krones Academy – B&R Hardware

B&R Hardware

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Contents

g B&R - the company

g Overview
g System 2003
g System 2005
g X20 system
g X67 system
g Compact I/O system
g ACOPOS servomotor inverter
g ACOPOSmulti servomotor inverter
g Automation PC
g Industrial PC
g DART Controller
g Automation Panel/iPanel
g Power Panel

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B&R - the Company

g The B&R company, Bernecker + Rainer
Industrie-Elektronik Ges.m.b.H., was
founded by Erwin Bernecker and Josef
Rainer in 1979 in Eggelsberg near
Braunau in Upper Austria. With about
2300 employees and an annual turnover
of approx. 360 million €, B&R is one of the
largest controller manufacturers
worldwide. B&R has subsidiaries in
68 countries all around the world.

www.br-automation.com
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Overview of the B&R hardware used at Krones

Labelling technology Filling technology Plastics technology Inspection technology

g X20 g (2003) g (2005) g Compact I/O system

g ACOPOS g X20 g X20 g DART Controller
g ACOPOS+AC140 g (ACOPOS) g X67 g Automation Panel
g ACOPOSmulti g ACOPOSmulti g ACOPOS g Automation PC
g Automation PC g Automation Panel g ACOPOSmulti g Industrial PC
g Automation Panel g Automation PC g Automation Panel
g Power Panel g Automation PC

Product treatment and Packing and palletising

Cleaning technology Conveyor technology
process technology technology
g Automation Panel g Automation Panel g ACOPOS + AC140 g (2005)
g Automation PC g Automation PC g Automation Panel g X20
g Automation PC g X67
g Power Panel g ACOPOS
g ACOPOSmulti
g Automation Panel
g Power Panel
g Automation PC

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e.g., module 1 labelling stations

System 2003 (CP 476)

g 1 PCMCIA slot
for B&R memory cards
g 2 Status LEDs
g 3 Node number switch
g 4 Local slots
for adapter modules
g 5 CAN interface
g 6 RS 232 interface
g 7 Power supply +24 VDC

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System 2003 CP 476 status LEDs

LED Meaning
CAN Data transfer to or from CAN controller
RS232 Indicates if data is being transmitted or received
ERR Lit when in Service mode
RUN Lit in RUN and in Service mode
RDY Lit when in Service mode
MODE Lit when programming FlashPROM
1, 2, 3, 4 These LEDs show the operating state of the
respective screw-in module.

Not lit Screw-in module defective or not inserted

Blinking Communication error with screw-in module
slowly
Exception: On the IF361 and IF371 modules, a
slow-blinking LED means that frame driver
communication is running correctly.
Blinking Screw-in module is new or has been exchanged
quickly with another module type

Lit Screw-in module is ready for operation

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e.g., SDC controller

System 2003 CP570

g 1 Mode of operation selector switch
g 2 Battery compartment
g 3 RESET button
g 4 Adjustment switch for station address
g 5 Slot for iPCI card
g 6 USB interface
g 7 Power supply +24 VDC
g 8 RS 232 interface
g 9 Ethernet interface
g 10 Slot for compact flash disk

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System 2003 CP570 status LEDs

LED Identification Colour Meaning

READY Green CPU is active

RUN Green Programme is in progress
ERROR Red Service mode
BAT Red Battery is discharged or not (properly) inserted

BUSY Red Accessing compact flash disk

CF OK Green Compact flash disk OK
TXD Green Data is received by the serial interface

RXD Green Data is received by the serial interface

DC OK Green Power supply OK

100TX Green 100 Mbits/s data transfer rate at the Ethernet
interface (if from: 10 Mbit/s)

ACT/LINK Yellow Ethernet connection (blinks during data

transmission)
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System 2003 node number switch

The INA2000 address, also referred to as node number or
ETHERNET station address, of the CPU on the Ethernet bus
(communication with the master CPU) is set by means of
two rotary switches (see the adjacent illustration).

g The adjustment range is 00...FD. The upper rotary switch

always defines the setting of the higher digit.

g The default setting is 00 (see illustration).

Æ When receiving the valid IP address via a clock pulse

data line, the INA address is placed to the last position of
the IP address.

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System 2003 module carrier plate

g All parts of system 2003 are mounted on the

module carrier plate.
- Power supply unit
- CPU
- Modules

g The carriers are available with 2 to

10 slots.

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System 2003
Inputs
g DM 435 I/O module
- 8 inputs Outputs
- 8 outputs

g D 465 I/O module

- 16 inputs
- 16 outputs
Toggle switch

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System 2003 Powerlink modules

g EX 481
- Powerlink bus controller
- 1 Powerlink interface

g EX 484
- Powerlink bus controller
- 4 Powerlink interfaces

g AC 808
- Ethernet hub
- Can be used for Ethernet and
Powerlink networks

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Contiform, Variopac

System 2005

CP260 CP340, CP360, CP380 CP382

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System 2005 (CP360)

1 2
g 1 Mode of operation switch
g 2 Status LEDs
g 3 Battery case
g 4 Slot for compact flash disk 3
g 5 RESET button
g 6 RS 232 interface 4
g 7 ETHERNET RJ45 socket 5 10
g 8 Node number switch
6
g 9 Slot for aPCI interface modules
g 10 Status LEDs for RS 232 9
- Send
- Receive

8
7
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System 2005 status LEDs

LED Description
READY CPU is active
RUN Application running
ERROR SERVICE mode
BAT CPU CPU battery empty or not present
BAT BUS Bus battery empty or not present
CF BUSY Compact Flash BUSY
CF OK Compact Flash OK
100TX 10/100 MBaud ETHERNET
ACT/LNK ETHERNET Activity/Link

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I/O modules of system 2005

g DI 486
- Module for digital inputs
- 32 inputs 24 VDC

g DO 486
- Module for digital outputs
- 32 outputs 24 VDC

g BM 150
- Blind module
- Is used as a spacer and protection for the module carrier plate.

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Status LEDs of the I/O modules

g DI 486
LED Description
DCOK The DCOK LED is controlled by the respective input supply and is
lit if the supply voltage is over +18 VDC.
Jan 32 Input status of the corresponding digital inputs.

g DO 486
LED Description
ERR The ERR LED is an accumulative indication for all high-side drivers
in an output group. This LED is lit if an output which is being
controlled has a short circuit or overtemperature or if the module
voltage sinks below 18 VDC.
DCOK The DCOK LED is controlled by the respective output supply and is
lit if the supply voltage is over +18 VDC.
Jan 32 Control status of the corresponding digital output.

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IF786 /IF789 communications module

g 1 Status LEDs for X2X interface

g 2 IF786 RS232 interfaces

IF789 X2X interface

g 3 Lock screw

g 4 Status LEDs for Powerlink interface

g 5 Node number switch

g 6 Powerlink interface (Ethernet, RJ-45)

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IF789 status LEDs

LED Colour Description of
Lit when data is being sent or received via the Powerlink interface
Rx Orange
(bus activity)

Tx Orange The CPU is transmitting data via the Powerlink interface.

Green The CPU is correctly connected with the Powerlink L/C

L/C
Red Data collision on the Powerlink communication fault
Green The Powerlink interface is operating trouble-free.

Red, Fatal system error. The system is no longer able to perform tasks
permanently on correctly. It may be possible to eliminate the error by
Status restarting the CPU.

System stop. The system is no longer able to perform its tasks

Flashing red correctly. It may be possible to eliminate the error by
restarting the CPU.

Status LEDs for Powerlink Interface

During booting, the Status LED permanently lights up red; all other LEDs are dark.
The current status is displayed during operation (see table).

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IF789 communications module

g Powerlink interface
The Powerlink interface is designed as an RJ45 plug-in
connector at the bottom end of the plug-in card.

g Node number switch

Both node number switches of the Powerlink interface must
be set to 0 (managing node) as shown in the adjacent
illustration.

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System 2005 module carrier plate

g The module carrier plates are available

with 6, 9, 12 and 15 module slots.

g Automatic module address assignment

g Module carrier either with or without

integrated buffer battery

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e.g., Contiform, Variopac,
Modulfill
X20 system

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X20 system
g 1 X20 CPU CP3485 g 2 IF2772 double CAN master
g 3 X20 power supply module g 4 DS1119 SSI encoder card
g 5 DI9371 digital inputs 12x g 6 DO9322 digital outputs 12x

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X20 system
g 1
Module slots g 8 CPU power supply (8) and
g 2
USB interfaces RS232 interface
g 3
RS 232 interface g 9 Mode of operation selector switch
g 4
Ethernet interface g 10 Node number switch
g 5
Ethernet POWERLINK g 11 Buffer battery 1 8
interface
g 6 Status LEDs
g 7 Slot for CF card
6
7
9 3

10 4 5 11
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X20 system status LEDs

LED Color Status Description
R/E Green On Application running

Red On SERVICE mode

RDY/F Yellow On SERVICE or BOOT mode

Red On Over-temperature

S/E Green/red Status/error LED. The status of the LED is described in section S/E LED.
EPL Green On A link to the POWERLINK remote station has been established.

Blinking A link to the POWERLINK remote station has been established. The
LED blinks when Ethernet activity is present on the bus.

ETH Green On A link to the Ethernet remote station has been established.

Blinking A link to the Ethernet remote station has been established. The
LED blinks when Ethernet activity is present on the bus.

CF Yellow On CompactFlash OK

Green On CompactFlash active

DC OK Yellow On CPU power supply OK

Red On Backup battery is empty

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X20 system
g The CF card is fixed by a
locking mechanism.

g Replacing the backup

battery.

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X20 system power supply / RS 232 interface

Pin Description
1 Gnd
2 Tx
5 Rx

TX RS232 RX RS232

GND RS232

+24 V CP/X2X L. +24 V I/O

+24 V CP/X2X L. +24 V I/O

GND GND

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e.g., Variocart

X20 system Compact CPU

g Embedded μP 16/μP 25 with

additional I/O processor

g 100/750 Kbytes user SRAM

g 1 MByte/3 MByte user FlashPROM

g Ethernet, CAN, RS232 on board

g Very compact: only 37.5 mm wide

g Without battery

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X20 system Compact CPU status LEDs

LED Color Status Description

R/E Green On Application running

Red On SERVICE mode

RDY Yellow On SERVICE or BOOT mode

L/A Green On A link to the Ethernet remote station has been established.

Blinking A link to the Ethernet remote station has been established. The LED blinks when
Ethernet activity is present on the bus.

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X20 system BC0083 POWERLINK controller

g 1 Status LEDs
1
g 2 Node number switch

g 3 POWERLINK interfaces
2

LED Color Status Description

S/E (1) Green / Status/error LED. The status of
red the LED is described in
section S/E LED. 3
L/A IFx Green On A link to the remote station has
been established.
Blinking A link to the remote station has
been established. The LED blinks
when Ethernet activity is present
on the bus.

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X20 system IF2772, double CAN master

LED Color Status Description
STATUS Green On Interface module is active
Red On CPU starting up
TxD CAN 1 Yellow On The module is sending data via the CAN bus 1
interface (IF1)
TxD CAN 2 Yellow On The module is sending data via the CAN bus 2
interface (IF2)
TERM CAN 1 Yellow On The integrated terminating resistor for the CAN bus
interface (IF1) is turned on
3
TERM CAN 2 Yellow On The integrated terminating resistor for the CAN bus
interface (IF2) is turned on

g 1 Status LEDs IF1 switch for

terminating resistor 4
g 2 Node number switch "x16"
g 3 Node number switch "x1"
g 4 IF2 interface, CAN bus 5
g 5 IF1 interface, CAN bus
g 6 Switch for terminating resistors IF2 switch for
6
terminating resistor

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X20 system BC0063 Profibus controller

g 1 Status LEDs
g 2 Node number switch
g 3 Profibus DP connection 1
g 4 Field terminal for bus controller
LED Description
and I/O supply
STATUS Status indicator for Profibus DP bus controllers. 2
and
ERROR STATUS (green) ERROR (red) Description
Off Off HARDWARE FAULT / POWER FAIL
On On BUS OFF
4
On Blinking WAIT FOR CONFIG
Blinking Off DATA EXCHANGE - DIAGNOSTICS
On Off DATA EXCHANGE - NO ERROR
3
Blinking Blinking CONFIG ERROR
Off Blinking SERVICE MODE - BOOT
Single flash Single flash HARDWARE FAULT
For a more detailed description see the section Diagnostics.
RxD The yellow RxD LED lights up when the bus controller is receiving data from the
Profibus DP fieldbus.
TxD The yellow TxD LED lights up when the bus controller is transferring data via the
Profibus DP fieldbus.

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X20 system DS1119, SSI encoder card

g The Synchronous Serial Interface (SSI) is an
interface for absolute shaft-angle encoders
(position measuring systems). By means of
serial data transmission, it allows absolute
information about the position to be gathered.

LED Color Status Description

r Green Off Module supply not connected
Channel 1 Channel /1
Single Reset mode
flash
Channel 2 Channel /2
Double Linked mode
flash
Channel 3 Channel /3
Blinking Preoperational mode
On RUN mode Channel 4 Channel 5
e Red Off Module supply not connected or
+24 V +5 V
everything is OK
On Error or reset state GND GND
1-5 Green Status of the corresponding
digital signal

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X20 system digital I/O modules

g 12 digital inputs g 12 digital outputs

DI 1 DI 2 DO 1 DO 2

DI 3 DI 4 DO 3 DO 4
DI 5 DI 6 DO 5 DO 6
DI 7 DI 8 DO 7 DO 8
DI 9 DI 10 DO 9 DO 10
DI 11 DI 12 DO 11 DO 12
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X20 system assembly

g Completely attachable design
g Mounting on a top-hat rail

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X20 system disassembly

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e.g., Robobox, Variopac Pro,
Contiform
X67 system

X2X link

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X67 system BC8321

Powerlink X2X link
g POWERLINK V1/V2
Node
number
g 8 digital channels which can be configured as
switch
inputs or outputs

I/Os
g I/O configuration and FW update via the field
bus

g Integrated connection for local expansion via Status

the X2X link for up to 250 further modules LEDs

g Cycle time for local expansion can be set from

200 μs
Power supply unit
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X67 system BC8321 status LEDs

LED Description
Status Status indicator for POWERLINK bus controller.
indicator
1 LED Status Description
L/A IF1 On A link to the remote station has been established.
(green)
Blinking A link to the remote station has been established. The LED blinks
when Ethernet activity is present on the bus.

S/E (1)
Status/error LED. The status of the LED is described in section
(green/red) S/E LED.
1-8 Input / output status of the corresponding channel. The LEDs are orange.
Status Status indicator for module function.
indicator
2 LED Status Description
Green Off Module supply not connected
Single flash Reset mode
Blinking Preoperational mode
On RUN mode
Red Off Module supply not connected or everything is OK
On Error or reset state
Single flash Warning / error for an I/O channel. Level monitoring for digital
outputs has been triggered.
Double flash Supply voltage not in the valid range

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X67 system S/E LED

Red - error Description
On The bus controller has encountered an error (failed Ethernet frames, increased number of collisions on the network, etc.).
Note: The LED blinks red several times immediately after startup. This is not an error.
Green - status Description
Off The bus controller is either not getting power, or it is NOT_ACTIVE. The bus controller waits in this state for about 5 seconds
after a restart. No communication with the bus controller is possible.
If no POWERLINK communication is detected during these 5 s, the bus controller goes into the BASIC_ETHERNET state
(flickering). If, however, POWERLINK communication is detected during this time, the bus controller goes directly into the
PRE_OPERATIONAL_1 status (single flash).
Flickering green The bus controller did not detect any POWERLINK communication. In this state you can communicate directly with the bus
(approx. 10 Hz) controller using UDP. If an POWERLINK communication is detected while in this state, the bus controller goes into the
PRE_OPERATIONAL_1 state (single flash).
Single flash The bus controller is in PRE_OPERATIONAL_1.
(approx. 1 Hz) With operation on a POWERLINK V1 master, the bus controller goes directly into PRE_OPERATIONAL_2.
With operation on a POWERLINK V2 manager, the CN (Controlled Node) waits for the reception of a SoC frame and then
switches over to PRE_OPERATIONAL_2 (double flash).
Double flash The bus controller is in PRE_OPERATIONAL_2.
(approx. 1 Hz) In this state the bus controller is normally configured by the manager. A command (POWERLINK V2) or setting the data valid
flag in the output data (POWERLINK V1) then switches the state to READY_TO_OPERATE (triple flash).
Triple flash The bus controller is in READY_TO_OPERATE.
(approx. 1 Hz) In a POWERLINK V2 network, the manager then switches via command to OPERATIONAL.
In a POWERLINK V1 network, the bus controller then switches automatically to OPERATIONAL as soon as input data are present.

On The bus controller is in OPERATIONAL.

Blinking The bus controller is in STOPPED.
(approx. 2.5 Hz) No output data is produced and no input data is received. Only the appropriate command from the manager can enter or leave
this state.

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X67 system DM1321.L12

g 16 digital mixed channels which can

be configured as inputs or outputs

g Passive distributors are replaced

g Presettable digital input filters

g 2 additional channels with counting

functions

g All outputs with single-channel

diagnostics

g Extensive additional status

information

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X67 system DM1321.L12 status LEDs

LED Description
Status Status indicator - X2X Link.
indicator 1
Green Red Description
Off Off No supply via X2X Link
On Off X2X Link supplied, communication is functioning
Off On X2X supplied, but X2X communication is not functioning
On On Preoperational: X2X Link supplied, module not initialized
1 - 16 or 1- Input / output status of the corresponding channel. The LEDs are orange.
1/2 to 8-1/2
Status Status indicator for module function.
indicator 2
LED Status Description
Green Off Module supply not connected
Single flash Reset mode
Blinking Preoperational mode
On RUN mode
Red Off Module supply not connected or everything is OK

On Error or reset state

Single flash Warning/error for an I/O channel. Level monitoring for digital outputs has been
triggered.
Double Supply voltage not in the valid range
flash

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X67 system AM1223/33

g AM1223 module: 2 analog inputs,
2 analog outputs ±10 V

g AM1323 module: 2 analog inputs,

2 analog outputs 0 - 20 mA

g Broken wire detection for the inputs

g Presettable digital input filters

g Very short cycle times

g Optimal shielding dissipation on all

channels

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X67 system AM1223/33 status LEDs

LED Description
Status Status indicator - X2X Link.
indicator
Green Red Description
1
Off Off No supply via X2X Link
On Off X2X Link supplied, communication is functioning
Off On X2X supplied, but X2X communication is not functioning
On On Preoperational: X2X Link supplied, module not initialized
1-2 Status display for corresponding analog input (green).
LED Status Description
1-2 On The analog/digital converter is running
Blinking Overflow or underflow of the input signal (starting from
revision ³C5)
Off Open connection or sensor is disconnected
3-4 Status display for corresponding analog output (orange).
LED Status Description
3-4 On Lit as soon as the enable relay is activated (a value ¹ 0 was
output).
Off The enable relay is not closed yet (a value ¹ 0 has not yet been
output).
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X67 system AM1223/33 status LEDs

LED Description

Status Status indicator for module function.

indicator 2
LED Status Description

Green Off Module supply not connected

Single flash Reset mode

Blinking Preoperational mode

On RUN mode

Red Off Module supply not connected or everything is OK

On Error or reset state

Single flash Warning / error for an I/O channel. Overflow or

underflow of the analog inputs.

Double flash Supply voltage not in the valid range

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e.g., Checkmat

Compact I/O XX408 system

The space-saving modules of the Compact I/O 5
system reduce the wiring of sensors and 2
actuators. Discrete input and output
signals are bundled on the modules and
transferred to the controller via a field bus.
4
g 16 digital inputs (1)
g 16 digital outputs (2) 3
g X2X interface (3)
g Status LEDs (4)
g Select button (5)
g Power supply (6)
6

1
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Compact I/O XX408 system

Status LEDs
g I/O Select LED
Two-colour LEDs 01-16 are provided for the status of
the inputs and outputs. The display is switched using
the "I/O Select" button. The status is indicated by the
I/O LED. g Status LED
Color Meaning
LED Status Description
Green Off Module supply not connected
Green The I/O LEDs 01-16 indicate the status of the inputs.
Single Reset mode
Red The I/O LEDs 01-16 indicate the status of the outputs.
flash

g I/O 01-16 if I/O Select LED green Double Preoperational mode

flash
Color Meaning
On Run mode
Green The corresponding input = 1.
Red Off Module supply not connected or everything is OK
Off The corresponding input = 0.
Single Warning/error for an I/O channel - Level
flash monitoring for digital outputs has responded.
g I/O 01-16 if I/O Select LED yellow
Double Possible error:
Color Meaning flash Module supply voltage is outside the valid range.
Sensor supply monitor responded. The monitor
Yellow The corresponding output = 1.
for the supply of digital outputs registered an
Off The corresponding output = 0. error.

Blinking, The corresponding output is operating in PWM On Error or reset state

approximately 10 Hz mode.
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e.g., Variopac Pro, Contiform
Isofill, Modulfill, SynCo, SDC
ACOPOS servomotor inverter
g Servomotor inverters are used to drive
servomotors.

g They are available in various sizes and

designs.

g The ACOPOS servo drive controller series

covers a current range of 1.0 – 128 A and an
output range of 0.5 – 64 kW.

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ACOPOS diagnostics

LED Signal Colour Description

1 Ready Green LED lights up permanently, if
• the ACOPOS servomotor inverter is ready for operation and
• if it is possible to enable the output stage (i.e.: operating system present and booted, no
permanent or intermittent faults present).
2 Run Orange The LED lights up permanently if the output stage of the servomotor inverter is enabled.
3 Error Red The LED lights up as long as the servomotor inverter is signalling one or several malfunction
warnings. As soon as the cause of the fault has been eliminated, the LED will go out
automatically.
Examples of permanent faults
• Motor feedback malfunction or motor not connected
• Low level at the "Enable" input port
• Motor temperature sensor not connected or faulty
• Internal device error (for example, faulty servomotor controller heat sink temperature sensor).
Examples of intermittent faults
•Power supply (24 VDC) exceeds the tolerance range
• Intermediate circuit voltage exceeds the tolerance range
• Internal 15 VDC) auxiliary voltage exceeds the tolerance range
• Motor temperature too high (by temperature sensor)
• Servomotor inverter temperature too high
• Powerlink network malfunction

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ACOPOS blink codes

Booting of basic hardware
active

g Status display during

Configuring network plug-in
booting module active

Waiting for network message

Network communication
active

g Status display in
combination with Powerlink basic hardware
boot error
AC112 plug-in card
Error while booting the
AC112-ARM

Powerlink node number is 0

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krones Academy – B&R Hardware

ACOPOS 1090 wiring

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Replacing the ACOPOS

g 1. Important!! --> Turn OFF the machine's master switch. (motor protector
ahead of ACOPOS is not sufficient)

g 2. Remove the faulty servo drive controller:

- 2.1 Remove all connectors and the lower
cables from the screw terminals.
!!! CAUTION !!!
DC-link voltage front
with SDC 565 VDC! top bottom
Wait until DC voltage has
dropped below 48 VDC.

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Replacing the ACOPOS

- 2.2 Unscrew the earthing cable.

- 2.3 Loosen the top and bottom fastening screws.
Fastening screws

Screw terminal
Earthing cable connection
- 2.4 Lift out the ACOPOS.

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Replacing the ACOPOS

g 3. Compare the identification plates (sticker on the side of the ACOPOS)

Must be identical!

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Replacing the ACOPOS

g 4. Remove the plug-in cards from the faulty ACOPOS and insert them into the
same slot of the new one. (Removal and installation are explained on
slides 65 and 66.)

!!! Caution !!!

If the plug-in cards are also replaced, please
make sure you compare the node number switches.

g 5. Install the new ACOPOS in the machine in the reverse order as described
under item 2.

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Replacing the ACOPOS

g 6. Turn ON the machine's master switch.

g 7. Wait until the B&R CPU has transferred the ACOPOS operating system to the
inverter. (maximum 5 minutes)

g 8. RESET malfunctions on the machine's control panel.

g 9. If an inverter with an AC140 has been replaced, load the types and basic
data (machine parameters) to the machine as a safety precaution.

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Instructions for replacing the ACOPOS

g The connections for the power and
control sections are all plugged in.

g The individual modules with the

settings must be transferred exactly
as they are to the new ACOPOS.

g All of the ACOPOS servomotor

inverters are earthed with a
10 mm² cable to avoid dangerous
fault currents.

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ACOPOS AC110 plug-in module

g CAN interface

g The status LEDs indicate if data has been

received via the CAN interface (RXD) or if it is
being transmitted (TXD).

g At the beginning and at the end of the CAN

bus, there must be a terminating resistor
(120 Ω, 0.25 W) between CAN_H and CAN_L.

g Changing the CAN node number using the

coding switches
- 1 16-place position (Hi)
- 2 1-place position (Lo)

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ACOPOS AC112 plug-in card – Powerlink V1 interface

Diagnostics via LEDs

Error-free operation

Fatal System Error

Master has failed

System stop

(one box corresponds to 150 ms)

Output of fault code via red LED

(one box corresponds to 150 ms)

(old card, AC114 is used in new machines)

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ACOPOS AC114 plug-in card – Powerlink V2 interface

Label Color Function

R/E Green/red Ready/Error
L/D1 Green Link / Data activity Port 1
L/D2 Green Link / Data activity Port 2

16-place position (Hi)

1-place position (Lo)

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ACOPOS plug-in modules for the position encoders

g AC120 EnDat interface

g AC121 HIPERFACE interface

g AC122 resolver interface

g AC123 SSI absolute interface

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ACOPOS AC130 plug-in module

g Encoder emulation

Connection Designation Principle of operation

1 O1 Thousandth clock pulse A

2 O2 NC

3 O3 Thousandth clock pulse B

4 O4 NC

5 O5 NC

O6 Set-up clock pulse (variable clock

6
pulse)

O7 Fine clock pulse (10-digit clock

7
pulse)

8 O8 Clock pulse

9 O9 Revolution clock pulse

10 0 10 NC
If the AC130 plug-in card is properly
11 +24 V +24 V DC supply supplied with power, the 24V LED
12 GND GND supply
is permanently lit.

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krones Academy – B&R Hardware
e.g., AirCo, MultiCo, SynCo,
RPC
ACOPOS AC 140 CPU plug-in module
g 1 CAN node number
g 2 Profibus address switch 5
for the Profibus slave address 6
g 3 Profibus interface
g 4 CAN interface 7
1
g 5 CF card
g 6 Battery 8
g 7 Ethernet interface 2
g 8 RESET button
9
g 9 Inputs/outputs 3
g 10 RS232 interface
10
4

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ACOPOS AC 140 diagnostics LEDs

LED Name Color Description
1 Status (RUN) Red ERROR/RESET
Red with Load/unload and start BOOT AR
orange
blinking
Red/green Startup of BOOT or CF - AR
blinking (1
Hz)
Orange SERVICE/DIAG/BOOT mode
Green RUN
Green with RUN - BATTERY LOW
orange
blinking
2 RS232 (X1) Orange Data transfer to application interface IF1 (RS232)
blinking
3 Profibus (RX) Orange Receive data on application interface IF3
(Profibus)
4 Profibus (TX) Orange Send data to application interface IF3 (Profibus)
5 CAN (RX) Orange Receive data on application interface IF2 (CAN)
6 CAN (TX) Orange Send data to application interface IF2 (CAN)

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Replacing the ACOPOS plug-in modules

1. Disconnect the ACOPOS servo drive
controller from the mains supply and lock it
to prevent it being turned ON.
2. 24 Turn OFF the VDC power supply.
3. Remove the screw at the bottom of the
plug-in module.
4. Loosen the screw at the front of the plug-in
module.
5. Remove the plug-in module.
6. Insert the blank cover into the free slot.
7. Secure the blank cover with the two screws.
8. Turn ON the VDC power supply.
9. Connect the ACOPOS servo drive controller
to the power supply.

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Installing the ACOPOS plug-in modules

1. Disconnect the ACOPOS servo drive
controller from the mains supply and lock
it to prevent it being turned ON.
2. 24 Turn OFF the VDC power supply.
3. Remove the screw at the bottom of the
blank cover.
4. Loosen the screw at the front.
5. Remove the blank cover.
6. Insert the plug-in module into the free
slot (see illustration above).
7. Secure the plug-in module with the two
screws.
8. Turn ON the VDC power supply.
9. Connect the ACOPOS servo drive
controller to the power supply.

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e.g., Contiform, Modulfill,
Variopac Pro, Multireel C/S
ACOPOSmulti servomotor inverter
g The ACOPOSmulti system comprises:
Line filter Regeneration chokes

Inverter
modules

Auxiliary power Power

supply module supply module

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ACOPOSmulti line filter

g The line filters are optimally

adjusted to the ACOPOSmulti
power supply modules.

g They avoid disturbances in the

supply network caused by
interference signals which occur
when the IGBTs (Insulated Gate
Bipolar Transistor) in the
servomotor inverter are switched.

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ACOPOSmulti regeneration chokes

g The regeneration chokes are optimally

adjusted to the ACOPOSmulti power
supply modules.

g They redirect power that is generated

in the servomotor inverters' DC link
back into the power network. This
would happen, for example, if all
connected motors brake. The motors
would generate electrical power from
kinetic energy, which would be
returned to the DC-link.

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ACOPOSmulti power supply and auxiliary power supply

modules
g Power supply module
- Not every ACOPOSmulti servomotor
inverter is equipped with a rectifier.
- A central power supply unit provides
the power for the DC-link.
- To ensure the DC-link voltage can
reach all servomotor inverters, they
are connected by rails on the
mounting plate.
g Auxiliary power supply module
- The auxiliary power supply module
generates the power for the control
circuit.

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ACOPOSmulti inverter modules (single-axis modules)

g 1.4 kW ... 11 kW

g 16 kW … 32 kW

g 64 kW

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ACOPOSmulti connections

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ACOPOSmulti inverter modules (single-axis modules)

Indicator group Label Color Function Description
Ethernet R/E Green/red Ready/Error
POWERLINK
L/D1 Green Link /
Data activity Port 1
L/D2 Green Link / See section LED status
Data activity Port 2 Ethernet POWERLINK.

Inverter axis 1 RDY Green Ready

RUN Orange Run See section LED status RDY,
RUN, ERR (8BVI inverter
ERR Red Error modules).

Supply voltage 24V Green 24 V OK The 24V module supply

voltage is within the tolerance
range.
Encoder SLOT1 UP Orange Encoder direction of The encoder position of the
rotation + connected encoder changed in
the positive direction. The
faster the encoder position
changes, the brighter the LED
is lit.
DN Orange Encoder direction of The encoder position of the
rotation - connected encoder changed in
the negative direction. The
faster the encoder position
changes, the brighter the LED
is lit.
Encoder SLOT2 UP Orange Encoder direction of see Encoder SLOT1
rotation +
DN Orange Encoder direction of
rotation -

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ACOPOSmulti inverter modules (double-axis modules)

g Double-axis modules are
equipped with two equal,
separate inverters installed in one
inverter module.

g 1.4 kW ... 5.5 kW

g 11 kW

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ACOPOSmulti inverter modules (double-axis modules)

Indicator Label Color Function Description
group
Ethernet R/E Green/red Ready/Error
POWERLINK
L/D1 Green Link / Data activity Port 1
1
L/D2 Green Link / Data activity Port 2 See section LED status Ethernet POWERLINK.

Inverter axis 1 RDY Green Ready

5 6
RUN Orange Run
See section LED status RDY, RUN, ERR (8BVI
2 ERR Red Error inverter modules).

Inverter axis 2 RDY Green Ready See inverter axis 1

RUN Orange Run

3 ERR Red Error

Supply voltage 24V Green 24 V OK The 24V module supply voltage is within the
tolerance range.
4 1
4 Encoder SLOT1 UP Orange Encoder direction of
rotation +
The encoder position of the connected encoder
changed in the positive direction. The faster the
encoder position changes, the brighter the LED
is lit.
DN Orange Encoder direction of The encoder position of the connected encoder 2 3
5 rotation - changed in the negative direction. The faster
the encoder position changes, the brighter the
LED is lit.
Encoder SLOT2 UP Orange Encoder direction of see Encoder SLOT1
rotation +
DN Orange Encoder direction of
6 rotation -

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Status LED Ethernet POWERLINK

Label Color Function Description

R/E Green/red Ready/Error LED isn't lit Supply voltage is not applied to the module or initialization of the network
interface has failed.

Red (lit) The POWERLINK node number of the module is 0.

Red/green blinking The client is in an error state (drops out of cyclic operation).

Green blinking (1x) The client recognizes a valid POWERLINK frame on the network.

Green blinking (2x) Cyclic operation on the network; however the client itself is not yet participating
in cyclic operation.

Green blinking (3x) Cyclic operation of the client is in preparation.

Green (lit) The client is participating in cyclic operation.

Green (flickering) The client is not participating in cyclic operation and also does not detect any
other stations on the network that are participating in cyclic operation.

L/D1 Green Link / Data Green (lit) There is a physical connection to another station on the network.
activity Port 1
Green (blinking) Activity Port 1

L/D2 Green Link / Data Green (lit) There is a physical connection to another station on the network.
activity Port 2
Green (blinking) Activity Port 2

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Status LED RDY, RUN, ERR (8BVI inverter modules)

Label Color Function Description

RDY Green Ready Green (lit) The module is operational and the power stage can be enabled (operating system
present and booted, no permanent or temporary errors).
Green No signal on or both enable inputs; otherwise there is no permanent or temporary
(blinking) error present on the module.

RUN Orange Run Orange (lit) The module' power stage is enabled.
ERR Red Error Red (lit) A permanent or temporary error exists on the module.
Examples of permanent errors:
•Low level on an enable input
•Internal error on the device (e.g. IGBT heat sink temperature sensor defective)
•Motor feedback not connected or defective
•Motor temperature sensor not connected or defective
Examples of temporary errors:
•24 VDC supply voltage exceeds the tolerance range
•DC bus voltage exceeds the tolerance range
•Internal 15 VDC control voltage exceeds the tolerance range
•Over-temperature on the module (IGBT junction, heat sink)
•Powerlink network disturbance
•IGBT current limit reached
•Over-temperature on the motor (temperature sensor)
Red The module is in boot state.
(blinking)

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ACOPOSmulti plug-in modules for the position encoders

g AC120 EnDat 2.1 interface

g AC121 HIPERFACE interface

g AC122 resolver interface

g AC123 SSI absolute interface

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ACOPOSmulti installation
g Engage the module with the Mounting plate
assembly flap(s) on top of the
mounting plate.
g Swing the module down to the
back panel module(s).
To ensure proper contact of the
module, insert it straightly into the
back panel module(s) until it snaps
into place.
g Tighten all M6 fastening screws (2
screws per module width each) on Back panel modules
the module with a torque of max.
5 Nm.
g The plug-in modules are easy to !!! CAUTION !!!
handle and can be inserted or Do not do any assembly work
on the ACOPOSmulti unless
removed after the cover has been
it has been disconnected from
lifted.
the power supply.
Fastening screws
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e.g., Contiflow, Linacool,
Linatronic, Variopac Pro
Automation PC 620

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e.g., AirCo, MultiCo

Automation PC 620

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Automation PC 620

Battery Meaning
status

N/A Hardware, i.e.

firmware used is too
old and does not
support read.

GOOD Data buffering is

guaranteed

BAD Data buffering is

guaranteed for
approx. another 500
hours from the point
in time that the
battery capacity is
determined to be
BAD (insufficient).

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Automation PC 620 status LEDs

LED Color Meaning

Power Green On Supply voltage OK

Red On The system is in standby mode (S5: soft-

off mode or S4: hibernate mode -
Suspend-to-Disk)

On Supply voltage not OK; the system is

Orange(1) operating on battery power.

HDD Yellow On Signals IDE drive access (CF, HDD, CD, etc.)

Link 1 Yellow On Active SDL connection.

blinking An active SDL connection has been

interrupted by a loss of power in the
display unit.

Link 2 Yellow - In preparation

(1) Only lit when add-on UPS module is installed.

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Automation PC 620 connections

g Ethernet LED On Off

Green 100 MBit/s 10 MBit/s
Orange Link Activity
(Ethernet network (blinking)
connection (Data transfer in
available) progress)

Caution!
g Monitor/panel Do not connect or disconnect the RGB, DVI or SDL
cable unless the APC620 and the display unit
have been disconnected from the power supply.

Pin Description
1 +
g Power supply
2 Functional ground
3 -

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Automation PC 620 buttons

g POWER button
•The POWER button can be actuated with a
pointy object (e.g., the tip of a ball pen).

•The POWER button acts as follows:

Press it briefly ... to turn the APC620 ON or
shut down the operating system and turn the
APC620 OFF.
By pressing it long, ... the ATX power supply
unit will turn the APC620 OFF without shutting
it down (data loss possible!).
•Pressing the POWER button will not reset the
MTCX processor.

g RESET button
•The RESET button can be actuated with a
pointy object (e.g., the tip of a ball pen).

•Pressing the RESET button will start a hardware

reset, i.e. a PCI reset. The APC620 will be
restarted (cold start).

•The MTCX processor will not be reset during this

process.
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e.g., Contiform, Contiflow,
Varioline, Isofill
Automation PC 810

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Automation PC 810

Battery Meaning
status

N/A Hardware, i.e. firmware

used is too old and does
not support read.

GOOD Data buffering is

guaranteed

BAD Data buffering is

guaranteed for approx.
another 500 hours from
the point in time that the
battery capacity is
determined to be BAD
(insufficient).

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Automation PC 810 status LEDs

LED Color Meaning
Power Green On Supply voltage OK
Red On The system is in standby mode (S5: soft-off mode
or S4: hibernate mode -Suspend-to-Disk)

On Supply voltage not OK; the system is operating on

Orange(1) battery power.

HDD Yellow On Signals IDE drive access (CF, HDD, CD, etc.)

Link 1 Yellow On Indicates an active SDL connection on the monitor

/ panel plug.
blinking An active SDL connection has been interrupted by
a loss of power in the display unit.

Link 2 Yellow On Indicates an active SDL connection on the AP Link.

blinking An active SDL connection on the AP link has been

interrupted by a loss of power in the display unit.

(1) Only lit when add-on UPS module is installed.

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Automation PC 810 connections

g Ethernet LED On Off

Green 100 MBit/s 10 MBit/s
Orange Link Activity
(Ethernet network (blinking)
connection (Data transfer in
available) progress)

Caution!
g Monitor/panel Do not connect or disconnect the RGB, DVI or SDL
cable unless the APC810 and the display unit
have been disconnected from the power supply.

Pin Description
1 +
g Power supply
2 Functional ground
3 -

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Automation PC 810 buttons

g POWER button
• The POWER button can be actuated with a pointy object (e.g.,
the tip of a ball pen).
• The POWER button acts as follows:
Press it briefly ... to turn the APC810 ON or shut down the
operating system and turn the APC810 OFF.
By pressing it long, ... the ATX power supply unit will turn the
APC810 OFF without shutting it down (Data loss possible!).
• Pressing the POWER button will not reset the MTCX processor

g RESET button
•The RESET button can be actuated with a pointy object (e.g.,
the tip of a ball pen).
•Pressing the RESET button will start a hardware reset,
i.e. a PCI reset. The APC810 will be restarted (cold start).
•The MTCX processor will not be reset during this process.

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e.g., Dart Checkmat

Industrial PC IPC 5000

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e.g., Checkmat, Sekamat,
Cantronic, Modulcheck
DART controller
g Intel Celeron 600

g 256 MB main memory

g 24 V power supply

g 2 serial interfaces

g 2 USB 2.0 interfaces

g 1 Ethernet 10/100 Mbit interface

g 1 CAN and 1 X2X Link Master interface

g Interface for serial shift register

g Interface for analog signals

g Linux operating system

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DART controller Status LEDs

CAN CAN & X2X link
USB node number switch X2X link interface

Ethernet RESET button

Serial interfaces CAN interface

LED Color Description

Satus indicator for the
CAN yellow
CAN interface

Satus indicator for the

Monitor connection Analog Shift register X2X yellow X2X-Link interface
interface interface
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DART controller
LED Colour Description

red --> power failure

PWR red/green green --> power OK

Status LEDs Battery

Customer-specific display,
L1 red/green connected with customer FPGA Earth connection

Customer-specific display,
L2 red/green connected with customer FPGA

Identification plate

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Visualisation displays in
nearly all machines
Automation Panel / iPanel

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Automation Panel 920 - 19‘‘

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iPanel AP920 - 15‘‘

RFID tag reader

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iPanel
g RFID tags
- Operator (green)

- Setter (black)

- Maintenance personnel (yellow)

- Administrator, customer (red)

- Individual user (white)

- Krones service (blue)

internally "personalised"

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iPanel AP920
g Connection between Automation
PC and panel via SDL

- With only one panel

- Or with several at the same

time

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iPanel AP920

g Panel link plug-in cards

g USB port
- on the rear

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iPanel AP920 link plug-in cards

g SDL receiver
For connecting only one
panel.

g SDL transceiver
For connecting several panels
in series.

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iPanel AP920 link plug-in cards

g Link DVI receiver

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Power panel

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e.g., Vinetta

Power Panel PP35

Battery case
Digital inputs and
outputs CAN node number switch

CAN/RS232 interfaces
Caution! 24 VDC power supply
The simultaneous pressing
of several function Status LEDs
or system buttons may, under
certain circumstances, lead
to unwanted actions. Interface status LEDs
I/O status LEDs
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Power Panel PP35

g The status LED of the power panel indicates the power panel's operating condition by a
blink code:

g The I/O LED indicates whether the I/O LEDs (01 ... 16) display the status of the digital
inputs or outputs. The I/O button can be used to change between the displays:

I/O LED LEDs 01 ... 16

Green The state of the 16 digital inputs is indicated (LEDs are green).
Yellow The state of the 16 digital outputs is indicated (LEDs are yellow).
g Interface status LEDs

Interface LED Description

CAN Indicates if data is being transmitted or received.
RS232 Indicates if data is being transmitted or received.
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Power Panel PP35

g Change contrast: reduce contrast

hold

increase contrast

g Node number switch:

The PP35 is equipped with 2 hex switches which
are used as mode of operation switches.
Switch position Description
00 In this switch position, the operating system can be programmed via the online interface. User
FlashPROM is only deleted after the update begins.
01 - FE Freely available for use in an application (e.g. CAN node number)
FF Diagnostics mode: The CPU boots in Diagnostics mode. Program sections in User RAM and User
FlashPROM are not initialized. After diagnostics mode, the CPU always boots with a cold restart.

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e.g, Autocol label applicators

Power Panel P127

LC display

Identification plate

4B1270.00-K04
Power supply unit

CAN interface

CAN node number switch

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Power Panel P127

g Adjust contrast: Press button "7" to select the display; by simultaneously
pressing button "8" and "9" you can adjust the contrast to brighter or darker.

g Node number switch:

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Power Panel P127 trouble shooting

g Visual inspection:
- Checking the mechanical connections
- Check the positions of the number switches (node number, Baud rate) if necessary.

g Commissioning
- A first check is performed by connecting the panel to the 24 V power supply. In this case, all
LEDs should light up briefly and the following message should be displayed:

If this message is displayed, processor, display and internal

power supply unit are okay. If a valid node number and Baud
rate have been set, the set node number and the Baud rate will
be displayed instead of "--".
g Display remains dark: Is the panel really supplied with power between 18 and 30 VDC?

g It must be possible to adjust the contrast of the display to darker or brighter using the buttons 7 and
8 or 7 and 9.

g The display shows a welcome message as described above, but accepts no commands on the CAN
interface: Does the CAN identifier match the node number, is the correct Baud rate set? Is the correct
CAN cable being used?

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e.g., Contiroll labelling station,
Sleevematic labelling station
Power Panel PP210.0000-K20
CAN status LEDs Digital inputs/outputs
Analog inputs
DIMM I/O
Battery status LEDs
CAN node
number switch
CAN interface
Battery X2X link interface
CF card slot
IF786 plug-in card

Power supply unit

Node number switch
USB
RESET button
Ethernet Interface Status LEDs
RS232 interface
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e.g., MultiCo, PalCo

Power Panel 320.0573-39

g GEODE PROCESSOR LX800 / 500 MHZ

g RAM 256 MB DDR333 DRAM
g DISPLAY 5.7 INCH
TFT C VGA
g SERIAL PORT RS232
g ETHERNET 10/
100 MBIT/S
g 2X USB2.0
g COMPACT FLASH SLOT
g LEDS (POWER, CF)
g 24 VDC
g BIOS
g LITHIUM BATTERY

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Power Panel 320

g Power supply unit

Pin Description
1 -
2 Functional earth
3 +

g Functional earth tab

There is an earthing jumper next to the power supply
connector. The earthing jumper (for functional earth)
must be connected to a central earthing point of the
control cabinet using a 6.3 mm flat connector via the
shortest route and with the lowest possible impedance
(e.g., copper band, however, at least 2.5 mm²).

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Power Panel 320

g Node number switch/operating mode switch
Switch position
SW1 (x16) SW2 (x1) Function Description
0 0 Service Necessary for restoring the default BIOS
mode settings - for more information, see section
Restoring the default BIOS values.
x x None No other switch positions have
significance.

g Status LEDs
LED Color Meaning
1x three-colour, 1xsingle-colour
Power Green On Supply voltage OK
Red On The system is in standby mode (S5: soft-off mode or
S4: hibernate mode - suspend-to-disk)
User Yellow On Freely available for use in an application
(e.g. can be switched on/off directly via the ADI Library
Green Off - only possible in the S0 state).
S0 state possible).
CF Yellow On Indicates access to CompactFlash drive (read or write)

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Power Panel 320 buttons

g POWER button
•The POWER button can be actuated with a pointy object (e.g., the
tip of a ball pen).
•The POWER button acts as follows:
Press it briefly ... to turn the PP320 ON or shut down the operating
system and turn the PP320 OFF.
By pressing it long, ... the ATX power supply unit will turn the PP320
OFF without shutting it down (data loss possible!).
•Pressing the POWER button will not reset the MTCX processor.

g RESET button

•The RESET button can be actuated with a pointy object (e.g., the tip
of a ball pen).
•Pressing the RESET button will start a hardware reset, i.e. a PCI reset.
The PP320 will be restarted (cold start).
•The MTCX processor will not be reset during this process.

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Power Panel 320 compact flash slot

g Replacing the CF card

!!! Caution !!!

Do not replace the compact flash card unless the system has
been disconnected from the power supply!
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Thank you very much for your attention!

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