Conductix-Wampfler iDM-MCU User manual

STB_0016_iDM-MCU
www.conductix.com
Operating manual
iDM-MCU
Master Control Unit ( MCU)
iDM System with LJU communication

BDA_0016, 17, en_GB
Translation of the original operating manual
© 2022 Conductix-Wampfler Automation GmbH
Conductix-Wampfler Automation GmbH
Handelshof 16 A
14478 Potsdam
Germany
Telephone: [phone]
Fax: [phone]
Email: [email protected]
Internet: www.conductix.com

Table of contents
1 Information on the description.................................................................. 7
1.1 Revision history............................................................................. 7
1.2 How to use and store the description............................................ 7
1.3 Applicable documents................................................................... 7
1.4 Copyright protection...................................................................... 8
1.5 Illustrations.................................................................................... 8
1.6 Picture credits and brands............................................................. 8
2 Warranty and liability.................................................................................. 9
2.1 Warranty........................................................................................ 9
2.2 Limitation of liability....................................................................... 9
3 Safety instructions.................................................................................... 11
3.1 Warning concept.......................................................................... 11
3.1.1 Arrangement of warnings............................................................. 11
3.1.2 Structure of warnings................................................................... 11
3.1.3 Signal words................................................................................ 12
3.1.4 Hazard symbols........................................................................... 12
3.1.5 Suggestions and recommendations............................................ 12
3.2 Intended use................................................................................ 13
3.3 Foreseeable incorrect use........................................................... 13
3.4 Modifications and alterations....................................................... 13
3.5 Responsibility of the operator...................................................... 14
3.6 Personnel and qualifications........................................................ 14
3.7 Special hazards........................................................................... 15
4 The iDM system with LJU communication............................................. 17
4.1 iDM system overview................................................................... 17
4.2 System architecture..................................................................... 18
4.3 Performance capabilities and properties..................................... 19
5 Product description.................................................................................. 21
5.1 Function....................................................................................... 21
5.2 Structure...................................................................................... 21
5.3 MCU modules.............................................................................. 22
5.4 Type label.................................................................................... 23
5.5 MCU variants............................................................................... 23
5.6 Scope of delivery......................................................................... 25
6 Transport and storage.............................................................................. 27
6.1 Transport..................................................................................... 27
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6.2 Transport inspection.................................................................... 27
6.3 Storage........................................................................................ 28
7 Mechanical installation............................................................................ 29
7.1 Installation location and position.................................................. 31
7.2 Installation on top-hat rail............................................................ 32
8 Electrical installation................................................................................ 33
8.1 Requirements for the voltage supply........................................... 35
8.1.1 General requirements.................................................................. 35
8.1.2 UL requirements.......................................................................... 36
8.1.3 Connection according to low-voltage directive............................ 36
8.2 Connection overview................................................................... 37
8.2.1 Connections on MCUs with TCP/IP............................................. 37
8.2.2 Connections on MCUs with PROFINET...................................... 38
8.2.3 Connections on MCUs with EtherNet/IP...................................... 39
8.3 Connection instructions............................................................... 40
8.4 Electrical connection procedure.................................................. 40
8.5 Connecting the power supply...................................................... 41
8.6 Connecting external PLCs........................................................... 42
8.6.1 Connecting external PLCs (MCU with TCP/IP)........................... 42
8.6.2 Connecting external PLCs (MCU with PROFINET)..................... 43
8.6.3 Connecting external PLCs (MCU with EtherNet/IP).................... 44
8.7 Connecting TCUs........................................................................ 45
8.8 Connect EtherCat redundancy (only MCU with ECR)................. 46
8.9 Extending the EtherCAT connection (optional)............................ 47
8.9.1 Overview...................................................................................... 47
8.9.2 Extending EtherCAT using a EK1100 bus coupler...................... 48
8.9.2.1 EK1100 bus coupler installation and connection data............ 48
8.9.2.2 Connection variants................................................................ 49
8.9.2.3 Installing the EK1100 bus coupler.......................................... 50
8.9.2.4 Connecting the EK1100 bus coupler...................................... 51
8.9.3 Extending the EtherCAT using CU1521 media converters.......... 53
8.9.3.1 CU1521 media converter installation and connection data.... 53
8.9.3.2 Connection variants................................................................ 54
8.9.3.3 Installing CU1521 media converters...................................... 55
8.9.3.4 Connecting CU1521 media converters.................................. 56
9 Commissioning......................................................................................... 59
9.1 Commissioning procedure........................................................... 60
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9.2 Establishing access to the MCU.................................................. 60
9.3 Configuring the interfaces............................................................ 62
9.3.1 Configuring the SyMa interface................................................... 62
9.3.2 Configuring TCP/IP interfaces for the PLCs................................ 63
9.3.3 Configuring PROFINET interfaces for the PLCs......................... 64
9.3.4 Configuring EtherNet/IP interfaces for the PLCs......................... 65
9.4 Transferring the system configuration to the MCU with SyMa..... 66
10 Operation................................................................................................... 67
10.1 Switching ON and OFF the MCU................................................ 68
10.1.1 Switching on the MCU................................................................. 68
10.1.2 Switching off the MCU................................................................. 68
10.2 MCU messages........................................................................... 69
10.2.1 MCU status LEDs........................................................................ 69
10.2.2 PSU module status LEDs............................................................ 70
10.2.3 PROFINET module status LEDs................................................. 71
10.2.4 EtherNet/IP module status LEDs................................................. 72
10.2.5 EtherCAT module status LEDs.................................................... 73
11 Service and maintenance......................................................................... 75
11.1 Updating system software using the MCU Software Update....... 75
11.2 Backing up the MCU license data............................................... 77
11.2.1 Backing up and restoring license data using the MCU Software
Update......................................................................................... 77
11.2.2 Manually backing up and restoring license data.......................... 78
11.3 Dismantling/replacing the MCU................................................... 80
11.3.1 Dismantling the MCU................................................................... 80
11.3.2 Replacing the MCU..................................................................... 81
11.4 Repairing the MCU...................................................................... 81
12 Disposal..................................................................................................... 83
12.1 Information on disposal and environmental regulations.............. 83
12.2 Disposal of batteries and rechargeable batteries........................ 83
13 Technical Data........................................................................................... 85
14 Customer service and addresses........................................................... 89
15 Index.......................................................................................................... 91
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1 Information on the description
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/reason for change
11 04.2019 Complete revision
12 06.2019 Added EtherCAT extension with media converters
CU1521
13 09.2020 Structure of the chapters has changed
14 02.2021 New: MCU-4PN and MCU-4PN+ECR
15 03.2021 Adaptation of SyMa/Service interfaces
16 05.2021 Installation data corrected
17 08.2022 Conductix-Wampfler Automation GmbH
1.2 How to use and store the description
To work safely with the product, it is necessary to observe the safety notes
and action instructions. All persons working with the product must have
understood the user information in this description and apply it conscien-
tiously. The operator must fulfil his duty of care and ensure that all persons
working with the product have read and understood the user information
and are implementing it.
This description forms part of the product and must be accessible to all per-
sons working with the product at all times.
1.3 Applicable documents
The documents contained in the project documentation also apply if the
device / system is part of a project-specific system plan.
Their own documentation applies to connected devices and components.
Information on the description
Applicable documents
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1.4 Copyright protection
The contents, texts, drawings, pictures and other illustrations of this
description are protected by copyright and subject to intellectual property
rights. Any misuse is punishable by law.
Reproduction in whole or in part of this description is only permitted within
the limits of the legal provisions of the copyright law. Any modification or
shortening of the text is prohibited without the explicit written consent of
Conductix-Wampfler Automation GmbH.
1.5 Illustrations
The illustrations that accompany this description have been purposely
selected. They are provided for basic understanding and may differ from
the actual design. No claims shall be accepted for possible discrepancies.
1.6 Picture credits and brands
Pictures marked with (BN):
nSource: Beckhoff Automation GmbH & Co. KG
nPartly edited pictures
The popular names, trade names, production descriptions, etc. used in this
description may constitute trademarks even without special designations
and as such may be subject to legal requirements.
is a registered trademark and a patented technology licensed by Beckhoff
Automation GmbH, Germany.
Picture credits
Trademarks
Information on the description
Picture credits and brands
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2 Warranty and liability
2.1 Warranty
The warranty only covers production defects and faulty components.
The manufacturer assumes no responsibility for damages caused during
transport or unpacking. In no case and under no circumstances will the
manufacturer be liable for defects or damages caused by misuse, incorrect
installation or inadequate environmental conditions or from dust or corro-
sive substances.
Consequential damages are excluded from the warranty.
Should you have further questions regarding the warranty, please contact
the supplier.
2.2 Limitation of liability
All information and notes in this description have been compiled taking into
account the applicable standards and regulations, the state of the art and
our many years of knowledge and experience.
Conductix-Wampfler Automation GmbH assumes no liability for damage
and malfunctions during operation due to:
nFailure to comply with the description
nNon-intended use
nUse by untrained personnel
nUnauthorised alteration or modification
nUse of the product, despite negative transport inspection
Furthermore, Conductix-Wampfler Automation GmbH's warranty obligation
will cease to exist in case of a failure to comply with the description.
Warranty and liability
Limitation of liability
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Warranty and liability
Limitation of liability
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3 Safety instructions
This section contains information on all safety aspects for optimum protec-
tion of personnel and for safe operation without malfunctions.
To prevent dangers, these notes must be read and followed by personnel.
Only then can safe operation be guaranteed.
Of course, all legally applicable general safety and accident prevention reg-
ulations must be complied with.
Conductix-Wampfler Automation GmbH assumes no liability for damage or
accidents that were caused by non-observance of these safety notes.
3.1 Warning concept
This description contains notes that must be observed for your own per-
sonal safety and to avoid property damage. Notes regarding your personal
safety are highlighted by a warning triangle; notes regarding property
damage do not have a warning triangle.
When several hazard levels occur, the warning always refers to the highest
level. If a warning of injury to persons is indicated with a warning triangle,
the same warning might include an additional warning of property damage.
3.1.1 Arrangement of warnings
If warnings refer to an entire section, they are placed at the beginning of the
section (e.g. chapter start).
If warnings refer to a specific action instruction, they are placed in front of
the respective action instruction.
3.1.2 Structure of warnings
nSIGNAL WORD
n↳ Type of danger and its source
n↳ Possible consequences, if not observed
n↳ Danger avoidance measures
n↳ Preventive measures
Safety instructions
Warning concept > Structure of warnings
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3.1.3 Signal words
Warnings are indicated using signal words based on hazard levels.
Signal word Meaning
LWARNING! This combination of symbol and
signal word indicates a possible
dangerous situation that can result
in death or serious injury if it is not
avoided.
NOTICE! This combination of symbol and
signal word indicates a possible
dangerous situation that can result
in material damage if it is not
avoided.
ENVIRONMENT! This combination of symbol and
signal word indicates a possible
dangerous situation that can result
in environmental damage if it is not
avoided.
3.1.4 Hazard symbols
Warnings of the groups 'danger' and 'warning' are content-based. They are
presented with clear danger symbols.
Warnings of the 'caution' group do not have a specific danger symbol.
Warning signs Type of danger
Warning – high-voltage.
Warning – danger zone.
3.1.5 Suggestions and recommendations
This symbol indicates important information to help you handle the
product.
Safety instructions
Warning concept > Suggestions and recommendations
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3.2 Intended use
The Master Control Unit (MCU) has been designed and constructed exclu-
sively for the intended use described below.
The Master Control Unit (MCU)
nis a device for industrial and commercial systems.
nis used exclusively for the central system administration of an iDM
system.
nregulates, controls and manages all components and vehicles within an
installed iDM system.
nforms the interface between the system controller and the iDM system.
Intended use assumes compliance with all information in this manual and
the applicable documents.
Any use beyond the intended use or other ways of use are considered
misuse.
3.3 Foreseeable incorrect use
Any use that goes beyond this description is forbidden.
L WARNING!
Hazard from non-intended use!
Any use of the device other than and/or beyond the intended use can
cause hazardous situations.
nOnly use the device as intended.
nIt is paramount to comply with all the specifications and permitted
conditions at the place of use.
nDo not use the device in potentially explosive atmospheres.
nDo not operate the device in environments with harmful oils, gases,
vapours, dusts, radiation, etc.
3.4 Modifications and alterations
For the purpose of avoiding hazards and for ensuring optimum perform-
ance, any modifications, additions, or alterations to the device require Con-
ductix-Wampfler Automation GmbH's express consent.
Safety instructions
Modifications and alterations
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3.5 Responsibility of the operator
The device is used in an industrial environment. The operator of the device
is therefore subject to statutory obligations regarding work safety.
In addition to the work safety instructions in this description, the safety,
accident prevention and environmental regulations applicable to the area
where the device is used must be complied with.
The following applies in particular:
nThe operator must familiarise with the applicable work safety regula-
tions and must also determine the dangers that are posed by the partic-
ular work conditions at the location of use by means of a risk assess-
ment. This must be realised in the form of operating instructions for
operating the device.
nThis description must be kept within easy reach of the device and be
accessible to those persons charged with working both on and with the
device at all times.
nThe specifications of the description must be adhered to fully and
unconditionally!
nThe device may only be operated when in a perfect and operationally
safe condition. The device must be checked for detectable defects prior
to each time it is put into service.
nThe system operator must ensure that the responsibilities for activities
on the system are unambiguously defined and only adequately qualified
personnel familiar with the operating and safety regulations are working
on and with the device.
3.6 Personnel and qualifications
The product / system belonging to this description may only be handled by
personnel qualified for the respective task. This is done taking into account
the descriptions associated with the particular task, especially the safety
and warning information contained therein.
Due to their training and experience, qualified personnel are able to recog-
nize risks and avoid possible hazards when dealing with this product /
system.
L WARNING!
Injury hazard from insufficient qualification!
Improper handling can cause substantial bodily harm or material
damage.
Safety instructions
Personnel and qualifications
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3.7 Special hazards
L WARNING!
Live parts
The device is intended for installation in control cabinets and switch
boxes. Contact with live parts poses an immediate danger to life.
nWhen performing any work on the device, disconnect the control cab-
inet or switch box from the power supply and secure it against being
switched on again.
nWorks on electric components may only be carried out by qualified
electricians or persons instructed and supervised by a qualified elec-
trician in accordance with the electro-technical regulations.
Safety instructions
Special hazards
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Safety instructions
Special hazards
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4 The iDM system with LJU communication
4.1 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 vehi-
cles within the system under the directions of the higher-level system con-
troller (PLC) or an independent soft PLC, in case of smaller systems.
Fig. 1: iDM system overview
1 TCU - Track Control Unit
2 MCU - Master Control Unit
3 SyMa - System Manager
4 Driving route with installed data bus
5 Vehicle with vehicle control
Track Control Unit
Communication interface between the MCU and vehicle controls in a TCU
area.
Master Control Unit
Central processing unit that regulates, controls and manages all compo-
nents and vehicles within the installed iDM system. Interface between the
system controller and the iDM system.
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.
TCU
MCU
SyMa
The iDM system with LJU communication
iDM system overview
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4.2 System architecture
The iDM system is a bus system, in which multiple communication buses
are used.
1 32MCU TCUPLC Vehicle
Fig. 2: Bus system
1 Field bus - TCP/IP, PROFINET or EtherNet/IP
2 EtherCAT
3 Rail bus or inductive wire bus
The following connection variants between PLCs, MCUs and TCUs are
possible:
Connection variant Illustration
Line (standard)
MCU
TCU TCU TCU TCU
PLC
Ring (redundancy)
MCU
TCU TCU TCU TCU
PLC
Line (standard)
with a connection for an addi-
tional PLC
not more than four PLCs on one
MCU (type-dependent)
MCU
TCU TCU TCU TCU TCU TCU
PLC PLC
Ring (redundancy)
with a connection for an addi-
tional PLC
not more than four PLCs on one
MCU (type-dependent)
MCU
TCU TCU TCU TCU TCU TCU
PLC PLC
Bus system
Connection
variants
The iDM system with LJU communication
System architecture
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4.3 Performance capabilities and properties
General information
Total route length per MCU 14000 m max. in the rail bus system (SB)
6300 m max. in the inductive wire bus system (iDB)
Manageable number of vehicles
per MCU
999 max.
Protocol MCU - PLC 1) TCP/IP (10/100/1000 Mbps)
PROFINET (100 Mbps)
EtherNet/IP (100 Mbps)
MCU interfaces to external PLCs 4 max. 1)
TCU areas per MCU 70 max.
MCU protocol - TCUs EtherCAT (100 Mbps)
MCU bus architecture - TCUs 1) Line
Ring (redundancy)
MCU - TCU cable length 100 m max. 2)
TCU - TCU cable length 100 m max. 2)
1) depending on the MCU
2) can be extended with optional hardware
TCU area
TCU area length 200 m max. in the rail bus system (SB)
90 m max. in the inductive wire bus system (iDB)
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 (crossovers) to adjacent
TCU areas
20 max.
Number of segments per TCU area 72 max. (can be extended to 84 max.)
Bus TCU - vehicles SB or iDB 3)
Bus TCU - vehicles LJU bus
Transfer rate 500 kbps max. in the rail bus system (SB) 4)
31.25 kbps max. in the inductive wire bus system (iDB)
3) depending on system used
4) max. transfer rate depending on the vehicle control system series used
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Performance capabilities and properties
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The iDM system with LJU communication
Performance capabilities and properties
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