Sys Tec Electronic PLCcore-5208 User manual

SYS TEC electronic GmbH - System House for distributed Automation
System Manual
PLCcore-5208
User Manual
Version 1.0
Edition September 2009
Document No.: L-1076e_1
SYS TEC electronic GmbH August-Bebel-Str. 29 D-07973 Greiz
Phone: [phone] Fax: [phone]
Web: http://www.systec-electronic.com Mail: [email protected]

System Manual PLCcore-5208
© SYS TEC electronic GmbH 2009 L-1076e_1 Page 1
Status/Changes
Status: released
Date/Version Section Changes Editor
2009/09/09
1.0
All Creation R. Sieber

System Manual PLCcore-5208
© SYS TEC electronic GmbH 2009 L-1076e_1 Page 2
This manual includes descriptions for copyrighted products that are not explicitly indicated as such.
The absence of the trademark (©) symbol does not infer that a product is not protected. Additionally,
registered patents and trademarks are similarly not expressly indicated in this manual.
The information in this document has been carefully checked and is believed to be entirely reliable.
However, SYS TEC electronic GmbH assumes no responsibility for any inaccuracies. SYS TEC
electronic GmbH neither guarantees nor accepts any liability whatsoever for consequential damages
resulting from the use of this manual or its associated product. SYS TEC electronic GmbH reserves
the right to alter the information contained herein without prior notification and does not accept
responsibility for any damages which might result.
Additionally, SYS TEC electronic GmbH neither guarantees nor assumes any liability for damages
arising from the improper usage or improper installation of the hardware or software. SYS TEC
electronic GmbH further reserves the right to alter the layout and/or design of the hardware without
prior notification and accepts no liability for doing so.
©Copyright 2009 SYS TEC electronic GmbH. All rights – including those of translation, reprint,
broadcast, photomechanical or similar reproduction and storage or processing in computer systems, in
whole or in part – are reserved. No reproduction may occur without the express written consent from
SYS TEC electronic GmbH.
Inform yourselves:
Contact Direct Your local distributor
Address: SYS TEC electronic GmbH
August-Bebel-Str. 29
D-07973 Greiz
GERMANY
Ordering
Information:
+49 (0) 36 61 / 62 79-0
[email protected]
Technical Support: +49 (0) 36 61 / 62 79-0
[e-mail]
Fax: [phone] / 6 79 99
Web Site: http://www.systec-electronic.com
Please find a list of our
distributors under:
http://www.systec-
electronic.com/distributors
1st Edition September 2009

System Manual PLCcore-5208
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Table of Contents
1Introduction .....................................................................................................................5
2Overview / Where to find what?.....................................................................................6
3Product Description........................................................................................................8
4Development Kit PLCcore-5208...................................................................................10
4.1 Overview.............................................................................................................................. 10
4.2 Electric commissioning of the Development Kit PLCcore-5208 .......................................... 11
4.3 Control elements of the Development Kit PLCcore-5208 ................................................... 12
4.4 Optional accessory ..............................................................................................................13
4.4.1 USB-RS232 Adapter Cable .................................................................................... 13
4.4.2 Driver Development Kit........................................................................................... 14
5Pinout of the PLCcore-5208 .........................................................................................15
6PLC Functionality of the PLCcore-5208......................................................................17
6.1 Overview.............................................................................................................................. 17
6.2 System start of the PLCcore-5208 ...................................................................................... 17
6.3 Programming the PLCcore-5208......................................................................................... 18
6.4 Process image of the PLCcore-5208 .................................................................................. 18
6.4.1 In- and Outputs of Development Kit PLCcore-5208 ............................................... 19
6.4.2 In- and outputs of user-specific baseboards........................................................... 19
6.5 Communication interfaces ................................................................................................... 20
6.5.1 Serial interfaces ...................................................................................................... 20
6.5.2 CAN interface ......................................................................................................... 20
6.5.3 Ethernet interface ................................................................................................... 20
6.6 Control and display elements .............................................................................................. 21
6.6.1 Run/Stop switch...................................................................................................... 21
6.6.2 Run-LED (green) .................................................................................................... 21
6.6.3 Error-LED (red) ....................................................................................................... 22
6.7 Local deletion of a PLC program......................................................................................... 22
6.8 Using CANopen for CAN interfaces .................................................................................... 23
6.8.1 CAN interface CAN0............................................................................................... 24
6.8.2 Additional CAN interfaces....................................................................................... 24
7Configuration and Administration of the PLCcore-5208 ...........................................25
7.1 System requirements and necessary software tools........................................................... 25
7.2 Activation/Deactivation of Linux Autostart ........................................................................... 26
7.3 Ethernet configuration of the PLCcore-5208 ....................................................................... 27
7.4 PLC configuration of the PLCcore-5208.............................................................................. 29
7.4.1 PLC configuration via WEB-Frontend..................................................................... 29
7.4.2 PLC configuration via control elements of the Development Kit PLCcore-5208.... 31
7.4.3 Setup of the configuration file "plccore-5208.cfg"................................................... 32
7.5 Boot configuration of the PLCcore-5208 ............................................................................. 34
7.6 Selecting the appropriate firmware version ......................................................................... 34
7.7 Predefined user accounts.................................................................................................... 36
7.8 Login to the PLCcore-5208.................................................................................................. 36
7.8.1 Login to the command shell.................................................................................... 36
7.8.2 Login to the FTP server .......................................................................................... 37
7.9 Adding and deleting user accounts ..................................................................................... 39
7.10 How to change the password for user accounts ................................................................. 40
7.11 Setting the system time ....................................................................................................... 41
7.12 File system of the PLCcore-5208 ........................................................................................ 42
7.13 Software update of the PLCcore-5208 ................................................................................ 43
7.13.1 Updating the PLC firmware..................................................................................... 44

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7.13.2 How to update the uClinux-Image .......................................................................... 45
8Adaption of In-/Outputs and Process Image...............................................................48
8.1 Data exchange via shared process image .......................................................................... 48
8.1.1 Overview of the shared process image .................................................................. 48
8.1.2 API of the shared process image client .................................................................. 51
8.1.3 Creating a user-specific client application .............................................................. 55
8.1.4 Example for using the shared process image ........................................................ 57
8.2 Driver Development Kit (DDK) for the PLCcore-5208......................................................... 61
8.3 Testing the hardware connections ...................................................................................... 62
Appendix A: Firmware function scope of PLCcore-5208 .................................................64
Appendix B: Reference design for the PLCcore-5208......................................................67
Appendix C: GNU GENERAL PUBLIC LICENSE................................................................69
Index......................................................................................................................................74

System Manual PLCcore-5208
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1 Introduction
Thank you that you have decided for the SYS TEC PLCcore-5208. This product provides to you an
innovative and high-capacity PLC-kernel which – due to its numerous interfaces – is well-suitable as
communication and control processor for embedded applications.
Please take some time to read through this manual carefully. It contains important information about
the commissioning, configuration and programming of the PLCcore-5208. It will assist you in getting
familiar with the functional range and usage of the PLCcore-5208. This document is complemented by
other manuals, e.g. for the OpenPCS IEC 61131 programming system and the CANopen extension for
IEC 61131-3. Table 3 in section 4.1 shows a listing of relevant manuals for the PLCcore-5208. Please
also refer to those complementary documents.
For more information, optional products, updates et cetera, we recommend you to visit our website:
http://www.systec-electronic.com. The content of this website is updated periodically and provides to
you downloads of the latest software releases and manual versions.
Declaration of Electro Magnetic Conformity for PLCcore-5208
(EMC law)
The PLCcore-5208 has been designed to be used as vendor part for the integration into devices
(further industrial processing) or as Development Board for laboratory development (hard- and
software development).
After the integration into a device or when changes/extensions are made to this product, the
conformity to EMC-law again must be assessed and certified. Only thereafter products may be
launched onto the market.
The CE-conformity is only valid for the application area described in this document and only under
compliance with the following commissioning instructions! The PLCcore-5208 is ESD-sensitive and
may only be unpacked, used and operated by trained personal at ESD-conform work stations.
The PLCcore-5208 is a module for the application in automation technology. It features IEC 61131-3
programmability, uses standard CAN-bus and Ethernet network interfaces and a standardized network
protocol. Consequently, development times are short and hardware costs are reasonable. PLC-
functionality is created on-board through a CANopen network layer. Hence, it is not necessary for the
user to create firmware.

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2 Overview / Where to find what?
The PLCcore-5208 is based on SYS TEC ECUcore-5208 hardware and is extended by PLC-specific
functionality (I/O driver, PLC firmware). There are different hardware manuals for all hardware
components such as the ECUcore-5208 and the PLCcore-5208 (the hardware of both modules is
identical), development boards and reference circuitry. Software-sided, the PLCcore-5208 is
programmed with IEC 61131-3-conform OpenPCS programming environment. There are additional
manuals for OpenPCS that describe the handling of programming tools and SYS TEC-specific
extensions. Those are part of the software package "OpenPCS". Table 1 lists all relevant manuals for
the PLCcore-5208.
Table 1: Overview of relevant manuals for the PLCcore-5208
Information about… In which manual?
Basic information about the PLCcore-5208
(configuration, administration, process image,
connection assignment, firmware update,
reference designs et cetera)
In this manual
Development of user-specific C/C++ applications
for the ECUcore-5208 / PLCcore-5208, VMware-
Image of the Linux development system
System Manual ECUcore-5208
(Manual no.: L-1202)
Hardware description about the ECUcore-5208 /
PLCcore-5208, reference designs et cetera
Hardware Manual ECUcore-5208
(Manual no.: L-1232)
Development Board for the ECUcore-5208 /
PLCcore-5208, reference designs et cetera
Hardware Manual Development Board 5208
(Manual no.: L-1074)
Driver Development Kit (DDK) for the ECUcore-
5208
Software Manual Driver Development Kit (DDK)
for ECUcore-5208
(Manual no.: L-1231)
Basics about the OpenPCS IEC 61131
programming system
Brief instructions for the programming system
(Entry "OpenPCS Documentation" in the
OpenPCS program group of the start menu)
(Manual no.: L-1005)
Complete description of the OpenPCS IEC 61131
programming system, basics about the PLC
programming according to IEC 61131-3
Online help about the OpenPCS programming
system
Command overview and description of standard
function blocks according to IEC 61131-3
Online help about the OpenPCS programming
system
SYS TEC extension for IEC 61131-3:
- String functions
- UDP function blocks
- SIO function blocks
- FB for RTC, Counter, EEPROM, PWM/PTO
User Manual "SYS TEC-specific extensions for
OpenPCS / IEC 61131-3"
(Manual no.: L-1054)

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CANopen extension for IEC 61131-3
(Network variables, CANopen function blocks)
User Manual "CANopen extension for
IEC 61131-3"
(Manual no.: L-1008)
Textbook about PLC programming according to
IEC 61131-3
IEC 61131-3: Programming Industrial Automation
Systems
John/Tiegelkamp
Springer-Verlag
ISBN: 3-540-67752-6
(a short version is available as PDF on the
OpenPCS installation CD)
Section 4 of this manual explains the commissioning of the PLCcore-5208 based on the
Development Kit for the PLCcore-5208.
Section 5 describes the connection assignment of the PLCcore-5208.
Section 0explains details about the application of the PLCcore-5208, e.g. the setup of the
process image, the meaning of control elements and it provides basic information
about programming the module. Moreover, information is given about the usage of
CAN interfaces in connection with CANopen.
Section 7describes details about the configuration of the PLCcore-5208, e.g. the
configuration of Ethernet and CAN interfaces, the Linux Autostart procedure as well as
choosing the firmware version. Furthermore, the administration of the PLCcore-
5208 is explained, e.g. the login to the system, the user administration and the
execution of software updates.
Section 8defines the adaptation of in- and outputs as well as the process image and it
covers the data exchange between a PLC program and a user-specific C/C++
application via shared process image.

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3 Product Description
The PLCcore-5208 as another innovative product extends the SYS TEC electronic GmbH product
range within the field of control applications. In the form of an insert-ready core module, it provides to
the user a complete and compact PLC. Due to CAN and Ethernet interfaces, the PLCcore-5208 is best
suitable to perform decentralized control tasks.
Figure 1: Top view of the PLCcore-5208
These are some significant features of the PLCcore-5208:
•High-capacity CPU kernel (Freescale 32-Bit MCF5208 ColdFire, 166 MHz CPU clock, 159 MIPS)
•32 MByte SDRAM Memory, 4 MByte NOR-FLASH Memory, 64 MByte NAND-Flash Memory
•1x 10/100 Mbps Ethernet LAN interface (with on–board PHY)
•1x CAN 2.0B interface, usable as CANopen Manager (CiA 302-conform)
•3x asynchronous serial ports (UART)
•Flexible in-/output circuit by address /data bus leading towards the outside
•Externally usable I2C
•On-board peripherals: RTC, temperature sensor
•On-board software: uClinux, PLC firmware, CANopen Master, HTTP and FTP server
•Programmable in IEC 61131-3 and in C/C++
•Function block libraries for communication (CANopen, Ethernet and UART)
•Function block libraries for hardware components (RTC, Counter, PWM/PTO)
•Support of typical PLC control elements (e.g. Run/Stop switch, Run-LED, Error-LED)
•uClinux-based (other user programs may run in parallel)
•Easy, HTML-based configuration via WEB Browser
•Remote Login via Telnet
•Small dimension (72 x 51 mm)
There are different types of firmware available for the PLCcore-5208. They differ regarding the
protocol used for the communication between Programming PC and PLCcore-5208:
Order number: 3390014: PLCcore-5208/Z4 (CANopen)
communication with Programming PC via CANopen Protocol
(Interface CAN0)

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Order number: 3390015: PLCcore-5208/Z5 (Ethernet)
communication with Programming PC via UDP Protocol
(Interface ETH0)
Making PLC available as an insert-ready core module with small dimensions reduces effort and costs
significantly for the development of user-specific controls. The PLCcore-5208 is also very well suitable
as intelligent network node for decentralized processing of process signals (CANopen and UDP).
Additionally, it can be used as basic component for special assemblies or as PLC in hard-to-access
areas.
The on-board firmware of the PLCcore-5208 contains the entire PLC runtime environment including
CANopen connection with CANopen master functionality. Thus, the module is able to perform control
tasks such as linking in- and outputs or converting rule algorithms. Data and occurrences can be
exchanged with other nodes (e.g. superior main controller, I/O slaves and so forth) via CANopen
network, Ethernet (UDP protocol) and serial interfaces (UART). Moreover, the number of in- and
outputs either is locally extendable or decentralized via CANopen devices. For this purpose, the
CANopen-Chip is suitable. It has also been designed as insert-ready core module for the appliance in
user-specific applications.
The address/data bus leading towards the outside provides to the user most effective degrees of
freedom for designing the in-/output circuit of the PLCcore-5208. Therewith, all in- and outputs of the
PLCcore-5208 can be flexibly adjusted to respective requirements. Saving the PLC program in the on-
board Flash-Disk of the module allows an automatic restart in case of power breakdown.
Programming the PLCcore-5208 takes place according to IEC 61131-3 using the OpenPCS
programming system of the company infoteam Software GmbH (http://www.infoteam.de). This
programming system has been extended and adjusted for the PLCcore-5208 by the company
SYS TEC electronic GmbH. Hence, it is possible to program the PLCcore-5208 graphically in
KOP/FUB, AS and CFC or textually in AWL or ST. Downloading the PLC program onto the module
takes place via Ethernet or CANopen – depending on the firmware that is used. Addressing in- and
outputs and creating a process image follows the SYS TEC scheme for compact control units. Like all
other SYS TEC controls, the PLCcore-5208 supports backward documentation of the PLC program as
well as the debug functionality including watching and setting variables, single cycles, breakpoints and
single steps.
The PLCcore-5208 is based on Embedded Linux (uClinux) as operating system. This allows for an
execution of other user-specific programs while PLC firmware is running. If necessary, those other
user-specific programs may interchange data with the PLC program via the process image. More
information about this is provided in section 8.
The Embedded Linux (uClinux) applied to the PLCcore-5208 is licensed under GNU General Public
License, version 2. Appendix C contains the license text. All sources of LinuxBSP are included in the
software package SO-1096 ("VMware-Image of the uClinux development system for the ECUcore-
5208"). If you require the LinuxBSP sources independently from the VMware-Image of the Linux
development system, please contact our support:
[e-mail]
The PLC system and the PLC- and C/C++ programs developed by the user are not subject to GNU
General Public License!

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4 Development Kit PLCcore-5208
4.1 Overview
The Development Kit PLCcore-5208 is a high-capacity, complete package at a particularly favorable
price. Based on a compact PLC, it enables the user to perform decentralized, network-compatible
automation projects. Moreover, it facilitates the user to get to know the advantages of graphical and
textual PLC programming according to IEC 61131-3 – compared to conventional programming
languages.
Figure 2: Development Kit PLCcore-5208
The Development Kit PLCcore-5208 ensures quick and problem-free commissioning of the PLCcore-
5208. Therefore, it combines all hard- and software components that are necessary to create own
applications: the core module PLCcore-5208, the corresponding Development Board containing I/O
periphery and numerous interfaces, the OpenPCS IEC 61131 programming system as well as further
accessory. Thus, the Development Kit forms the ideal platform for developing user-specific
applications based on the PLCcore-5208. It allows for a cost-efficient introduction into the world of
decentralized automation technology. All components included in the Kit enable in- and output
extensions of the PLCcore-5208 through CANopen-I/O-assemblies. Thus, the Development Kit may
also be used for projects that require PLC with network connection.
The Development Kit PLCcore-5208 contains the following hardware components:
PLCcore-5208
Development Board for the PLCcore-5208
24V DC Power adapter
Ethernet cable
RS232 cable
CD with programming software, examples, documentation and other tools

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The Development Board included in the Kit facilitates quick commissioning of the PLCcore-5208 and
simplifies the design of prototypes for user-specific applications based on this module. Among other
equipment, the Development Board comprises different power supply possibilities, Ethernet interface,
CAN-bus interface, 5 push buttons and 5 LED as control elements for digital in- and outputs and it
comprises a potentiometer for the analog input. Signals that are available from plug connectors of the
PLCcore-5208 are linked to pin header connectors and enable easy connection of own peripheral
circuitry. Hence, the Development Board forms an ideal experimentation and testing platform for the
PLCcore-5208.
The OpenPCS IEC 61131 programming system included in the Kit serves as software development
platform and as debug environment for the PLCcore-5208. Thus, the module can either be
programmed graphically in KOP/FUB, AS and CFC or textually in AWL or ST. Downloading the PLC
program onto the module takes place via Ethernet or CANopen – depending on the firmware that is
used. High-capacity debug functionality such as watching and setting variables, single cycles,
breakpoints and single steps simplify the development and commissioning of user software for this
module.
4.2 Electric commissioning of the Development Kit PLCcore-5208
A 24V DC power adapter necessary for running the Development Kit PLCcore-5208 and Ethernet and
RS232 cables are already included in the Kit delivery. For commissioning the Kit, it is essential to use
at least the power supply connections (X600/X601), COM0 (X304 on top) and ETH0 (X302).
Furthermore, connection CAN0 (X303) is recommended. Table 2 provides an overview over the
connections of the Development Kit PLCcore-5208.
Table 2: Connections of the Development Kit PLCcore-5208
Connection Labeling on the
Development
Board
Remark
Power supply X600 or X601 The 24V DC power adapter included in the delivery
is intended for direct connection to X601.
ETH0 (Ethernet) X302 This interface serves as communication interface
with the Programming PC and is necessary for the
program download (PLCcore-5208/Z5, order
number 3390015), besides can be used freely for
the user program.
COM0 (RS232) X304 / on top This interface is used for the configuration of the
unit (e.g. setting the IP-address) and can be used
freely for general operation of the user program.
COM1 (RS232) X304 / below Interface can be used freely for the user program.
COM2 (RS422) X301 Interface can be used freely for the user program.
CAN0 (CAN) X303 This interface serves as communication interface
with the Programming PC and is necessary for the
program download (PLCcore-5208/Z4, order
number 3390014), besides can be used freely for
the user program.
Figure 3 shows the positioning of the most important connections of the Development Board for the
PLCcore-5208. Instead of using the 24V DC power adapter included in the Kit, the power supply may
optionally take place via X600 with an external source of 24V/1A.

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Figure 3: Positioning of most important connections on the Development Board for the PLCcore-5208
Advice: Upon commissioning, cables for Ethernet (ETH0, X302) and RS232 (COM0, X304 on
top) must be connected prior to activating the power supply (X600 / X601).
4.3 Control elements of the Development Kit PLCcore-5208
The Development Kit PLCcore-5208 allows for easy commissioning of the PLCcore-5208. It has
available various control elements to configure the module and to simulate in- and outputs for the
usage of the PLCcore-5208 as PLC kernel. In Table 3 control elements of the Development Board are
listed and their meaning is described.
Table 3: Control elements of the Development Board for the PLCcore-5208
Control element Name Meaning
Pushbutton 0 S500 Digital Input DI0 (Process Image: %IX0.0)
Pushbutton 1 S501 Digital Input DI1 (Process Image: %IX0.1)
Pushbutton 2 S502 Digital Input DI2 (Process Image: %IX0.2)
Pushbutton 3 S503 Digital Input DI3 (Process Image: %IX0.3)
Pushbutton 4 S504 Digital Input DI4 (Process Image: %IX0.4)

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LED 0 D500 Digital Output DO0 (Process Image: %QX0.0)
LED 1 D501 Digital Output DO1 (Process Image: %QX0.1)
LED 2 D502 Digital Output DO2 (Process Image: %QX0.2)
LED 3 D503 Digital Output DO3 (Process Image: %QX0.3)
LED 4 D504 Digital Output DO4 (Process Image: %QX0.4)
Poti (ADC) R407 Analog Input AI0 (Process Image: %IW8.0)
Test point (DAC) TP400 / TP401 Analog Output AO0 (Process Image: %QW8.0)
Run/Stop Switch S405 Run / Stop to operate the PLC program, Reset control (see
section 6.6.1)
Run-LED D403 Display of activity state of the PLC (see section 6.6.2)
Error-LED D404 Display of error state of the PLC (see section 6.6.3)
Hex-Encoding
Switch
S402/S401 Configuration of node address CAN0 (see section 7.4.2)
DIP-Switch S400 Configuration of bitrate and master mode CAN0 (see section
7.4.2)
Table 6 in section 6.4.1 provides a complete listing of the process image.
4.4 Optional accessory
4.4.1 USB-RS232 Adapter Cable
The SYS TEC USB-RS232 Adapter Cable (order number 3234000) provides a RS232 interface via an
USB-Port of the PC. Together with a terminal program, it enables the configuration of the PLCcore-
5208 from PCs, e.g. laptop computers which do not have RS232 interfaces any more (see section
6.1).
Figure 4: SYS TEC USB-RS232 Adapter Cable

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4.4.2 Driver Development Kit
The ECUcore-5208 Driver Development Kit (order number SO-1101) allows the user to independently
adjust the I/O level to his own baseboard. Section 8.2 provides information about the Driver
Development Kit.

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5 Pinout of the PLCcore-5208
Connections of the PLCcore-5208 are directed to the outside via two pin header connectors that are
double-row (with each 2 x 52 pins) and mounted on the bottom of the module. Appropriate female
headers as correspondent to the PLCcore-5208 are available from company "W+P Products":
W+P Products name: 7351Series
W+P Products order number: 7450-52-20-xx-xx (see W+P Products Datasheet)
Figure 5: Pinout of the PLCcore-5208 - bottom view
Figure 5 exemplifies the positioning of pin header connectors on the PLCcore-5208. The complete
connection assignment of this module is listed up in Table 4. Appendix B includes reference designs
for using the PLCcore-5208 in customer-specific applications.
Table 4: Connections of the PLCcore-5208, completely, sorted by connection pin
Signal Pin Pin Signal Signal Pin Pin Signal
GND A01 B01 /MR 2V5_EPHY C01 D01 ETH_TX-
/RSTO A02 B02 /RSTI GND C02 D02 ETH_TX+
PFI A03 B03 PI2C_DATA ETH_RX+ C03 D03 ETH_LINK/ACT
WDI A04 B04 GND ETH_RX- C04 D04 GND
TP_0 A05 B05 PI2C_CLK ETH_SPEED C05 D05 GPIO_PUART2
A0 A06 B06 A10 D16 C06 D06 D24
GND A07 B07 A11 GND C07 D07 D25
A1 A08 B08 A12 D17 C08 D08 D26
A2 A09 B09 A13 D18 C09 D09 D27
A3 A10 B10 GND D19 C10 D10 GND
A4 A11 B11 A14 D20 C11 D11 D28
A5 A12 B12 A15 D21 C12 D12 D29
GND A13 B13 A16 GND C13 D13 D30
A6 A14 B14 A17 D22 C14 D14 D31
A7 A15 B15 A18 D23 C15 D15 PSPI_/CS2
A8 A16 B16 GND PSPI_/CS0 C16 D16 GND
A9 A17 B17 A19 PSPI_/CS1 C17 D17 PSPI_/CSCAN
/CS1 A18 B18 /CS4 PSPI_CLK C18 D18 PSPI_MRST
GND A19 B19 /CS5 GND C19 D19 GPIO_PIRQ1
R/W A20 B20 /OE PSPI_MTSR C20 D20 GPIO_PIRQ7
/BWE0 A21 B21 GPIO_BWE1 GPIO_PTIMER2 C21 D21 GPIO_PCS2
GPIO_PBUSCTL0 A22 B22 GND GPIO_PTIMER3 C22 D22 GND

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Signal Pin Pin Signal Signal Pin Pin Signal
GPIO_PBUSCTL2 A23 B23 /BOOTSELECT PUART_RXD0 C23 D23 GPIO_PCS3
VBAT A24 B24 PCAN_RX0 PUART_RXD1 C24 D24 PUART_TXD0
GND A25 B25 PCAN_TX0 GND C25 D25 PUART_TXD1
3V3 A26 B26 3V3 PUART_RXD2 C26 D26 PUART_TXD2
Advice: The PLCcore-5208 only executes a PLC program if the Run/Stop switch is
positioned to "Run". If no Run/Stop switch is intended for the usage of the
PLCcore-5208 on an application-specific baseboard, the coding for "Run" must be
hard-wired at the module connections (also see reference design in Appendix B).

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6 PLC Functionality of the PLCcore-5208
6.1 Overview
The PLCcore-5208 realizes a complete uClinux-based compact PLC as an insert-ready core ("Core").
There, the PLCcore-5208 is based on the hardware ECUcore-5208 and extends it by PLC-specific
functionality (I/O driver, PLC firmware). Both modules, the ECUcore-5208 and the PLCcore-5208, use
the same Embedded Linux (uClinux) as operating system. Consequently, the configuration and the
C/C++ programming of the PLCcore-5208 are almost identical with the ECUcore-5208.
6.2 System start of the PLCcore-5208
By default, the PLCcore-5208 loads all necessary firmware components upon Power-on or Reset and
starts running the PLC program afterwards. Hence, the PLCcore-5208 is suitable for the usage in
autarchic control systems. In case of power breakdown, such systems resume the execution of the
PLC program independently and without user intervention. Figure 6 shows the system start in detail:
Power-on / Reset
Start Linux-Bootloader
"CoLilo"
Start Linux
Operating System
Run Boot Script
"/home/etc/autostart"
Start PLC Firmware
Load Module Drivers
(I/O, CAN, RTC, etc.)
Run PLC User Program
Start Servers
(HTTP-Server, FTP-Server)
For more details on how to
deactivate the autarchic Linux
start and to activate the “CoLilo"
command prompt compare
section 7.2.
Details about the start script
"/home/etc/autostart" are
covered in section 7.5.
For detailed information about
PLC programming of the
PLCcore-5208 compare section
6.3.
Figure 6: System start of the PLCcore-5208

System Manual PLCcore-5208
© SYS TEC electronic GmbH 2009 L-1076e_1 Page 18
6.3 Programming the PLCcore-5208
The PLCcore-5208 is programmed with IEC 61131-3-conform OpenPCS programming environment.
There exist additional manuals about OpenPCS that describe the handling of this programming tool.
Those are part of the software package "OpenPCS". All manuals relevant for the PLCcore-5208 are
listed in Table 1.
PLCcore-5208 firmware is based on standard firmware for SYS TEC`s compact control units.
Consequently, it shows identical properties like other SYS TEC control systems. This affects
especially the process image setup (see section 6.4) as well as the functionality of control elements
(Hex-Encoding switch, DIP-Switch, Run/Stop switch, Run-LED, Error-LED).
Depending on the firmware version used, PLCcore-5208 firmware provides numerous function blocks
to the user to access communication interfaces. Table 5 specifies the availability of FB communication
classes (SIO, CAN, UDP) for different PLCcore-5208 firmware versions. Section 7.6 describes the
selection of the appropriate firmware version.
Table 5: Support of FB communication classes for different types of the PLCcore
Type of
Interface PLCcore-5208/Z3 Art. no: 3390013 PLCcore-5208/Z4 Art. no: 3390014 PLCcore-5208/Z5 Art. no: 3390015 Remark
CAN - x X FB description see
manual L-1008
UDP - x X FB description see
manual L-1054
SIO x x X FB description see
manual L-1054
Table 18 in Appendix A contains a complete listing of firmware functions and function blocks that are
supported by the PLCcore-5208.
Detailed information about using the CAN interfaces in connection with CANopen is provided in
section 6.8.
6.4 Process image of the PLCcore-5208
The process image of PLCcore-5208 is significantly conditioned by the particular, user-specific
in-/output circuit. A precise definition of the process image always is only possible for concrete output
circuit such as for the Development Kit PLCcore-5208.

System Manual PLCcore-5208
© SYS TEC electronic GmbH 2009 L-1076e_1 Page 19
6.4.1 In- and Outputs of Development Kit PLCcore-5208
The PLCcore-5208 is delivered with a preinstalled I/O driver that supports the in- and outputs and the
control elements that are available on the Development Kit PLCcore-5208. Compared to other SYS
TEC compact control systems, the standard I/O driver obtains a process image with identical
addresses. All in- and outputs listed in Table 6 are supported by this standard driver.
Table 6: In-/Output assignment of the Development Kit to the process image of the PLCcore-5208
I/O of the Development Kit Address and Data type in the Process Image
DI0 ... DI4 %IB0.0 as Byte with DI0 … DI4
%IX0.0 … %IX0.4 as single Bit for each input
AI0
(external ADC of the Development
board),
see (1)
%IW8.0 15Bit + sign (0 … +32767)
On-board Temperature Sensor,
see (1)
%ID72.0 31Bit + sign as 1/10000 °C
DO0 ... DO4 %QB0.0 as Byte with DO0 … DO4
%QX0.0 … %QX0.4 as single Bit for each output
AO0
(external DAC of the Development
board),
see (1)
%QW8.0 15Bit + sign (0 … +32767)
(1) This marked components are only available in the process image, if the Option "Enable
extended I/Os" is activated within the PLC configuration (see section 7.4.1).
Alternatively, entry "EnableExtIo=" can directly be set within section "[ProcImg]" of the
configuration file "/home/plc/plccore-5208.cfg" (see section 7.4.3). The appropriate
configuration setting is evaluated upon start of the PLC firmware.
Advice: The PLCcore-5208 works with Big-Endian format ("Motorola-Notation"). Consequently
and on the contrary to controls using Little-Endian format ("Intel-Notation"), it is not
possible to sum up several BYTE variables of the process image to one WORD or
DWORD and to access Bits above Bit7. The following example shows issue described:
bInByte0 AT %IB0.0 : BYTE;
bInByte1 AT %IB1.0 : BYTE;
wInWord AT %IW0.0 : BYTE;
wInWord.0 <> bInByte0.0 due to Big-Endian: wInWord.0 == bInByte1.0
wInWord.8 <> bInByte1.0 due to Big-Endian: wInWord.8 == bInByte0.0
In- and outputs of thePLCcore-5208 are not negated in the process image. Hence, the H-level at one
input leads to value "1" at the corresponding address in the process image. Contrariwise, value "1" in
the process image leads to an H-level at the appropriate output.
6.4.2 In- and outputs of user-specific baseboards
The address/data bus leading towards the outside provides to the user most effective degrees of
freedom for designing the in-/output circuit of the PLCcore-5208. Therewith, all in- and outputs of the
PLCcore-5208 can be flexibly adjusted to respective requirements. This implicates that the process
image of PLCcore-5208 is significantly conditioned by the particular, user-specific in-/output circuit.