ESD CPCI-405 User manual

CPCI-405 Hardware-Manual • Doc.-No.: I.2306.21 / Rev. 3.5 Page 1 of 57
esd electronic system design gmbh
Vahrenwalder Str. 207 • 30165 Hannover • Germany
http://www.esd.eu
Phone: [phone] • Fax: [phone]
CPCI-405
CompactPCI-Controller Board
with CAN and ETHERNET
Hardware Manual
to product: I.2306.04, I.2306.05, I.2306.07,
I.2306.08, I.2306.12, I.2306.47,
I.2306.49

Hardware-Manual • Doc.-No.: I.2306.21 / Rev. 3.5 CPCI-405
Page 2 of 57
N O T E
The information in this document has been carefully checked and is believed to be entirely reliable.
esd makes no warranty of any kind with regard to the material in this document, and assumes no
responsibility for any errors that may appear in this document. In particular descriptions and technical
data specified in this document may not be constituted to be guaranteed product features in any legal
sense.
esd reserves the right to make changes without notice to this, or any of its products, to improve
reliability, performance or design.
All rights to this documentation are reserved by esd. Distribution to third parties and reproduction of
this document in any form, whole or in part, are subject to esd’s written approval.
© 2015 esd electronics system design gmbh, Hannover
esd electronic system design gmbh
Vahrenwalder Str. 207
30165 Hannover
Germany
Phone: [phone]
Fax: [phone]
E-mail: [email protected]
Internet: www.esd.eu
This manual contains important information and instructions on safe and efficient
handling of the CPCI-405. Carefully read this manual before commencing any work
and follow the instructions to avoid serious injury or death.
The manual is a product component, please retain it for future use.
Trademark Notices
CANopen® and CiA® are registered community trademarks of CAN in Automation e.V.
CompactPCI® is a registered trademark of the PCI Industrial Computers Manufacturers Group.
CompactFlash® is a registered trademark of the SanDisk Corporation in the United States.
All other trademarks, product names, company names or company logos used in this manual are
reserved by their respective owners.

CPCI-405 Hardware-Manual • Doc.-No.: I.2306.21 / Rev. 3.5 Page 3 of 57
Document file:
I:\Texte\Doku\MANUALS\CPCI\CPCI405\Englisch\CPCI-405_Hardware_en_35.wpd
Date of print: 2015-11-13
Serial Number: from BC882
Changes in the chapters
The changes in the document listed below affect changes in the hardware as well as changes in the
description of the facts, only.
Version Chapter Changes as compared with previous version
3.4
1.3.3 NVRAM specified
2.1 Table completed
3.1.2 Addresses inserted
3.2.1 Default settings corrected (Handshake: none)
3.3.1 Table completed
3.5
- Safety instructions revised
1.3.7 New chapter "CompactFlash Card Interface"
4.1.1 Note concerning cable type inserted
4.5 Note concerning cable type inserted
6., 7. Chapters updated
8. Declaration of Conformity updated
9. Chapter "Order Information" moved and revised
Technical details are subject to change without further notice.

Hardware-Manual • Doc.-No.: I.2306.21 / Rev. 3.5 CPCI-405
Page 4 of 57
Safety Instructions

When working with CPCI-405 modules follow the instructions below and read the manual carefully to
protect yourself and the CPCI-405 module from damage.

The device is a built-in component. It is essential to ensure that the device is mounted in a way that
cannot lead to endangering or injury of persons or damage to objects.
Do not use damaged or defective cables to connect the CPCI-405 and follow the CAN wiring hints in
chapter: "Correct Wiring of Electrically Isolated CAN Networks"

The device has to be securely installed in the control cabinet before commissioning.

Protect the CPCI-405 module from dust, moisture and steam.

Protect the CPCI-405 module from shocks and vibrations.

The CPCI-405 module may become warm during normal use. Always allow adequate ventilation around
the CPCI-405 module and use care when handling.

Do not operate the CPCI-405 module adjacent to heat sources and do not expose it to unnecessary
thermal radiation. Ensure an ambient temperature as specified in the technical data.

Do not use damaged or defective cables to connect the CPCI-405 module.

In case of damages to the device, which might affect safety, appropriate and immediate measures must be
taken, that exclude an endangerment of persons and domestic animals and property.

Current circuits which are connected to the device have to be sufficiently protected against hazardous
voltage (SELV according to EN 60950-1).

The CPCI-405 may only be driven by power supply current circuits, that are contact protected. A power
supply, that provides a safety extra-low voltage (SELV or PELV) according to EN 60950-1, complies
with this conditions.
DANGER
Hazardous Voltage - Risk of electric shock due to unintentional contact with uninsulated live
parts with high voltages inside of the system into which the CPCI-405 is to be integrated.
Disconnect all hazardous voltages (mains voltage) before opening the system.
NOTICE
Electrostatic discharge may cause damage to electronic devices. In order to avoid this please
discharge your personal static electricity before you touch the module.
Qualified Personal
This documentation is directed exclusively towards qualified personal in control and automation engineering.
The installation and commissioning of the product may only be carried out by qualified personal, which is
authorized to put devices, systems and electric circuits into operation according to the applicable national
standards of safety engineering.
Conformity
The CPCI-405isanindustrial product and meetsthe demandsof the EUregulations andEMC standards printed
in the conformity declaration at the end of this manual.
Warning: In a residential, commercial or light industrial environment the CPCI-405 may cause radio
interferences in which case the user may be required to take adequate measures.
Data Safety
This device is equipped with an Ethernet or other interface which is suitable to establish a connection to data
networks. Depending on the software used on the device, these interfaces may allow attackers to compromise

CPCI-405 Hardware-Manual • Doc.-No.: I.2306.21 / Rev. 3.5 Page 5 of 57
normal function, get illegal access or cause damage.
esd does not take responsibility for any damage caused by the device if operated at any networks. It is the
responsibilityofthedevice'susertotakecarethatnecessarysafetyprecautionsforthedevice'snetworkinterface
are in place.
Intended Use
The intended use of the CPCI-405 module is the operation as High Performance PowerPC™ with Ethernet and
CAN.
The esd guarantee does not cover damages which result from improper use, usage not in accordance with
regulations or disregard of safety instructions and warnings.

The CPCI-405 module is intended for installation in a CompactPCI-system only.

The operation of the CPCI-405 module in hazardous areas, or areas exposed to potentially explosive
materials is not permitted.

The operation of the CPCI-405 module for medical purposes is prohibited.
Service Note
The CPCI-405 module does not contain any parts that require maintenance by the user. Unauthorized
intervention in the device voids warranty claims.
Disposal
Devices which have become defective in the long run have to be disposed in an appropriate way or have to be
returned to the manufacturer for proper disposal. Please, make a contribution to environmental protection.

Hardware-Manual • Doc.-No.: I.2306.21 / Rev. 3.5 CPCI-405
Page 6 of 57
Contents Page
1. Overview ....................................................................8
1.1DescriptionoftheCPCI-405Board ............................................8
1.2 PCB View with Connector Designations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
1.3SummaryofTechnicalData ................................................. 11
1.3.1GeneralTechnicalData............................................... 11
1.3.2CompactPCIBus....................................................12
1.3.3MicroprocessorandMemory ..........................................12
1.3.4SerialInterfaces.....................................................13
1.3.5CAN-Interfaces .....................................................13
1.3.6ETHERNETInterface................................................14
1.3.7CompactFlashCardInterface ..........................................14
1.3.8SoftwareSupport....................................................14
2. Front Panel View with LED-Display ............................................15
2.1LEDsintheFrontPanel ....................................................15
3.1 PowerPC Microcontroller PPC405GPr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.1.1General ...........................................................17
3.1.2AddressAssignment .................................................18
3.1.3InterruptSettings....................................................19
3.2SerialInterface............................................................20
3.2.1DefaultSetting .....................................................20
3.2.2Configuration ......................................................20
3.2.3 Connecting the RS-232-Interface SER 0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.2.4 Connecting the Serial Interface SER 1 with TTL-Level . . . . . . . . . . . . . . . . . . . . . . 21
3.3FunctionofCodingSwitch ..................................................22
3.3.1Overview..........................................................22
3.3.2 Switching the Boot-Flash-EPROM via Coding Switch Bit 4 . . . . . . . . . . . . . . . . . . 22
3.4CAN/DeviceNetUnit ......................................................23
3.4.1General ...........................................................23
3.4.2InterfaceCircuits....................................................24
4. Connector Assignment ........................................................25
4.1SerialInterfaces ........................................................... 25
4.1.1 SER 0: Assignment of the RJ12 Socket X700 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.1.2 SER 0: Connection Cable RJ12-DSUB9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.1.3 SER 0: DSUB-Socket when Using the Adapter Cable RJ12-DSUB9 . . . . . . . . . . . 27
4.1.4 SER 1: Assignment of the 6-pin Post Connector X710 . . . . . . . . . . . . . . . . . . . . . . 28
4.2CAN-BusInterface(X1000) .................................................29
4.3CAN-TTLSignals(X1010)..................................................30
4.4Option:DeviceNet-AdapterBoards ...........................................31
4.5 ETHERNET 10/100BASE-T Connection (X1200) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.6DebugPortX720..........................................................35
4.6.1 Signal Alignment of the 16-pole SMD-Strip and JTAG-Adapter (PCB-Rev. 1.x) . . 35
4.6.2 Signal Alignment of 8-pole SMD-Strip and JTAG-Adapter (from PCB-Rev. 2.x) . 36
5. Special Designs: CPCI-405 with CPCI-CAN-ISO11898 Add-On .....................37
5.1 CPCI-405-2 PowerPC Host with 8 HP Front Panel (I.2306.49) . . . . . . . . . . . . . . . . . . . . . 37
5.1.1 Front Panel view of CPCI-405-2 with Adapter Board and 8 HP Front Panel . . . . . 38

CPCI-405 Hardware-Manual • Doc.-No.: I.2306.21 / Rev. 3.5 Page 7 of 57
5.2 CPCI-405-A PCI-Adapter with 6 U Front Panel (I.2306.47) . . . . . . . . . . . . . . . . . . . . . . . . 39
5.2.1 Front Panel view of the CPCI-405-A PCI-Adapter with 6 U Front Panel . . . . . . . . 40
5.3SerialInterface............................................................41
5.3.1RS-232Interface ....................................................41
5.3.2RS-422interface ....................................................41
5.3.3RS-485interface ....................................................42
5.3.4 Solder Bridges for the Configuration of the Serial Interface SER1 . . . . . . . . . . . . . 43
5.4 Connector Assignments of the Special Designs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.4.1CAN-InterfaceCAN1................................................44
5.4.2 SER1: Assignment of the RJ12 Socket P100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6. Correct Wiring of Electrically Isolated CAN Networks .............................46
6.1StandardsconcerningCANWiring ............................................46
6.2 Heavy Industrial Environment (Double Twisted Pair Cable) . . . . . . . . . . . . . . . . . . . . . . . . 47
6.2.1GeneralRules ......................................................47
6.2.2DeviceCabling .....................................................48
6.2.3Termination ........................................................48
6.3 Light Industrial Environment (Single Twisted Pair Cable) . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.3.1GeneralRules ......................................................49
6.3.2Cabling ........................................................50
6.3.3Termination ........................................................50
6.4ElectricalGrounding .......................................................51
6.5BusLength...............................................................51
6.6ExamplesforCANCables ..................................................52
6.6.1 Cable for Light Industrial Environment Applications (Two-Wire) . . . . . . . . . . . . . . 52
6.6.2 Cable for Heavy Industrial Environment Applications (Four-Wire) . . . . . . . . . . . . . 52
7. CAN-Bus Troubleshooting Guide ...............................................53
7.1Termination ..............................................................53
7.2ElectricalGrounding .......................................................54
7.3ShortCircuitinCANWiring.................................................54
7.4CAN_H/CAN_LVoltage ...................................................54
7.5CANTransceiverResistanceTest ............................................55
7.6Supportbyesd ............................................................55
8. EU Declaration of Conformity .................................................56
9. Order Information ...........................................................57

Overview
Hardware-Manual • Doc.-No.: I.2306.21 / Rev. 3.5
CPCI-405
Page 8 of 57
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1. Overview
1.1 Description of the CPCI-405 Board
Fig. 1.1.1: Block circuit diagram
The CPCI-405 is a CompactPCI board in Euro format. It is available as PCI-master CPU or as
intelligentslaveboard.Bothoptionsonlydifferintheconfigurationof the PowerPC 405GPrprocessor.
Apart from a powerful CPU the PowerPC 405GPr processor has got an SDRAM controller, a PCI-bus
interface, a controller for serial interfaces and an MII-interface which is here used to realize an
ETHERNET interface.
In addition to Flash EPROM and NVRAM as system memory, the memory of the CPCI-405 has got
up to 128 Mbyte SDRAM as working memory. Furthermore, the board has got a CompactFlash card
interface. The boards plugged in can be accessed by standard system drivers like an IDE-drive.
One of the two serial interfaces has been designed as an RS-232-interface. It can be accessed via an
RJ12-connector in the front panel. The second serial interface is accessible via a post connector on
board. The signals of this interface are of TTL-level.
The CAN-interface which can be accessed via the front panel, is controlled by an SJA1000-CAN-
controller. The interface corresponds to ISO11898, is electrically insulated and can be used for
transmission rates of up to 1 Mbit/s. The second CAN-interface has got an SJA1000-CAN-controller
as well.

Overview
CPCI-405 Hardware-Manual • Doc.-No.: I.2306.21 / Rev. 3.5 Page 9 of 57
The TTL-signals of both controllers are led to a post connector. Here, two adapter boards can be
connectedviaflatribboncables,realisingthephysicallayer.TheadapterboardsareavailablewithCAN
(ISO11898) or DeviceNet interfaces. Optionally the CPCI-405 together with the adapter board is
available in two special designs (page 37).
The ETHERNET interface is suitable for 10 Mbit/s and 100 Mbit/s networks. They are connected via
an RJ45 socket in the front panel.
The status of the board is shown by LEDs in the front panel.

Overview
Hardware-Manual • Doc.-No.: I.2306.21 / Rev. 3.5
CPCI-405
Page 10 of 57
1.2 PCB View with Connector Designations
Fig. 1.2.1: PCB view (diagram without front panel)
The connector pin assignments can be found on page 25 and the following.