Wieland podis CON User manual

podis
®
CON
podis
® CON Power Bus System
Installation system for decentralized power distribution
Instructions
Product and system description
Doc. no. BA000369
Last updated: 02/2016 (Rev. B)

Copyright
2 Wieland Electric GmbH | BA000369 (Rev. B) | 02/2016
This document is copyright-protected. The rights derived from this copyright are reserved for Wieland
Electric GmbH. Reproduction of this document or parts of this document is only permissible within the
limits of the statutory provision of the Copyright Act. Any modification or abridgment of the document is
prohibited without the express written agreement of Wieland Electric GmbH.

Content
Wieland Electric GmbH | BA000369 (Rev. B) | 02/2016 3
1About this manual ........................................................................................ 5
Target groups and qualification of personnel ........................................................ 5
Presentation of safety-relevant information ........................................................... 5
2System overview .......................................................................................... 6
3
podis CON
flat cable ..................................................................................... 9
3.1 Current-carrying capacity of flat cables and points of contact .............................. 9
3.2 Notes on routing of flat cables ............................................................................. 10
General instructions and precautionary measures ............................................... 10
Monitoring and safety devices ............................................................................. 10
Routing instructions ............................................................................................. 11
Mounting and routing of flat cables with cable clamps ....................................... 12
3.3 Cutting flat cables to length ................................................................................. 12
3.4 Stripping of flat cables ......................................................................................... 13
Stripping of flat cable for attachment of cable end cap ....................................... 14
Stripping of flat cables for connection to the distributor module or terminal strips
.............................................................................................................................. 14
3.5 Termination of the flat cable ................................................................................ 16
3.6 Making the connection ........................................................................................ 17
Conductor assignment ......................................................................................... 18
4Rapid assembly using basket trays ............................................................ 19
4.1 Example using flat cable outlet ............................................................................ 20
5Feeding into a power bus segment and power tapping ............................. 22
5.1 Feed directly from the switchgear cabinet ........................................................... 22
Insertion, retaining and connection of flat cable inside switchgear cabinet ........ 22
5.2 Feeding through distributor module .................................................................... 23
5.3 Feeding through 7-pin connection module .......................................................... 23
Mounting of connection and tapping modules .................................................... 24
5.4 Connection modules ............................................................................................ 26
5.5 Flat cable outlet, pluggable (power tap) ............................................................... 26
Protective lid ......................................................................................................... 27
6Attachment of pluggable devices and functional modules ........................ 28
6.1 Connector for round conductor connection ......................................................... 28
6.2 Connection of multiple flat cable sections ........................................................... 28
6.3Socket module ..................................................................................................... 29
6.4
Drive control systems
podis
®
MOT
,
podis
®
MCU
................................................ 29
6.5 Maintenance switch
podis
®
SWITCH
.................................................................. 30
6.6 LED lights
podis
®
LED
.......................................................................................... 30
7Accessories ................................................................................................ 31
Sealing sleeve ....................................................................................................... 31
Protective lid ......................................................................................................... 31
Cable bushing ....................................................................................................... 31
Cable glands ......................................................................................................... 31
Cable clip .............................................................................................................. 32

4 Wieland Electric GmbH | BA000369 (Rev. B) | 02/2016
Wieland Electric GmbH
Brennerstraße 10-14
96052 Bamberg, Germany
Phone: [phone]  0
Fax: [phone]  1 98
E-mail: [e-mail]
http://eshop.wieland-electric.com
http:// www.wieland-electric.com
Hotline for technical support
Contact person for: technical questions regarding accessories, function, product properties, and usage
options
Phone: +49 (0) 9 51 / 93 24  9 95
Fax: +49 (0) 9 51 / 93 26  9 96
E-Mail: [e-mail]

1
About this manual
Wieland Electric GmbH | BA000369 (Rev. B) | 02/2016 5
1About this manual
This manual provides you with support regarding the project planning and development of electrical facil-
ities as well as the installation and commissioning of
podis
®
CON
-Modules. It contains information as to
how the devices can be used.
This document contains the information required for the intended use of the device as well as technical
data. It describes the technical characteristics, the usage of the device as well as the boundary condi-
tions. Case studies that are used in practice are presented as part of illustrative application examples.
Target groups and qualification of personnel
Commissioning and installation of components should only be carried out by specialized technicians. The
legal and valid regulations for such types of installations must be considered.
Therefore, the system manual is targeted at the following:
•Those who can verify that they have the corresponding training and already have corresponding
basic knowledge of planning and commissioning of electrical installations.
•System integrators
•Electricians
Presentation of safety-relevant information
Information that warns of personal injury or property damage are emphasized by safety instructions.
Warning of personal injury
Safety instructions that warn of personal injury are indicated by the signal word
DANGER
. Failure to ob-
serve can cause serious health effects or even death.
Example:
DANGER
•Only qualified electricians may install and commission this device.
•Do not open the device. Do not introduce any foreign objects. Keep
device away from water and fire.
•Only connect or disconnect the device when the device is powered
down.
•
The relevant standards, guidelines, regulations and provisions of the
respective country must be observed.
Warning of property damage
Text that warns of property damage is indicated by the signal word
CAUTION
.
Example:
CAUTION
In the event of damage to the unit or any malfunctions, please
contact your Wieland sales partner or an authorized dealer.
General instructions
Texts that contain general instructions on installation and handling are marked with the signal word
NOTE
Example:
NOTE
Openings in the sheath of the flat cable must be closed by a seal-
ing collar.

2
System overview
6 Wieland Electric GmbH | BA000369 (Rev. B) | 02/2016
2System overview
1. Cable end cap
2. Cable bushing
3. 7-pin connection module
4. Distributor module
5. Front plug connector
6. 2-pin and 3-pin connection module
7. Pluggable outlet, 7-pin with connector
8. Flat cable
9. Sealing sleeve
10. 7-pin connection module with repair switch
1
2
3
4
5
6
7
8
9
10

2
System overview
Wieland Electric GmbH | BA000369 (Rev. B) | 02/2016 7
Example of a
podis
®
system configuration for a conveyor system

2
System overview
8 Wieland Electric GmbH | BA000369 (Rev. B) | 02/2016
Example of a
podis
®
system configuration for the tower of a wind energy plant.

3
podis CON flat cable
Wieland Electric GmbH | BA000369 (Rev. B) | 02/2016 9
3
podis CON
flat cable
Item No.
Image
Description
00.709.0504.1
Flat cable EVA 7G4 BLACK - VDE
Flat cable 7 x 4 mm² EVA, finely stranded, numbered cores, external dimensions of
approx. 35 x 6 mm, weight approx. 440 g/m, 450/750V in accordance with VDE,
free of halogen and silicone, resistant against oils and acids, low fire load, black
sheath
00.729.0504.1
Flat cable XLPE 7G4 SCHWARZ - UL
Flat cable 7 x 4 mm² XLPE, finely stranded, numbered cores, external dimensions
of approx. 35 x 6 mm, 600 V in accordance with UL, UL 1277, free of halogen, low
smoke, black sheath.
3.1 Current-carrying capacity of flat cables and points of contact
The maximum power load of the conductors refers to free routing of the cables in the open (>10 mm).
Diagram 1: Maximum permissible power load per conductor and contact for load currents applied to L1,
L2 and L3, for flat cable EVA 7G4 (00.709.0504.1) and flat cable XLPE (00.729.0504.1) as fed entirely by
plug FCS 4 7 ST SA SO0 (75.015.0151.0) and flat cable outlet FCS 4 7 SI BU SW FM (99.800.4866.1).
®

3
podis CON flat cable
10 Wieland Electric GmbH | BA000369 (Rev. B) | 02/2016
Table 2: Current-carrying capacity of podis
®
CON flat cable EVA 7G4 mm ² (00.709.0504.1)
In the open d > 10 mm
Loose on wall or floor
Cable duct
Loaded cores
3 5 6 3 5 6 3 5 6
Ta [°C]
Max. cross current
Max. cross current
Max. cross current
20
40
35
35
40
32
32
35
30
25
25
40
35
35
35
32
30
35
30
25
30
40
35
32
35
30
25
32
25
25
35
35
32
30
32
25
25
30
25
25
40
35
30
30
30
25
25
25
20
20
45
32
30
30
25
20
20
25
20
20
50
30
30
30
25
20
20
20
20
16
3.2 Notes on routing of flat cables
The flat cable is convenient and easy to handle and install. Some rules apply to the installation and rout-
ing, which are described in the following.
General instructions and precautionary measures
The
podis
®
flat cable is operated in grids with grounded feeds (TN-S networks). A floating installation of
podis
®
systems is not permitted.
CAUTION
•The flat cable may only be commissioned if it is in a faultless condition and does not exhibit any damage to or openings of the
sheath.
•Unused connections, outlets or devices on the flat cable must be sealed off using the corresponding measures (lids, blind plugs,
etc.). It is not permitted to work on or operate the flat cable with open connections, outlets or devices.
•When conducting any working operations on the flat cable (assembly, maintenance, installation, etc.) the power must be turned
off.
•The flat cable must always be closed off using the suitable end caps (see ordering instructions) due to the required air gaps and
creepage distances. It is not permitted to operate the flat cable with open ends or using other
sealing solutions than the end caps
prescribed herein.
NOTE
Openings in the sheath caused by the insulation-piercing termination must be sealed using the sealing collar (see ordering in-
structions).
Monitoring and safety devices
Depending on the field of application, different components and protective measures are required to
complete a system or installation. The type of components and the level of obligation associated with
these protective measures depends on which VDE guideline affects your system or installation. Please
take note of Section 1 in this regard as well.
The assignment of safety guards to protect from short-circuits of cables and lines of the main or auxiliary
circuits outside of switchgear combinations must be conducted under consideration of the loop imped-
ance. DIN VDE 0100 Part 430 is to be applied in this regard.
The flat cable must be protected against overloads and short-circuits using a three-phase 16A (Inominal ) cir-
cuit breaker with tripping characteristic class C. The tripping current is between 8 and 10 Irated in this case
(EN 60898, DIN VDE 0641 Part 11 and IEC 898). The auxiliary circuit must be protected by a single-phase
16 A (Irated ) circuit breaker with tripping characteristic class C. Emergency stop devices (in accordance
with IEC 204, complies with DIN VDE 113) must be available. Their functioning may not be impaired in
any way.

3
podis CON flat cable
Wieland Electric GmbH | BA000369 (Rev. B) | 02/2016 11
The feed must be grounded (TN-S network). The plant into which the podis systems are to be integrated
should be connected to the protective ground (neutral point of the mains transformer). If this is not the
case, every consumer connected to the
podis
®
flat cable must be separately connected to the neutral
point of the mains transformer through a protective conductor. The diameter of the protective conductor
must be at least 4 mm2. The protective conductor may not be looped through the consumers.
Effective lightning protection measures must be fitted to the plant in order to prevent damage to elec-
tronic devices.
The safe electric separation between main and auxiliary circuits is required for the motor starters. The
main and auxiliary circuits are constructively separated in the
podis
®
system in a safe and secure manner.
When connecting motor/contactor combinations made by third party manufacturers, make sure that
electric separation is guaranteed for these devices (separation voltage of at least 2.5 kV AC).
Regarding the 24 V or 50 V supply, make sure that lightning protection measures are fitted and the low
voltage supply is separated in an electrically safe manner.
Routing instructions
Assembly
EVA 7x4 mm² (00.709.0504.1)
XLPE 7 x 4 mm² (00.729.0504.1)
Bending radius
> 18 mm
≥100 mm
Assembly temperature
-5 °C…+50°C
+5 °C…+50°C
Routing type
Cable duct, platform with cable clamps
(see "Cable collar" Section)
Cable duct, platform with cable clamps
(see "Cable collar" Section)
Protection
380V supply
Three-phase 16A circuit breaker,
tripping characteristics class C
Three-phase 16A circuit breaker,
tripping characteristics class C
24 V supply
Single-phase 16A circuit breaker,
tripping characteristics class C
Single-phase 16A circuit breaker,
tripping characteristics class C
CAUTION
The flat cables are not non-trailing cables.
When routing the flat cables inside cable ducts, you must consider the derating according to VDE 0660
Part 507 and the maximum ambient temperature of 50°C. Please also consider the following diagram
regarding the derating.

3
podis CON flat cable
12 Wieland Electric GmbH | BA000369 (Rev. B) | 02/2016
Mounting and routing of flat cables with cable clamps
The cable clamps (see ordering instructions) are fitted to solid subsurfaces by means of screw fitting. The
flat cable is suspended from the mounted cable clamps (see drawing, variant A).
To secure the flat cable against being pulled out, mount two cable clamps immediately next to one an-
other so that they are put up on the opposing sides of the flat cable (see drawing, variant B).
This type of mounting can also be applied for the vertical routing of flat cables. However, offset cable
clamps with alternating stops are also sufficient in this case (see drawing, variant C).
3.3 Cutting flat cables to length
In order to cut the
podis
®
CON
flat cables to length, the cables are separated by a single cut with a pair of
cable shears.
Required tools:
Figure: Cable shears (95.300.0300.0)
Cut the flat cable to length as desired using the cable shears
(95.300.0300.0). Ensure a clean, square cut. Avoid fraying of the cop-
per cores.
Figure: Cutting flat cable to length

3
podis CON flat cable
Wieland Electric GmbH | BA000369 (Rev. B) | 02/2016 13
3.4 Stripping of flat cables
The
podis
®
CON
flat cable has to be stripped for some applications. Required for this purpose:
•Assembly of flat cable end caps (Z5.562.7553.1)
•Connection to distributor module (75.010.0053.1)
Required tools:
Figure: Stripping pliers (95.350.0300.0)
Figure: Stripping knife (95.350.0700.0)
Procedure:
1. Cut the cable to the desired length.
2. Strip the flat cable in accordance with the following table.
Stripping lengths (X mm)
Cable end cap
19 mm
Distributor module
50 mm
Terminal block inside switchgear
cabinet
> 50 mm (depending on specific connecting conditions)

3
podis CON flat cable
14 Wieland Electric GmbH | BA000369 (Rev. B) | 02/2016
Stripping of flat cable for attachment of cable
end cap
We recommend use of the stripping pliers (95.350.0300.0) for
stripping the
EVA 7 x 4 mm²
(00.709.0504.1) as well as
XLPE
7 x 4 mm²
(00.729.0504.1) flat cables. These are equipped
with a cable stop that is specially designed for the flat cables in
question and thereby allow a clean stripping of the cables. The
end of the flat cable is placed into the stripping pliers and the
sheath is cut by a powerful press. Keep the pliers closed and
lock them using the yellow slider (slide in the direction of the
grip until it meets the stop). Slight tilting motions cause the
sheath to be separated and then safely stripped.
A training video regarding stripping of the cables and attachment of the cable end cap is available here:
https://www.youtube.com/watch?v=oLoFVR-LJ-w
Stripping of flat cables for connection to the distributor module or terminal strips
Scratch the sheath of the cable on the front and rear sides of the flat cable in the longitudinal and trans-
verse directions as shown in the following images. A standard cable stripping knife suffices for this pur-
pose. Do not scratch deeper into the rubber sheath than a maximum of 0.7 mm in order to avoid damage
to the insulation.
When using the stripping knife (95.350.0700.0), the blade protrudes by exactly 0.7 mm in order to pre-
vent any damage to the insulation. The stripping knife is supplied with a set of instructions.
CAUTION
Significant tilting motions can cause the insulation of the conductors to
be cut. Only tilt the cable slightly in the direction of the stripping pliers.

3
podis CON flat cable
Wieland Electric GmbH | BA000369 (Rev. B) | 02/2016 15
Knife 95.350.0700.0 and combination pliers Scratching: first transverse, then longitudinal
Scratch the flat cable as follows:
1x all around in the transverse direction and then 2x in the
longitudinal direction on both sides
The longitudinal cut should end shortly before the transverse
cut in order to prevent tearing
Scratching on the edges.
After scratching, tear open the edges from the front using a
pair of pliers.
Pull off the sheath on the torn edges
Tear the cable cleanly from below along the transverse
scratch.
Expose all conductors
1
2
3
4
5
6
7
8

3
podis CON flat cable
16 Wieland Electric GmbH | BA000369 (Rev. B) | 02/2016
Pull off the web with the remaining sheath residue
3.5 Termination of the flat cable
After the flat cable has been routed, all free cable ends must be safely terminated and sealed in accord-
ance with IP65. Use the cable end pieces (Z5.562.7553.1) for this purpose. They are composed of a
shorter part (cover) and a longer part, which contains the screws, the seal and the insulation ducts. The
following images illustrate the termination of the flat cable.
Route the stripped end of the flat cable into the end
cap (the openings in the end cap are coded in ac-
cordance with the cable outline)
CAUTION
Due to the required air gaps and creepage distances,
podis
®
CON
flat cables must always be terminated by end caps on both
ends.
9
10

3
podis CON flat cable
Wieland Electric GmbH | BA000369 (Rev. B) | 02/2016 17
Tighten both clamping screws.
Note: A training video regarding stripping of the cables and attachment of the cable end cap is available
here:
https://www.youtube.com/watch?v=oLoFVR-LJ-w
3.6 Making the connection
The modules for power feed and tap can be installed at any desired point of the flat cable. The conduc-
tors of the flat cable remain uninterrupted. The connection is made using contact screws.
Microsection of a contact point, penetration of the sheath and insulation, con-
tact with the conductor through the contact screw.
CAUTION
The flat cable is protected against polarity reversal via cod-
ing. One edge of the flat cable is V-shaped. The cable re-
ceptacles in all system components (flat cable outlets,
cable end caps) are shaped correspondingly. The flat cable
is inserted in such a manner that the V-shaped side is op-
posed to the hinge of the opened cable receptacle.
Coding/polarity reversal
protection

3
podis CON flat cable
18 Wieland Electric GmbH | BA000369 (Rev. B) | 02/2016
Conductor assignment
The individual conductors of the flat cable can generally be assigned freely apart from PE. In order to
guarantee flawless interaction with other
podis
®
CON
components, we recommend the following assign-
ment for the individual cores:
L1: Phase 1
L2: Phase 2
L3: Phase 3
L4: N
PE: PE
L5: +24 V DC
L6: 0 V
DANGER
All connecting and removal operations may only be performed on
the flat cable in an unpowered state!

4
Rapid assembly using basket trays
Wieland Electric GmbH | BA000369 (Rev. B) | 02/2016 19
4Rapid assembly using basket trays
The connection module and flat cable outlet are fitted with a rapid assembly panel on the
rear side. The rapid assembly panel simplifies the attachment of components inside basket
trays. The components are firmly connected to the basket tray by bending the clamping
loops. If there are large gaps between the components, the flat cable must be additionally
fixated using cable ties.
The assembly panels are suitable for grids with mesh sizes of 100 mm in the longitudinal
direction of the basket tray.
Item No.
Image
Description
99.801.4866.1
Connecting module FCS 4 7 SI FK FM
with rapid assembly panel for mounting inside basket trays; 7-pin, 20 A; 277/480 V
4 kV/3 (VDE); 600 V (UL, CSA); protection class IP65; insulation-piercing termina-
tion; connection of 1.5…6 mm² finely stranded/single-wire through spring termi-
nals.
99.801.4866.1
Flat cable outlet FCS 4 7 SI BU FM
with rapid assembly panel for basket trays; 7-pin, 20 A; 277/480 V 4 kV/3 (VDE);
600 V (UL, CSA); socket with plastic locking bolt; protection class IP65, plugged or
with protective lid 07.409.7256.0.
CAUTION
•
Ensure the correct mounting position of the components!
•For vertical installations, start routing the components from the
top.
•The coding of the flat cable must be located on the right.
Coding on the right!

4
Rapid assembly using basket trays
20 Wieland Electric GmbH | BA000369 (Rev. B) | 02/2016
4.1 Example using flat cable outlet
Attachment of component with assembly panel.
Bending of the clamping loops on the assembly panel.
Bending of the flat cable and closing of the flat cable outlet.
Termination of the outlet with the flat cable by screwing in the contact
screws.
Connection of the plug or functional module, lock and – done!
CAUTION
•
The contact screws must be screwed in until they meet the stop! The maximum tightening torque may not exceed 1 Nm.
•The use of an electric or pneumatic torque driver is recommended. Phillips-head screwdriver, size 1, shaft length at least
45 mm. Matching screwdriver blade in accordance with DIN 3128, PH 1, Item No. 06.502.5200.0 The minimum connection tem-
perature for the EVA 7G4 mm² flat cable is -5°C. for the XLPE 7G4 flat cable, the minimum assembly temperature is + 5 °C.