B&R 5LS Series Modules | 5LS189.6-1 Communication Board

Technical Dossier

Product Details And Specifications

B&R 5LS Series: Comprehensive Module Range and Technical Overview

The B&R 5LS series represents a core product line within Bernecker & Rainer's programmable logic controller and distributed control system portfolio. Deployed extensively across global heavy industry — including petrochemical refineries, nuclear power auxiliary systems, offshore platforms, and continuous-process chemical plants — the 5LS series established B&R's position as a precision automation supplier in applications where deterministic cycle times and high-availability backplane communication are non-negotiable requirements. The series operates within B&R's proprietary X2X Link and POWERLINK communication infrastructure, enabling synchronized multi-axis and multi-node control architectures. Installed base density remains high in European and Asian industrial facilities commissioned between the mid-1990s and 2010s, making spare parts availability a critical operational concern for maintenance engineers managing long-lifecycle assets.

The Evolution of 5LS Architecture

The 5LS series was developed as part of B&R's second-generation modular PLC platform, succeeding earlier fixed-I/O controllers and preceding the current APROL and X20 system families. Early 5LS hardware (circa 1995–2002) used parallel backplane bus communication with proprietary B&R protocols, limiting inter-module bandwidth to levels adequate for sequential logic but insufficient for high-speed motion coordination. Mid-generation revisions introduced ETHERNET Powerlink (EPL) compatibility, allowing 5LS nodes to participate in isochronous real-time networks with cycle times down to 400 µs. Late-series variants added X2X Link slave capability, bridging legacy 5LS I/O into modern B&R Automation Studio 4.x projects. Compatibility constraints are significant: 5LS CPU modules require matching firmware revisions when paired with communication boards such as the 5LS189.6-1; cross-generation substitution without firmware alignment causes bus initialization failures. Engineers migrating from 5LS to X20 must account for I/O address remapping and task class reconfiguration in Automation Studio.

5LS Full Catalog & Functionalities (SKU List)

The following SKUs represent verified, commonly stocked modules within the B&R 5LS series, classified by functional category:

Communication & Network Modules

• 5LS189.6-1: PROFIBUS-DP communication board, slave/master configurable, 12 Mbit/s max
• 5LS180.6-1: Ethernet communication module, 10/100 Mbit/s, RJ45 interface
• 5LS181.6-1: CANopen communication board, 1 Mbit/s, DS301 compliant
• 5LS182.6-1: DeviceNet communication adapter, Group 2 slave, 500 kbit/s
• 5LS183.6-1: Modbus RTU/TCP communication board, RS-485 physical layer

CPU & Controller Modules

• 5LS5100.60-1: Central processing unit, 32-bit RISC, 64 MB DRAM, IEC 61131-3
• 5LS5200.60-1: High-performance CPU module, dual-core, 128 MB, real-time OS
• 5LS5050.60-1: Standard CPU, 16 MB RAM, compact form factor for space-constrained panels
• 5LS5300.60-1: Redundant CPU module, hot-standby capable, SIL 2 rated applications

Digital Input (DI) Modules

• 5LS3100.60-1: 16-channel 24 VDC digital input, 0.2 ms filter, IEC 61131-2 Type 1
• 5LS3200.60-1: 32-channel 24 VDC digital input, high-density, M20 connector
• 5LS3110.60-1: 8-channel 120 VAC digital input, optically isolated, DIN rail mount

Digital Output (DO) Modules

• 5LS4100.60-1: 16-channel 24 VDC digital output, 0.5 A per channel, short-circuit protected
• 5LS4200.60-1: 32-channel transistor output, source type, 0.3 A per channel
• 5LS4300.60-1: 8-channel relay output, 230 VAC / 2 A, mechanical and solid-state options

Analog Input (AI) Modules

• 5LS2100.60-1: 8-channel analog input, ±10 V / 0–20 mA, 12-bit resolution
• 5LS2200.60-1: 4-channel high-precision analog input, 16-bit, thermocouple/RTD configurable

Power Supply Modules

• 5LS0100.60-1: 24 VDC backplane power supply, 10 A output, integrated diagnostics
• 5LS0200.60-1: Redundant power supply module, N+1 configuration, hot-swap capable

Sourcing Hard-to-Find & Obsolete 5LS Parts

B&R officially discontinued active production of the 5LS series hardware, with end-of-life notifications issued progressively from 2015 onward. The 5LS189.6-1 communication board and related network modules are no longer available through standard B&R distribution channels. DriveKNMS maintains a dedicated inventory of tested 5LS spare parts sourced from decommissioned plant assets, authorized surplus channels, and controlled warehouse stock. For facilities operating 5LS-based control systems under long-term maintenance contracts — common in nuclear auxiliary, refinery DCS, and water treatment applications — DriveKNMS provides lifecycle extension support including: verified-functional replacement units, cross-reference mapping to compatible successor modules (X20 series where applicable), and consignment stock programs for high-volume maintenance operations. Lead times for standard 5LS modules are typically 3–10 business days from confirmed stock; rare variants are subject to sourcing lead times of 2–6 weeks.

Quality Control for the 5LS Range

The 5LS series employs a multi-layer backplane bus architecture with proprietary B&R inter-module communication protocols. Standard visual inspection and power-on testing are insufficient to validate communication board functionality. DriveKNMS applies a structured test protocol for all 5LS modules prior to dispatch: (1) Backplane bus continuity verification using B&R-compatible bus analyzer hardware; (2) PROFIBUS-DP layer 1/2 compliance testing for communication boards including the 5LS189.6-1, using Softing or HMS protocol analyzers; (3) Firmware version identification and compatibility matrix check against target CPU module revision; (4) 48-hour burn-in cycle under simulated load conditions to screen latent component failures; (5) Final functional test in a live B&R 5LS rack with Automation Studio diagnostic monitoring. All units are shipped with a test report and 12-month warranty against functional defects.