).
20805 Base error EX48x.
20806 Powerlink station recognized as active.
20807 Node number used several times (Information specifies node number).
Error Numbers
Table 1: Base error numbers (error)

Appendix A

Error Numbers • Error Numbers (Information)
3. Error Numbers (Information)
Error Number Description

$0001 Error in memory management.
$0002 No RX buffer free on the Powerlink module.
$0003 The last transferred Firmware block was not finished being programmed.
$0004 An attempt was made to allocate a station several times.
$0005 The Powerlink module has insufficient memory for all allocated in/out buffer.
$0006 No response from the controller.
$0007 No data available on the selected channel.
$0008 Channel not implemented on the target.
$0009 Receiver cannot process frame because it is busy.
$000A No connection or connection lost.
$000B Not enough space for the firmware.
$0064 Data is sent faster than BDMA can deliver it from memory.
$0065 Internal ETHERNET MAC error.
$0066 No free RX buffer (BDMA).
$0067 No communication with the manager (only generated by Powerlink host cards in controller mode).
$0258 No more space in the exception buffer.
$0259 No free TX buffer.
Table 2: Error numbers (Information)

Figure Index
Figure 1: Powerlink cycle......................................................................................................... 13

Figure 2: Powerlink network diagram ...................................................................................... 14
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 22: IF786 ETHERNET Powerlink interface (IF2) .......................................................... 64
Figure 24: IF787 ETHERNET Powerlink station number switch.............................................. 71
Figure 26: IF787 CAN node number switch............................................................................. 73
Figure 30: Status LEDs AC112................................................................................................ 86
Figure 31: The error number is entered into the log book ....................................................... 89

Figure Index

Table Index
Table 1: Manual history ........................................................................................................... 11

Table 2: Technical data ........................................................................................................... 11
Table 3: Properties .................................................................................................................. 12
Table 4: Cabling....................................................................................................................... 12
Table 5: Memory requirements................................................................................................ 16
Table 6: Memory requirements for an AC112 module............................................................. 16
Table 7: Memory requirements for an EX48x module ............................................................. 16
Table 8: Maximum number of stations in tree topology ........................................................... 17
Table 9: Maximum number of stations in tree topology ........................................................... 17
Table 10: Legend for calculating the cycle time....................................................................... 18
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 Index

Table 49: IF786 status display RS232 interface ...................................................................... 60
Table 50: IF786 status display ETHERNET Powerlink interface ............................................. 61
Table 54: IF786 pin assignment for ETHERNET Powerlink interface (IF2) ............................. 64
Table 55: IF786 RS232 Interface (IF1) .................................................................................... 65
Table 58: IF787 status display CAN interface ......................................................................... 68
Table 62: IF787 ETHERNET Powerlink station number .......................................................... 71
Table 64: IF787 CAN interface (IF1)........................................................................................ 73
Table 67: IF789 status display X2X Link interface................................................................... 76
Table 73: IF789 X2X Link interface (IF1)................................................................................. 80
Table 74: Overview of ACOPOS Powerlink modules .............................................................. 83
Table 75: Order data AC112.................................................................................................... 84
Table 76: Technical data AC112 ............................................................................................. 85
Table 77: Setting the Powerlink node number with the two HEX code switches..................... 85
Table 78: Indication diagram for the AC112 status LEDs........................................................ 86
Table 79: System stop error codes.......................................................................................... 87
Table 80: Base error numbers (error) ...................................................................................... 89
Table 81: Error numbers (Information) .................................................................................... 90

Index
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

Index
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

Model Number Index
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
Model Number Index

Model Number Index

ETHERNET Powerlink: User's Manual

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ETHERNET Powerlink

Version: 1.0 (August 2002)

ETHERNET Powerlink User's Manual 1

Chapter 3: B&R 2003 Powerlink Modules

Chapter 4: B&R 2005 Powerlink Modules

Chapter 5: ACOPOS Powerlink Modules

Appendix A: Error Numbers

ETHERNET Powerlink User's Manual 3

Model Number Index

ETHERNET Powerlink User's Manual 5

Chapter 1: General Information ..................................................... 11

Chapter 2: Hardware ....................................................................... 31

Chapter 3: B&R 2003 Powerlink Modules ..................................... 33

ETHERNET Powerlink User's Manual 7

2.3 Technical Data .............................................................................................................. 34

Chapter 4: B&R 2005 Powerlink Modules ..................................... 51

8 ETHERNET Powerlink User's Manual

4.3 Technical Data .............................................................................................................. 67

Chapter 5: ACOPOS Powerlink Modules ...................................... 83

Appendix A: Error Numbers .......................................................... 89

ETHERNET Powerlink User's Manual 9

10 ETHERNET Powerlink User's Manual

Version Date Model No. and Product ID. Comments

Table 1: Manual history

2.1 Powerlink Definition

ETHERNET Powerlink is a strict, deterministic real-time protocol based on Fast ETHERNET

2.2 Technical Data

2.2.1 General Information

Transfer Standard Fast ETHERNET, IEEE 802.3u, 100Base-TX

Table 2: Technical data

ETHERNET Powerlink User's Manual 11

Possible Station Operating Modes Synchronous, asynchronous to Powerlink cycle

General recommendations for cabling ETHERNET in industrial environments should be adhered

Segment Length (distance between Maximum 100 m

2.3 General Function Principle

Two types of data traffic are possible on the Powerlink network:

12 ETHERNET Powerlink User's Manual

2.3.1 Powerlink Cycle

Cyclic communication terminates with an End of Cycle (EoC). Asynchronous communication

ETHERNET Powerlink User's Manual 13

2.3.2 Powerlink Network Diagram

Figure 2: Powerlink network diagram

2.3.3 Powerlink Manager

Only one manager is allowed in a Powerlink network.

14 ETHERNET Powerlink User's Manual

2.3.4 Powerlink Controller

4. User Configuration for the Controller Mode

4.1 General Information

4.2 68k Systems

4.3 x86 Systems

ETHERNET Powerlink User's Manual 15

5. Calculation of the Memory Size

5.1 Memory Requirements

Data Memory Requirements on the Manager Remark

Table 5: Memory requirements

5.2 Examples for In/Out Data Sizes

Data Memory Requirements on the Module

Table 6: Memory requirements for an AC112 module

Bytes In Bytes Out

Table 7: Memory requirements for an EX48x module

16 ETHERNET Powerlink User's Manual

6. Calculating the Cycle Time

6.1 Maximum Number of Stations