Resolving ACOPOS 1045 POWERLINK Connection Failures

POWERLINK communication becomes available only after the drive recognizes the AC114 hardware and the controller project contains the POWERLINK versions of the ACOPOS runtime modules. Five red Error LED flashes identify the first commissioning gate: correct drive compatibility or update its bootloader before changing network settings.

1. Fault-code capture and hardware isolation

Before anything else, confirm that the failure occurs at interface-card recognition rather than during POWERLINK network startup. The reported installation contains an ACOPOS 1045, an X20CP1584 controller, and an AC114 interface. After installing the interface, its Error LED flashes red five times and its R/E LED remains red.

Record the complete ACOPOS model designation, hardware revision, installed interface identity, and bootloader or firmware information visible in the engineering tools or on the equipment labels. Do not move on until the repeated code is confirmed as exactly five red flashes and the documentation identifies it as Invalid hardware ID.

2. AC114 compatibility gate

An older ACOPOS can operate with a CAN interface while failing immediately with an AC114. The drive bootloader must identify an interface before higher-level firmware or POWERLINK communication can use it. If the bootloader predates support for the newer card, inserting the card produces the hardware-ID fault before controller configuration can affect the result.

Check the B&R minimum-version information for AC114 against the exact ACOPOS model and hardware revision. Some later drives shipped with updated bootloaders and were identified as working with AC114; older units require the documented bootloader update path. The minimum supported hardware revision varies by model, so use the entry for the exact drive rather than transferring a threshold from another ACOPOS model.

1. Read the ACOPOS nameplate and record its complete model and hardware revision.
2. Compare that information with the AC114 minimum-version list.
3. If the drive meets the listed minimum, inspect card seating and verify that the installed interface is actually an AC114.
4. If the drive is below the listed minimum, classify the problem as a bootloader-compatibility issue and prepare the bridge-interface update procedure.

Do not move on until the drive is classified as either natively compatible with AC114 or requiring a bootloader update.

3. Bootloader bridge procedure

The incompatible drive cannot update itself through the unrecognized AC114: the communication path needed for the update is unavailable because recognition fails first. The documented update process requires a working AC110 or AC112 interface as the bridge. Follow the Bootloader Update section of Automation Studio Help for the applicable drive and interface combination.

1. Identify the former CAN interface instead of assuming that it is a suitable bridge. Confirm whether it is a working AC110 or AC112.
2. If neither supported bridge is available, contact the local B&R office or an official B&R support channel. An AC112 is discontinued, so borrowing a service interface may be more practical than purchasing one.
3. Install the working bridge interface and confirm that communication with the ACOPOS is restored through that interface.
4. Run the bootloader update exactly as described in Automation Studio Help. Keep the bridge installed until the engineering software reports successful completion.
5. Read back the resulting bootloader information and compare it with the required AC114 minimum version for the exact drive revision.

Do not remove the bridge or reinstall the POWERLINK card until the update reports success and the resulting version satisfies the published compatibility entry.

4. AC114 installation and POWERLINK bring-up

After the compatibility gate is satisfied, install the AC114 and separate local recognition from network commissioning. First verify that the five-flash invalid-hardware-ID sequence no longer appears. If it remains, return to the model/revision comparison, confirm the update result, and inspect whether the interface is fully seated. Repeatedly changing controller-side settings cannot clear a bootloader-level hardware-ID rejection.

1. Install the AC114 according to the ACOPOS hardware instructions.
2. Start the drive and observe the interface before relying on controller diagnostics.
3. Confirm that the Error LED no longer repeats five red flashes.
4. Connect the POWERLINK path to the X20CP1584 using the controller project’s intended topology.
5. Open the controller and network diagnostics and confirm that the configured interface is discovered without an invalid-hardware-ID indication.

Do not move on until the drive recognizes the AC114. Absence of the five-flash code proves the recognition gate has been passed; it does not yet prove that the Automation Studio project is configured for POWERLINK.

5. Automation Studio runtime-module conversion

A project previously built for the CAN interface contains different ACOPOS runtime modules from a POWERLINK project. Replace both Acp10man.br and Acp10sys.br with the variants intended for POWERLINK. Changing only the physical card leaves the controller application carrying the former communication-specific binaries.

1. Back up the working project configuration.
2. Remove or exchange the CAN-specific copies of both runtime modules.
3. Add the corresponding POWERLINK versions through the project’s supported library or module-selection workflow.
4. Rebuild the project and resolve every missing, duplicate, or incompatible module report.
5. Transfer the completed configuration to the X20CP1584 and restart the affected runtime as required by the engineering workflow.

Do not proceed to motion testing until both named modules are converted and the project builds without a CAN/POWERLINK interface mismatch.

6. End-to-end communication verification

Verify the repair in layers so a remaining project problem is not mistaken for another card failure.

1. Restart the controller and drive from a defined stopped condition.
2. Confirm that the AC114 does not display the five-red-flash Invalid hardware ID code.
3. Check POWERLINK diagnostics and confirm that the configured drive is present without an interface error.
4. Open the ACOPOS diagnostics and verify that status data updates cyclically rather than remaining stale or unavailable.
5. Check the controller diagnostic log for missing or incompatible Acp10man.br and Acp10sys.br entries.
6. Repeat the restart test. Accept the commissioning result only when card recognition, POWERLINK discovery, cyclic status updates, and runtime-module loading all pass again.

Recurring mistakes are bypassing the minimum-version check, assuming any former CAN card can perform the bootloader update, sourcing an obsolete AC112 before asking B&R about a service loan, and replacing the interface without exchanging both project runtime modules.

FAQ