CONDUCTIX Wampfler VSH_0037 Bus Laying Rail Bus iDM System Instruction Manual
- June 13, 2024
- Conductix Wampfler
Table of Contents
Installation instructions
VSH_0037 Bus Laying Rail Bus iDM System
Specifications
Bus laying in rail bus plants with iDM System
VSH_0037_Bus
Laying Rail Bus iDM System
www.conductix.com
Conductix-Wampfler Automation GmbH
Handelshof 16 A
14478 Potsdam
Germany
Telephone: +49 331 887344-0
Fax: +49 331 887344-19
Email: info.potsdam@conductix.com
Internet: www.conductix.com
Translation of the original
VSH_0037, 5, en_GB
© 2023 Conductix-Wampfler Automation GmbH
Allgemein
Notes on this document
1.1 Revision history
We reserve the right to make changes to the information present in this
document, which result from our constant effort to improve our products.
| Version | Date | Comment |
|---|---|---|
| 4 | 3.2022 | New documentation layout |
Trailing cables section amended
Stubs prohibited
New terminating resistor
5| 1.2023| Chapter “Cable and connection specification” revised
1.2 Notes on this document
This description contains information/specifications for laying the data bus
(data loops) in rail bus systems with iDM system.
It provides important information on how to lay the data bus!
Read this description carefully before you start the installation!
It is the only way to ensure trouble-free operation and to avoid errors,
damage and injuries. You must also comply with the applicable accident
prevention regulations for the area of use and the general safety regulations.
Anyone entrusted with work on the data bus must have read and understood this
description before starting work. This even applies if the person has already
worked with such a system or has undergone training by the manufacturer.
iDM system overview
The iDM system is an intelligent data management system for automatic vehicle
and communication management in driver-less transport systems.
The iDM system regulates, controls and manages all components and vehicles
within the system under the directions of the higher-level system controller
(PLC) or an independent soft PLC, in case of smaller systems.
Fig. 1: iDM
system overview
- TCU – Track Control Unit
- MCU – Master Control Unit
- SyMa – System Manager
- Driving route with installed data bus
- Vehicle with vehicle control
TCU| Track Control Unit
Communication interface between the MCU and vehicle controls in a TCU area.
---|---
MCU| Master Control Unit
Central processing unit that regulates, controls and manages all components
and vehicles within the installed iDM system. Interface between
the system controller and the iDM system.
SyMa| System Manager
Configuration and simulation software to set up, test, and visualise the iDM
system in real-time on-site, remotely or offline on a PC.
Rail bus installation
3.1 Introduction
In the iDM system, systems are split into several TCU areas (communication
areas).
In each TCU area, a data bus (data loop) is laid out in parallel to the route
over which the vehicles in this area communicate with the MCU.
In conductor line systems, the data bus is installed in conductor lines
(busbars). This data bus is called a rail bus (SB). When laying the rail bus,
two separate conductor lines (SB_A and SB_B) are required. (see Fig.
2)
3.2 Cable and connection specification
Proper selection of cables is a prerequisite for smooth operation of systems.
Only use cables that are intended for the respective system and function.
In principle, the cables used for connecting devices and components must meet
the minimum technical requirements or the regulations of the respective
country.
-
Supply and connection cables in rail bus systems with iDM system
Chapter ‘Supply and connection cables’ on page 7 -
Trailing cables in rail bus systems with iDM system
Chapter ‘Trailing cables’ on page 8
3.2.1 Supply and connection cables
NOTICE!
The use of incorrect cable types leads to system faults!
- Only use the cable type specified below!
Cable type
The supply or connection cable (fixed laying) must be of the following
cable type:
| Name | JE-LiYCY 2 x 2 x 0.5 BD |
|---|---|
| Manufacturer | Lapp |
| Manufacturer’s item number | 34200 |
| Conductix item number | 3211556 |
Connection instructions
-
Use the red and blue wires for the data bus!
SB_A = red
SB_B = blue -
Shielding of the supply and connection cables must not be connected to PE.
3.2.2 Trailing cables
NOTICE!
The use of incorrect cable types leads to system faults!
- Only use the cable type specified below!
Cable type
The trailing cable (e.g., in switches and levers) must be of the following
cable type:
| Name | UNITRONIC BUS PB FD P 1 x 2 x 0.64 |
|---|---|
| Manufacturer | Lapp |
| Manufacturer’s item number | 2170222 |
Connection instructions
- As a trailing cable, two cables must be laid in parallel and wired as in Fig. 3.
- The shielding of the trailing cables must not be connected to PE.
Fig. 3: Assembled trailing cable
3.3 Laying guidelines
NOTICE!
Cable routing!
Branching structures in cable routing lead to mismatches and reflections and
thus to interference during data transmission!
- To ensure proper functioning of the system, it is only permitted to route cables as a pure linear structure.
- Lateral branches (stubs) are not permitted.
- Data bus termination with terminating resistor
- Conductor lines
- Supply and connection cables
- Trailing cables
Laying instructions:
- Lay the data bus according to the specifications in the plant layout. ( Chapter ‘Layout information’ on page 10)
- The maximum bus length of 200 m (including supply/connection and trailing cables) per TCU area must not be exceeded.
- The data bus must be terminated with an 82 Ω resistor (provided with the TCU). The terminating resistor is connected in series at the end of the data bus and must be fitted in a terminal box.
3.4 Layout information
Observe the following instructions!
- The bus layout illustrated in the system layout is a schematic representation and is to be regarded as a suggestion. The final solution is to be determined by the system engineer.
- Check compliance with the maximum bus lengths in the course of your electrical planning and before installation.
Bus lengths: Chapter ‘Summary / technical information’ on page 15
| EtherCAT connections
---|---
| Supply and connection cables
| Conductor lines
*****| optional bus coupler
Layout information
-
The planned laying of the rail bus can be found in the system layout, in the layer ‘LJU_Bus laying’
-
In the layout, terminal points are identified with ‘KP’ and a consecutive letter. Cables are to be laid out in ascending order according to the consecutive letters.
-
On moving system components, such as switches, terminal points are identified with ‘KP+.’ From this point, trailing and connection cables must be used for connecting moving parts. (see also Chapter ‘Data bus layout in switches’ on page 12)
Subsequently, the laying of the data bus is continued at the terminal points in ascending order. -
The data bus must be terminated at the last terminal point – always indicated with ‘KPX.’ The size of the terminating resistor to be used is also specified here.
3.5 Data bus layout in switches
NOTICE!
Cable routing!
Branching structures in cable routing lead to mismatches and reflections and
thus to interference during data transmission!
- To ensure proper functioning of the system, it is only permitted to route cables as a pure linear structure.
- Lateral branches (stubs) are not permitted.
| Supply and connection cables
---|---
| Trailing cables
| Conductor lines
KP| Terminal point
Laying instructions:
- The data bus is laid out as a pure linear structure in switches.
- The cables of switches must be connected in accordance with the specifications in the project-related layout.
3.6 Conductor line sections at TCU area transitions
NOTICE!
At TCU area transitions, care must be taken to ensure that the separating
sections are not bridged by the collectors for the data transmission, leading
to a short circuit between the data buses of two TCU areas (as shown in Fig.
7).
Execution of sections
To exclude data bus short circuits, a communication-free area must be
provided at each TCU area transition.
- To do this, create two separation sections (as shown in Fig. 8).
- Do not connect the intermediate area to the data communication system.
lTot communication-free area
l₁ Total length of the current collector pair for data transmission
S₁ Safety area 5 mm min. / 10 mm max.
S₂ Safety area 5 mm min. / 10 mm max.
Calculation formula
lTot = l1 + S1 + S2
If the communication-free area is lTot < 200 mm,this can be increased to lTot
= 200 mm max.
Summary / technical information
TCU area
| Number of TCU areas | 70 max. |
|---|---|
| TCU area length | Max. 200 m |
| Number of vehicles per TCU area | TCU area without Safety Controller SCS: 30 |
max. (can be extended to 45 max.)
TCU area with Safety Controller SCS: 15 max.
Couplings (transitions) to adjacent TCU areas| 20 max.
Connections between TCU areas (transmission rate)| EtherCAT (100 Mbps)
Cable length between TCU – TCU (EtherCAT connection)| Max. 100 m 1)
- can be extended with optional hardware
Data bus
| Type | Rail bus (SB) |
|---|---|
| Bus protocol / transmission rate | LJU bus / 500 kbit/s max. (configurable) 2) |
| Data bus length per TCU area 3) | Max. 200 m |
| Bus layout | in cable structure |
| Bus termination | 82 Ω / 100 W |
- max. transmission rate depends upon the vehicle control system series deployed
- including supply/connection and trailing cables
Cable types
Cable specification
TCU – TCU (EtherCAT connection)| Network cable Cat.5 min. pursuant to DIN EN
50173-1
---|---
Cable specification
Supply and connection cables| Type: JE-LiYCY 2 x 2 x 0.5 BD
Manufacturer: Lapp
Manufacturer’s item number: 0034200 Conductix item number: 3211556
Cable specification Trailing cables 4)| Type: UNITRONIC BUS PB FD P 1 x 2 x
0.64
Manufacturer: Lapp
Manufacturer’s item number: 2170222
- As a trailing cable, there must be two cables laid out in parallel.
Customer service and addresses
Customer service
Our service team is available to provide technical information.
■ Conductix-Wampfler Automation – Service
Phone: +49 331 887344-15 | Fax: +49 331 887344-19
E-mail: service.potsdam@conductix.com
Service forms
Service forms are available for download under
www.conductix.com.
Please send completed service forms to
service.potsdam@conductix.com.
Further contacts
Conductix-Wampfler Automation GmbH
Handelshof 16 A | 14478 Potsdam | Germany
Phone: +49 331 887344-0 | Fax: +49 331 887344-19
E-mail: info.potsdam@conductix.com |
Internet: www.conductix.com
-
Conductix-Wampfler Automation – Sales
Phone:+49 331 887344-02 / -04 | Fax: +49 331 887344-19
E-mail: sales.potsdam@conductix.com -
Conductix-Wampfler Automation – Service
Phone: +49 331 887344-15 | Fax: +49 331 887344-19
E-mail: service.potsdam@conductix.com -
Conductix-Wampfler Automation – Repairs
Phone: +49 331 887344-615 | Fax: +49 331 887344-19
E-mail: repair.potsdam@conductix.com
Conductix-Wampfler GmbH
Rheinstrasse 27 + 33 | 79576 Weil am Rhein | Germany
Phone: +49 7621 662-0 | Fax: +49 7621 662-144
E-mail: info.de@conductix.com | Internet:
www.conductix.com
For further addresses of sales and service locations, visit:
Bus laying rail bus iDM system
Conductix-Wampfler Automation GmbH / 01/2023
VSH_0037, 5, en_GB
References
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