B&R 3IF661.9 Communication Interface Module

PROFIBUS-DP communication interface module for the System 2005 série

(Exclusive to legacy System 2005 rack CPUs, fin de vie)

2. Official Standard Description

Système 2005 interface module with 1 galvanically isolated RS485 port supporting PROFIBUS DP fieldbus; installed in the IF expansion slot between the CPU and additional expansion slots.

3. Répartition du code modèle

1. Core Hardware & Paramètres électriques (Original Datasheet)
2. Interface de bus

Physical layer: 1 galvanically isolated RS485 channel (PROFIBUS-compliant)

Isolation withstand voltage: 250 V AC galvanic isolation for enhanced on-site EMC immunity

Matching connector: 0G1000.00-090 standard PROFIBUS bus terminal (optional accessory)

2. Communication Specifications

Protocole: PROFIBUS-DP (Classe 1 Master only)

Débit en bauds: Adaptive range from 9.6 kbit/s to 12 Mbit/s

Station address range: 0 ~ 126

Supporting file: Official GSD file package V1.01 for 3IF661.9

3. Alimentation & Consommation d'énergie

Alimentation: Derived from System 2005 backplane bus; no external 24 VDC power required

Consommation électrique typique: 0.4 W

4. Évaluations environnementales

Température de fonctionnement: -20 ℃ ~ +60 ℃

Stockage / transport temperature: -40 ℃ ~ +85 ℃

Classe de protection: IP20 (cabinet-mount only)

Poids: Environ. 0.10 kilos

5. Certifications

CE, UKCA, UL cULus, EAC industrial control certifications

III. Installation & Configuration Instructions

1. Rack Mounting Rules

Compatible only with System 2005 series CPU racks (3CPxxx, 3RPxxx controllers)

Position de montage: First IF expansion slot on the right side of the CPU; IO slots are prohibited

Maximum quantity per CPU: 1 piece of 3IF661.9

2. Software Support

Logiciel de programmation: Automation Studio

Minimum compatible version: AS V4.0 (with hardware upgrade package 1.0.0.1)

Configurable items: DP station address, débit en bauds, process data mapping, diagnostic enable

3. Diagnostic

Module equipped with status LEDs for power supply, bus communication fault and DP bus disconnection diagnostics.

1. End-of-Life Replacement Solutions (Système 2005 to X20 Migration)

Solution 1: Direct replacement within the same architecture (retaining System 2005 rack, spare part procurement)

No compatible upgraded model in the same series. The 3IF661.9 has been officially discontinued; only used/refurbished spare parts are available.

Solution 2: Full system upgrade to X20 (Recommended for new projects & rénovations)

Notes de remplacement

1. Système 2005 programs cannot be migrated directly to X20; hardware configuration, bus mapping and compilation must be reworked.
2. PROFIBUS GSD files are fully compatible, no modifications required for DP slave devices.
3. Bus de fond de panier, power supply and mounting dimensions are completely incompatible; full replacement of X20 CPU + base unit is mandatory.
4. Scénarios d'application typiques

Machines-outils & machines d'emballage: Legacy System 2005 B&R PLCs communicating with inverters, servo drives and remote DP IO stations

Production line retrofits: PROFIBUS bus communication expansion for aging equipment

Métallurgie, plastique & textile legacy automation line communication capacity expansion

1. Matrice de dépannage des pannes courantes

VII. Supporting Document List (Official Downloadable)

1. Datasheet 3IF661.9 V1.0 (2004 English manual)
2. AS V4.0 hardware upgrade firmware package
3. PROFIBUS GSD description file package V1.01
4. 0G1000.00-090 bus connector wiring manual

Complete Communication Parameter Configuration Tutorial for B&R 3IF661.9 (System2005 PROFIBUS DP Master)

Preconditions

1. Hardware Constraints

Compatible only with System2005 rack CPUs (3CPxxx/3RPxxx), installed in the IF communication slot to the right of CPU (IO slots forbidden); maximum 1 unit per CPU.

DP bus accessories: Standard 0G1000 DP connectors; set terminating resistor to ON for the first & last bus nodes, OFF for intermediate nodes.

2. Software Environment

Automation Studio V4.0 ~ V4.7 (Hardware library for System2005 is removed in versions above V4.7)

System2005 full hardware library must be loaded; native driver for 3IF661.9 included, no separate module GSD import needed.

3. File Preparation

GSD files for all DP slave devices (onduleurs, remote IO, instruments, etc.)

1. Hardware Rack Configuration (Physical View)
2. Create a new standard project and select the corresponding 3CP/3RP System2005 CPU.
3. Switch to the Physical View hardware view on the left, drag and drop the CPU onto the rack.
4. Drag and drop module `3IF661.9` into the IF expansion slot on the right of the CPU.

> Note: Slot position must match physical hardware; hardware mismatch error will be triggered during download otherwise.

4. Right-click 3IF661.9 → Configuration to open the DP master parameter panel.
5. Core DP Master Communication Parameter Settings (3IF661.9 Configuration)
6. General Bus Parameters (General Tab)

2. Advanced Bus Control Parameters (Advanced Tab)
3. Retry count: Retransmission times upon communication failure; default = 3, adjust to 5 for high-interference environments.
4. Gap factor: DP token gap; keep default value 10.
5. Diagnostic enable: Check to activate slave diagnostic functions for fault code reading via PLC program.
6. Sync/Freeze support: Check for motion control synchronization scenarios; uncheck for standard IO applications.
7. Key Operation Mode Note

The 3IF661.9 acts as a Class 1 DP Master, supporting cyclic IO data exchange only. Slave mode and direct cross-slave DX communication are not supported.

III. Import DP Slave GSD Files & Configure Slaves

1. Top menu bar of AS: 【Tools】→【3rd Party Device Manager】(Third-party Device Manager)
2. Click 【Import Fieldbus Devices】 to import all slave `.gsd` files.
3. Return to the configuration window of 3IF661.9 and switch to the 【Topology】 bus topology tab.
4. Locate imported DP slaves in the left hardware library, drag and drop onto the DP bus line.
5. Double-click each slave to assign a unique station address (1~126), not overlapping with master address.
6. Double-click the slave to access IO mapping page; select input/output byte length matching device datasheet.
7. IO Process Data Mapping (I/O Mapping – Core PLC Program Interface)
8. Switch to the 【I/O Mapping】 tab in the 3IF661.9 configuration window.
9. DP_In (data received from slaves to PLC) & DP_Out (control commands sent from PLC to slaves) channels are displayed on the left.
10. Bind global or program variables as shown below:

Inverter frequency setpoint: Bind `Program.DP_Out.Freq_Set` to Slave Output Byte 0~1

Motor current feedback: Bind `Program.DP_In.Motor_Current` to Slave Input Byte 2~3

4. Mapping Rules

Set Consistency to All universally to prevent fragmented data misalignment

Maximum IO length per single slave shall not exceed 244 octets (DP standard limitation)

1. Compilation, Télécharger & Communication Diagnostics
2. Download Workflow
3. Click 【Apply】 to save module configuration after all parameters are set.
4. Build the whole project; download to System2005 CPU if no hardware errors occur.
5. Module LED Status Definition

PWR solid green: Backplane power supply normal

BUS flashing green: DP bus communication established normally

BUS solid red: Bus disconnection / duplicate address / mismatched baud rate

ERR solid red: Slave fault / mismatched IO mapping length

2. Online Diagnostic Troubleshooting
3. Open 【System Diagnostics Manager】 in online mode.
4. Filter for the 3IF661.9 module to view:

Bus packet transmit/receive counters

List of offline/fault slave station numbers

Watchdog timeout & CRC communication error counters

3. Rapid Fault Localization

All slaves offline: Vérifier le débit en bauds, terminating resistors and A/B wiring

Single slave offline: Check hardware DIP station address, GSD IO PPO type and A/B wiring

1. Common Configuration Errors & Éviter les pièges
2. Incorrect slot insertion: Installing 3IF661.9 into IO slot triggers hardware error during download.
3. Duplicate station address: Master address = 1; slaves cannot use address 1; adresse 0 must not be assigned to any device.
4. Débit en bauds incompatible: Any slave with inconsistent baud rate will result in solid red BUS LED and total communication loss.
5. Missing/wrong GSD version: Slaves cannot be added or IO mapping table empty; reimport original manufacturer GSD file.
6. Overly short cycle time: Target Rotation Time < 2 ms causes frequent packet loss and bus alarms.
7. Chinese characters in project path: GSD import failure & compilation error; only English & numerals allowed in file paths.

VIII. Supplementary End-of-Life Migration Reference

The legacy System2005 rack-mounted 3IF661.9 cannot be used directly in X20 systems. Recommended upgrade replacement model: X20IF1061. Configuration logic is consistent, yet backplane and hardware library are fully incompatible, requiring full CPU & base unit replacement.

Complete List of B&R Communication Interface Modules

Classified by four major hardware platforms: Système 2005 (3SI, EOL), X20 (X20IF, mainstream cabinet PLC), X67 (X67IF/BC, IP67 distributed remote IO bus controllers), X90 (X90IF, mobile construction machinery). Categorized by fieldbus master/slave, serial port and real-time Ethernet bus.

661. Système 2005 Series 3IF Communication Modules (Legacy Rack, End-of-Life; 3IF661.9 belongs to this series)

Naming rule: `3IFxxx.9` = IF expansion slot communication module for System2005; suffix `.6`/`.86` for early hardware revisions.

1. En série / Mixed Serial Modules

2. CAN Bus Series

3. PROFIBUS DP Series (Your Current Module)

4. Ethernet / Ethernet temps réel POWERLINK

5. aPCI Expansion Communication Cards (3IF7xx, CPU internal aPCI slot)

3IF722.9 (Multi-channel serial ports), 3IF761.9 (DP Master), 3IF789.9-1 (POWERLINK + X2X Link Master)

1. X20 Series X20IF Communication Modules (Current Mainstream Cabinet PLC, System2005 Migration Replacement)

Naming rule: `X20IF1xxx` single-bus module; `X20IF2xxx` dual mixed-bus module.

1. Serial Communication RS232/485

X20IF1020: 1 galvanically isolated RS232/422/485 port

X20IF1030: 2 independent galvanically isolated RS485 ports

2. PROFIBUS DP Series (3IF661.9 Replacement Options)

3. CAN / CANopen

X20IF1072: Single galvanically isolated CAN Master port

X20IF2792: 1 CAN port + 1 X2X Link (remote IO expansion bus)

4. POWERLINK Real-Time Motion Bus

X20IF1082: Single-channel POWERLINK with integrated 2-port hub, ring redundancy support

X20IF1082-2: Equipped with PRC high-speed synchronization (multi-axis synchronous control)

X20IF1086-2: Fiber-optic POWERLINK for long-distance high-noise environments

5. PROFINET E/S

X20IF10E3-1: PROFINET IO Device (Esclave)

X20IF10E1: PROFINET IO Controller (Maître)

6. X2X Link Remote IO Expansion Bus

X20IF2772: X2X Link Master, drives X67 distributed IP67 modules

III. X67 Series: IP67 Distributed Remote IO Communication Units

Two categories: X67BC bus controllers, X67IF serial modules

1. X67BC Bus Controllers (Integrated IO channels, direct fieldbus connection)

X67BC4321: CANopen bus controller

X67BC5321: DeviceNet bus controller

X67BC6321: PROFIBUS DP bus controller; suffix .L08/.L12 corresponds to M8/M12 connectors

X67BC7321: CAN IO bus controller

X67BC8321-1: POWERLINK bus controller

2. X67IF Standalone Serial Communication Modules (IP67 field-mount for scanners & instruments)

X67IF1121-1: Combined RS232/RS485 with onboard 2DI + 2DO digital channels

1. X90 Mobile Control Platform X90IF Expansion Boards (Machines de construction, Vehicle Controllers)

X90IF730.04-00: 3 CAN ports + 1 RS485 port dedicated to mobile equipment

General X90IF expansion boards: Support CAN, RS485 and Ethernet; PROFIBUS/PROFINET unsupported

1. Universal Model Code Decoding Rules (Quick Function Identification)
2. Platform Prefix

3IF = System2005 (Legacy Rack, End-of-Life)

X20IF = X20 Cabinet PLC Communication Module (Active Mainstream)

X67BC = IP67 Remote Bus Controller; X67IF = IP67 Serial Module

X90IF = Mobile Construction Machinery Controller Expansion Board

2. Mid Digit Bus Identifier

66x = PROFIBUS DP

67x = CAN Bus

62x = RS485/232 Serial Port

68x = Ethernet / POWERLINK

1061/1063 = X20 PROFIBUS

108x = X20 POWERLINK

3. Suffix Revision Code

.9 / .6 = System2005 Hardware Revision

-1 / -2 = X20/X67 Enhanced Function Version (Redondance, Fiber Optic, Advanced Diagnostics)

661. Cross-Platform Replacement Reference for 3IF661.9 (Retrofit Selection Cheat Sheet)