Powerlink Communication Issue between X20CP1484 and ACOPOS1640 (AC112 Detected as "Unplugged")

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I’m currently working on a project to control a servo motor using a B&R X20CP1484 PLC, connected to an ACOPOS1640 servo drive via Powerlink V1. The ACOPOS is equipped with an AC112 plug-in module, which only supports Powerlink V1.

The issue I’m facing:

  • After uploading the hardware configuration to the PLC, the AC112 module is shown as “unplugged” in System Diagnostic Manager.
  • The LED on the AC112 module is solid green, which I understand indicates normal operation with no communication errors.
  • The Node ID settings on both the PLC and the drive have been verified and are correct.

During my research, I found a post on the B&R Community Forum that suggests upgrading ACP10 (Motion Control Runtime) from version 2.x.x to 3.x.x to enable automatic detection of older plug-in modules such as AC112 (this solution is from @stephan.herbig ):
:link: Forum reference – ACOPOS 1045 and plug-in module detection

After upgrading ACP10 to version 3.x.x, I encountered a new issue:

  • When attempting to upload the project to the PLC, I receive the following error:

“Not enough memory”

  • The CF card currently installed is 128 MB, and the project contains only the hardware configuration (no application code yet).

My questions are:

  1. Is upgrading ACP10 to version 3.x.x really required to solve the “unplugged” issue with the AC112 module?
  2. What could be causing the “Not enough memory” error during project upload, even with a 128 MB CF card?
  3. Are there any alternative solutions or configurations I should try to get the system working?
    error 2
    error 21168×843 126 KB

Any guidance or suggestions would be highly appreciated. Thank you in advance!

Best Regards,
Hasan

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Hello Hasan @Hasan_Dzulfadli ,

regarding the topic ‘not enough memory’:

if you use a CF with the ‘safe file system’ the available storage space is divided into three partitions and there is double data storage.

You could check this with the HDD / CF Utility

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Thanks for the suggestion @christoph.hilchenbac

But can you please explain in more detail the suggestion you gave? maybe explain in more detail from the beginning why this memory problem can occur, even though it’s just an “empty” program and how can HDD/CF Utility solve this memory problem?

Thanks

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If the ‘safe file system’ is set, then you do not have the entire storage space of the CFast available. Three partitions are then created: one for the operating system files and two mirrored partitions for the application code.

One partition may be too small (for whatever reason). Since you are now using a new ACOPOS operating system, it may be larger than the old one and therefore no longer fit.

You can then, for example, use the ‘simple file system’ as a test. The entire storage space of the CF is then available.

Of course, I could be completely wrong, but it’s quite easy to check.

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Your suggestion seems good and I have tried it; I disabled the safe file system option. This makes the CF card only formatted into 1 partition C: . but unfortunately, when I try to upload the program, the error “not enough memory” still appears.

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Hi Hasan

This is because is not about memory in CF, is about memory en PLC RAM I think, X20CP1484 is really limited, I had this problem once when I try the same, changing from 2.0 to 3.0, there was no option for me than changing PLC for a newer one.

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yep, to check the DRAM would be next. Later on there was a X20CP1484**-1** with extended RAM.

@Hasan_Dzulfadli : an option for testing would be to create an ‘empty’ project with just one ACOPOS inserted and check the free RAM.
You can also use it to check whether ACP10 3.x solves your original issue.