Conductix-Wampfler Nexus BB User manual

NEXUS BB DATA TRANSMISSION MANUALXA-592094.3 - 11.01.22
www.conductix.us Nexus BB
Manual

NEXUS BB DATA TRANSMISSION MANUAL
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The technical data and images which appear in this manual are for informational purposes only. NO WARRANTIES, EXPRESS OR
IMPLIED, INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, ARE CREATED BY THE
DESCRIPTIONS AND DEPICTIONS OF THE PRODUCTS SHOWN IN THIS MANUAL. Conductix Inc. makes no warranty (and assumes
no liability) as to function of equipment or operation of systems built according to customer design or of the ability of any of its products to
interface, operate or function with any portions of customer systems not provided by Conductix Inc.
Seller agrees to repair or exchange the goods sold hereunder necessitated by reason of defective workmanship and material discovered
and reported to Seller within one year after shipment of such goods to Buyer.
Except where the nature of the defect is such that it is appropriate, in Seller’s judgment, to eect repairs on site, Seller’s obligation
hereunder to remedy defects shall be limited to repairing or replacing (at Seller’s option) FOB point of original shipment by Seller, any part
returned to Seller at the risk and cost of Buyer. Defective parts replaced by Seller shall become the property of Seller.
Seller shall only be obligated to make such repair or replacement if the goods have been used by Buyer only in service recommended
by Seller and altered only as authorized by Seller. Seller is not responsible for defects which arise from improper installation, neglect, or
improper use or from normal wear and tear.
Additionally, Seller’s obligation shall be limited by the manufacturer’s warranty (and is not further warranted by Seller) for all parts procured
from others according to published data, specifications or performance information not designed by or for Seller.
Seller further agrees to replace or at Seller’s option to provide a refund of the sales price of any goods that do not conform to applicable
specifications or which dier from that agreed to be supplied which non-conformity is discovered and forthwith reported to Seller within
thirty (30) days after shipment to the Buyer. Seller’s obligation to replace or refund the purchase price for non-conforming goods shall
arise once Buyer returns such goods FOB point of original shipment by Seller at the risk and cost of Buyer. Goods replaced by Seller shall
become the property of Seller.
There is no guarantee or warranty as to anything made or sold by Seller, or any services performed, except as to title and freedom
from encumbrances and, except as herein expressly stated and particularly, and without limiting the foregoing, there is no guarantee or
warranty, express or implied, of merchantability or of fitness for any particular purpose or against claim of infringement or the like.
Seller makes no warranty (and assumes no liability) as to function of equipment or operation of systems built to Buyer’s design or of the
ability of any goods to interface, operate or function with any portions of Buyer’s system not provided by Seller.
Seller’s liability on any claim, whether in contract, tort (including negligence), or otherwise, for any loss or damage arising out of,
connected with, or resulting from the manufacture, sale, delivery, resale, repair, replacement or use of any products or services shall in
no case exceed the price paid for the product or services or any part thereof which give rise to the claim. In no event shall Seller be liable
for consequential, special, incidental or other damages, nor shall Seller be liable in respect of personal injury or damage to property not
the subject matter hereof unless attributable to gross misconduct of Seller, which shall mean an act or omission by Seller demonstrating
reckless disregard of the foreseeable consequences thereof.
Seller is not responsible for incorrect choice of models or where products are used in excess of their rated and recommended capacities
and design functions or under abnormal conditions. Seller assumes no liability for loss of time, damage or injuries to property or persons
resulting from the use of Seller’s products. Buyer shall hold Seller harmless from all liability, claims, suits and expenses in connection
with loss or damage resulting from operation of products or utilization of services, respectively, of Seller and shall defend any suit or action
which might arise there from in Buyer’s name - provided that Seller shall have the right to elect to defend any such suit or action for the
account of Buyer. The foregoing shall be the exclusive remedies of the Buyer and all persons and entitles claiming through the Buyer.
CONDUCTIX INCORPORATED

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CONDUCTIX-WAMPFLER FIELD SERVICE
Need Field Service for our products? We Can Handle It!
Ask us for a quote on expert system installations,inspections, preventative maintenance, and repairs/retrofits.
As the world’s largest single source manufacturer of mobile electrification products, Conductix-Wampfler has the unique ability to oer a
degree of service not found anywhere else. Conductix-Wampfler’s team of highly qualified service technicians and engineers have years of
experience servicing our complete line of products.
We can provide:
• Annual Service contracts
• Installation
• Commissioning
• Installation supervision to ensure your installers avoid common mistakes.
• Troubleshooting to get you up and running.
• Pre-planned inspections to complement your preventive maintenance program.
Call 1-800-521-4888 for further details.

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TABLE OF CONTENTS
SECTION 1 - SAFETY 6-8
1.0 Safety Information Responsibility 6
1.1 Safety Messages 6
1.2 Limitation of Liability 6
1.3 Personnel Requirements-Qualifications 7
1.4 Personnel Requirements-Unauthorized Personnel 7
1.5 Personnel Requirements - Training 8
1.6 Personnel Protective Equipment 8
SECTION 2 - PRODUCT DISPOSAL 9
2.0 Product Disposal & Recycling 9
SECTION 3 - INSTALLATION 10-12
3.0 Intended Use 10
3.1 Improper Use 10
3.2 Protective Measurers to be Taken by Owner/Operator 11-12
3.3 Emergency Stop 12
3.4 In The Event of Accidents/Malfunctions 12
SECTION 4 - OVERVIEW 13-16
4.0 Nexus BB Modems 13-14
4.1 Nexus BB Modem Filters 15
4.2 Nexus BB Modem Filters Parts List 16
SECTION 5 - SYSTEM WIRING/CONNECTIONS 17-21
5.0 Connection-AC 17
5.1 Connection-DC 18
5.2 Connection-AC (Conductor Bar) 19-20
5.3 Connection-DC (Conductor Bar) 21
SECTION 6 - INSTALLATION 22-33
6.0 Required Tools 22
6.1 Application Examples 22
6.2 Installation Overview 22-23
6.3 Electromagnetic Compatibility (EMC) 23
6.4 Noise Coupling 23
6.5 Distances between cables with dierent classes 24
6.6 Installation Recommendations 25
6.7 Multiple Nexus BB Systems (domains) 26-27
6.8 EMC/EMI Installation Requirements 27-29
6.9 Equipment Operation 29
6.10 Installation (AC/DC) 29
6.11 Three-Phase Power Connection-Stationary Control Panel 30
6.12 Three-Phase Power Connection-Mobile Control Panel 30
6.13 Single-Phase (120 to 250 VAC/100 to 250 VDC) Power Connection -Stationary Power Control 30
6.14 Single -Phase (120 to 250 VAC/100 to 250 VDC) Power Connection-Mobile Control Panel 31
6.15 Single-Phase (24-48 VDC Modem) Power Connection-Stationary Control Panel 31
6.16 Single-Phase (24-48 VDC Modem) Power Connection - Mobile Control Panel 31
6.17 Termination Wiring 32
6.18 Clearance for Cooling/Wiring 33

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TABLE OF CONTENTS
7.0 MODEM SPECIFICATIONS 34-36
7.0 Maintenance Warnings 34
7.1 System Specifications 34-36
8.0 TROUBLESHOOTING 37

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SECTION 1 - SAFETY
1.0 Safety Information Responsibility
1.0.1 All owner, operator, and maintenance personnel must read and understand all manuals associated with this product before
installation, operation, or maintenance.
1.0.2 The manual provides information on the recommended installation, operation, and maintenance of this product. Failure to read and
follow the information provided could cause harm to yourself or others and/or cause product damage. No one should install, operate,
or attempt maintenance of this product prior to familiarizing themselves with the information in this manual.
1.1 Safety Messages
The following safety messages are used in this manual to alert you to specific and important safety related information.
CAUTION
CAUTION indicates unsafe actions or situations that have the potential to cause injury, and/or minor equipment or property damage.
DANGER
DANGER indicates hazards that have the potential to cause severe personal injury or death.
WARNING
WARNING indicates unsafe actions or situations that have the potential to cause severe injury, death, and/or major equipment or property
damage.
NOTE
NOTE is used to alert you to installation, operation, programming, or maintenance information that is important, but not hazard related.
1.2 Limitation of Liability
1.2.1 All data and information in this mounting instructions have been compiled in compliance with the applicable standards and
regulations, best practice and our many years of experience and knowledge.
1.2.2 The manufacturer accepts no liability for damages resulting from:
• Failure to comply with this document
• Improper use
• Use by untrained personnel
• Unauthorized modifications
• Technical changes
• Use of unauthorized replacement parts and accessories
• The actual scope of delivery may dier from the explanations and descriptions provided here if the model in question is a special
one, if additional equipment has been ordered or due to recent technical changes.
1.2.3 The obligations agreed upon in the delivery agreement and our General Terms and Conditions of business apply, as do the delivery
conditions of the manufacturer and the legal regulations applicable at the time the contract was concluded.
1.2.4 All products are subject to technical modifications in the context of improvement of function and further development.

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SECTION 1 - SAFETY
1.3. Personnel Requirements-Qualifications
WARNING
Inadequately trained persons are at risk of injury!
Improper use can result in serious personal injury or material damage. All activities must only be performed by qualified personnel.
1.3.1 Only persons who can be expected to perform their work reliably are acceptable personnel. People whose reactions are impaired by
drugs, alcohol or medications, for example, are not authorized.
1.3.2 When selecting personnel, follow all age- and occupation-specific guidelines applicable at the location of use.
1.3.3 The following qualifications are specified in the operating instructions for certain fields of activity.
1.3.4 Trained personnel and operators
• Will have participated in a training session, given by the owner, on the tasks assigned to them and the potential hazards in case of
improper conduct.
• The owner of the machine or system must document that the appropriate training has taken place.
1.3.5 Specialist personnel
• Will consist of persons capable of performing assigned tasks and independently identifying and avoiding potential hazards based
on their specialist training, knowledge and experience as well as their knowledge of the applicable regulations. Persons are
deemed to be technically qualified if they have successfully completed training as a master electrician, apprentice electrician,
electrical engineer or electrical technician. Persons are also considered technically qualified if they have been employed in an
appropriate capacity for several years, receiving theoretical and practical training in that line, and their knowledge and skills have
been tested by a specialist in the appropriate field of training.
• The machine or system owner must document that the appropriate certificates or other proofs of qualification have been or are
being provided.
1.4 Personnel Requirements-Unauthorized Personnel
WARNING
Danger due to unauthorized personnel!
Unauthorized persons who do not meet the requirements described here are not acquainted with the dangers in the working area. Keep
unauthorized personnel away from the working area. In case of doubt, address the person and direct them away from the working area.
Stop working, as long as unauthorized persons are in the working area.

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SECTION 1 - SAFETY
1.5 Personnel Requirements-Training
1.5.1 Before commissioning the equipment, personnel must be trained by the owner. Log the implementation of training for better
traceability.
Example of a training log:
Date Name Training Type Training Instructor Signature
11/5/2019 John Doe First safety training for personnel Dave Miller
1.6 Personal Protective Equipment
1.6.1 For every task, always use:
Safety helmet: For protection against falling or flying parts and materials.
Protective gloves: For the protection of hands against friction, scrapes, puncture or deeper wounds, as well as against contact with hot
surfaces.
Protective work clothing: Primarily for protection against entrapment by moving machine parts. Work clothing must be close fitting with
a low resistance to tearing; it must have close-fitting sleeves and no protruding parts.
Protective footwear: For protection against heavy failing parts and slipping on slippery floors.
For special tasks, specific protective equipment is required when executing particular tasks:
Safety eye wear: For eye protection against harmful influences such as strong light, chemicals, dust, splinters or weather eects.
Hearing protection: For protection against loud noises and to prevent acoustic trauma.
Breathing mask (FFP-3 - according to country-specific requirements): For protection against materials, particles, and organisms. In
this case, for protection against the dust produced by the abrasion of carbon brushes and the PVC insulation of the conductor rail.

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SECTION 2 - PRODUCT DISPOSAL
2.0 Product Disposal and Recycling
2.0.1 Once the product has reached it’s end of life it must be disassembled and disposed of in accordance with local and regional
environmental requirements.
2.0.2 In the absence of a return and disposal agreement, disassembled components must be recycled as follows:
• All metallic parts must be sorted and recycled by material type
• All plastic components must be sorted and recycled by material type
• All other components are to be disposed of in accordance with their material composition. Take care with items identified as
Substances of Concern.
2.0.3 Local authorities or special disposal companies can provide information about environmentally appropriate disposal.
CAUTION
Environmental damage due to improper disposal!
Electrical waste, electronic components, lubricants, and other auxiliary materials are subject to hazardous-waste disposal regulations and
may only be disposed of by authorized specialists!
Local authorities or specialist disposal companies can provide information about environmentally appropriate disposal.

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SECTION 3 - USAGE
3.0 Intended Use
3.0.1 The data transmission system is designed and built exclusively for the usage described here (intended use).
WARNING
Hazard due to improper use!
• Any application that deviates from or goes beyond the intended use of the devices can result in hazardous situations.
• Strict compliance with the specifications of this manual is required.
• Refrain from improper use of the system.
• Respect the instructions in the following section on improper use.
• The Nexus BB data transmission system is used for data communication between a stationary modem and a mobile modem.
Compliance with these technical conditions is mandatory for the installation:
• The maximum permitted traversing speed of the mobile device is 10 m/s.
Electrical operating conditions:
• The electrical system must be protected in accordance with local regulations and guidelines.
3.1 Improper Use
3.1.0 Claims of any kind due to damage incurred during use that deviates from the intended use described above (“use other than the
intended use”) are excluded. The owner bears sole liability for any damage resulting from improper use.
3.1.1 Improper use in particular includes the following forms of use:
• Operation that does not comply with the specified operating conditions.
• Use where there is risk of explosion (“ex” classified zones).
• Use of the system on a conductor not approved by Conductix-Wampfler.
• Use of the system with accessories that are not approved and not authorized by the manufacturer.
• Use of the system by untrained personnel.

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SECTION 3 - USAGE
3.2 Protective Measures To Be Taken by Owner/Operator
3.2.0 The data transmission system is used in industrial power distribution networks only. The owner of the data transmission system
is therefore subject to the legal obligations concerning workplace safety. In addition to the safety instructions in this document,
all safety, accident prevention and environmental regulations that apply where the data transmission system is used must also be
observed. In particular, pay attention to the following:
• All electrical connections must be made by trained and skilled personnel.
• Work on electrical components of the system may only be carried out when disconnected from the power supply.
• The owner must become acquainted with the applicable occupational safety regulations and perform a risk analysis to identify
additional hazards arising from the specific working conditions where the system is used. This knowledge must be implemented in
the form of operating instructions for the data transmission system.
• For the entire time that the data transmission system is in use, the owner must check whether the operating instructions it has
produced correspond to the current regulatory situation and adjust them if necessary.
• The owner must clearly regulate and define responsibilities for installation, operation, troubleshooting and maintenance.
• The owner must ensure that all employees involved with the system have read and understood this installation manual. The owner
must also train the personnel at regular intervals and inform them of hazards.
• The owner must provide personnel with the necessary protective equipment.
• Owner must keep keys for switching cabinets in a safe place. “Safe” means only explicitly authorized personnel have access to the
keys. The keys are only issued to specialist personnel as described in the Personnel Requirements-Qualifications section.
• The owner must verify that the operating frequency of the data transmission system is permitted in the place of use.
• The owner must observe the following standards, regulations and directives when operating the system (see following page):
EMC Directive 2014/53/EU “Radio Equipment” and The US
Code of Federal Regulation, Title 47, FCC Part 15B Class A
Using Harmonized Product Standards (EN 301 489-1 V2.1.1,
EN 55032, EN 55035 and ANSI C63.4)
EMC Description
EN 55032: FCC Part 15.109/ICES-003 Class A using ANSI C63.4 Radiated emissions, 30MHz - 1GHz
EN 55032: FCC Part 15.107/ICES-003 Class A using ANSI C63.4 Conducted emissions, AC Mains and Telecom 150kHz – 30MHz
EN 61000-3-2 Current frequency harmonics
EN 61000-3-3 Voltage fluctuations and flicker
IEC 61000-4-2 Electrostatic discharge, ±4kV contact, ±8 kV air discharge
IEC 61000-4-3 Radiated immunity, 3 V/m, 80MHz - 1GHz, 3 V/m; 1.4GHz -
2.0GHz; 1 V/m: 2.0GHz - 2.7GHz
IEC 61000-4-4 EFT - AC Mains, ±1kV
IEC 61000-4-5 Surge - AC Mains. ±1kV L-L, ±2kV L-PE
IEC 61000-4-6 Conducted immunity - AC Mains, 3 Vrms
IEC 61000-4-11 Immunity dips and interrupts
Electrical Safety to Directive 2014/35/EU
“Low Voltage Directive”
EN 62368-1 Audio/video, information and communication technology
equipment - Part 1: Safety requirements
UL and cUL
UL 61010-1 Safety Requirements for electrical equipment for measurement,
control, and laboratory use
CSA C22.2 NO. 61010-1-12 Safety Requirements for electrical equipment for measurement,
control, and laboratory use

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SECTION 3 - USAGE
3.2.1 The owner is also responsible for ensuring that the data transmission system is always in perfect working order. Therefore the
following applies:
• The operator must ensure that the service intervals described in this document are observed.
• The owner must have all safety systems inspected for functionality and completeness on a regular basis (once yearly if possible,
but at least as often as required by applicable national regulations).
• If components or the system have been modified, the safety systems must be re-inspected and adapted to the changed
circumstances such that the system is safe again.
3.3 Emergency Stop
3.3.0 The Nexus BB data transmission system is used for transparent transmission of safety-relevant signals. These signals must be
generated by a higher-level component. Suitable safety components must be used to guarantee the emergency-stop function. The
emergency stop must be implemented using safety equipment provided by the customer and depends on the nature of the power
supply.
3.4 In The Event of Accidents/Malfunctions
3.4.0 Shut down the system and secure it against unauthorized, unintentional and/or erroneous activation. Secure the danger zone and
remove all personnel from the danger zone.
• Initiate first-aid measures.
• Alert the rescue services.
• Inform responsible parties at the operating site.
• Clear access routes for emergency vehicles.
3.4.1 In the event of a malfunction:
• Shut down the system and secure it against unauthorized, unintentional and/or erroneous reactivation.
• Secure the work area against entry.
• Consult qualified personnel when analyzing the fault.
• Involve authorized personnel for maintenance and repair.
• Check for disconnection from power.
• Remove the component and replace with a new component.
• Determine the cause of the fault and repair the component.

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SECTION 4 - OVERVIEW
4.0 Nexus BB Modems
4.0.0 Nexus BB uses the Powerline Networking technology to send Ethernet data through electrified physical layers (i.e. conductor bar,
cable reel, festoon, slip ring) to turn them into a data transmission network. The data transfer is realized between the Nexus BB
modems located on the front end of the physical layer.
1. Power indicator 5. Ground
2. PLC (Power Line Communication) Indicator 6. Power supply (DC-)
3. Ethernet indicator 7. Power supply (DC+)
4. Ethernet port
Light Description
• Power: On-power on; O-power o
• PLC: On - successful connection to another modem; O-unsuccessful connection to another modem.
Flashing-receiving/transmitting data.
• Ethernet: On-successful connection to network, O-unsuccessful connection to network.
Flashing - receiving/transmitting Ethernet data.
1
2
4
5
3
6
7
Figure 4-1: Nexus BB (DC modem)

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SECTION 4 - OVERVIEW
12
4
5
3
6
Figure 4-2: Nexus BB (AC modem)
7
8
1. Power indicator 5. Power supply (L1-3φ or Neutral-1φ)
2. PLC (Power Line Communication) Indicator 6. Power supply (L2-3φ or Line-1φ)
3. Ethernet indicator 7. Power supply (L3-3φ)
4. Ethernet port 8. Ground
Light Description
• Power: On-power on; O-power o
• PLC: On - successful connection to another modem; O-unsuccessful connection to another modem.
Flashing-receiving/transmitting data.
• Ethernet: On-successful connection to network, O-unsuccessful connection to network.
Flashing - receiving/transmitting Ethernet data.

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SECTION 4 - OVERVIEW
4.1 Nexus BB Modem Filters
Figure: 4-3 Figure: 4-4 Figure: 4-5
Figure: 4-6 Figure: 4-7 Figure: 4-8
Figure: 4-9

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SECTION 4 - OVERVIEW
4.2 Nexus BB Modem Filters Parts List
Figure Part No. Description Length
in. (mm)
Width
in. (mm)
Height
in. (mm)
# of phases Weight
lb. (kg)
4-3 XA-592533 Filter EMC/RFI Nexus BB
10A with hardware
6.45
(163.83)
2.28
(57.91)
2.28
(57.91)
3 0.88
(0.40)
4-3 XA-592534 Filter EMC/RFI Nexus BB
20A with hardware
6.45
(163.83)
2.28
(57.91)
2.28
(57.91)
3 1.1
(0.50)
4-4 XA-592535 Filter EMC/RFI Nexus BB
50A with hardware
8.54
(216.92)
3.35
(85.09)
3.15
(80.01)
3 2.65
(1.20)
4-5 XA-592336 Filter EMC/RFI Nexus BB
80A with hardware
11.43
(290.32)
3.74
(95)
3.54
(89.92)
3 4.85
(2.20)
4-5 XA-592540 Filter EMC/RFI Nexus BB
100A with hardware
11.43
(290.32)
3.74
(95)
3.54
(89.92)
3 5.73
(2.60)
4-6 XA-592098 Filter EMC/RFI Nexus BB
150A w/ cover
12.6
(320.04)
8.96
(227.58)
3.39
(86.11)
3 13.45
(6.10)
4-6 XA-592099 Filter EMC/RFI Nexus BB
200A w/ cover
12.6
(320.04)
8.96
(227.58)
3.39
(86.11)
3 13.45
(6.10)
4-6 XA-592100 Filter EMC/RFI Nexus BB
600A w/ cover
12.6
(320.04)
8.92
(226.57)
3.39
(86.11)
3 16.98
(7.70)
4-7 XA-592103 Filter EMC/RFI Nexus BB
1000A w/ cover
16.14
(409.96)
8.62
(218.95)
4.92
(124.97)
3 34.83
(15.80)
4-8 XA-592554 Filter AC/DC EMI Nexus
BB 20A with hardware
3.49
(88.65)
2.13
(54.10)
1.59 1 0.63
(0.28)
4-9 *Terminator Terminating resistor-
Nexus BB
5.91
(150.11)
4.81
(122.17)
3.54
89.92
1 or 3 0.91
(.41)
NOTE:
*For DC applications other Single Phase Filters are available, please contact factory
*Terminating resistor part number varies on selected bar system

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SECTION 5 - SYSTEM WIRING/CONNECTIONS
5.0 Connection-AC
Figure 5-1: Three-Phase AC modem
Figure 5-2: Single-Phase AC modem
NOTE:
• The wiring diagrams shown in Section 5 are recommended; however, all local and regional electrical codes shall be adhered to. All
fuses shown in Section 5 are for protection of wiring providing power to the Nexus BB modem and the fuse size is dependent upon
the wiring size (20A maximum).

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5.1 Connection-DC
Figure 5-3: High-Voltage DC modem
Figure 5-4: 48V DC modem
SECTION 5 - SYSTEM WIRING/CONNECTIONS

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5.2 Connection - AC (Conductor Bar)
Figure 5-5: Three-Phase AC modem conductor bar (end feed)
Figure 5-6: Three-Phase AC modem conductor bar (center feed)
SECTION 5 - SYSTEM WIRING/CONNECTIONS

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SECTION 5 - SYSTEM WIRING/CONNECTIONS
5.2 Connection-AC (Conductor Bar)
Figure 5-7: Single-Phase AC modem conductor bar (end feed)
Figure 5-8: Single-Phase AC modem conductor bar (center feed)