DESCRIPTION AND

OPERATING INSTUCTIONS

POWERCOM 485

6A | EN 2014
 Powercom 485 2

Description and operating instuctions

1 Description and operating instuctions

1.1 VAHLE POWERCOM® 485

The VAHLE POWERCOM® 485 device is a modem for secure data transmission
via conductor rails. It can communicate with all PROFIBUS compatible products.
It accepts the various protocol variants of the PROFIBUS, and multiple VAHLE
POWERCOM® 485 units can be connected via the conductor rails.
The VAHLE POWERCOM® 485 devices pass all data transmitted from one or
more local PROFIBUS units to the conductor rails. The PROFIBUS units are con-
nected in multidrop mode to the integrated RS485 interface. All data received via
the conductor rails are passed to the local connected PROFIBUS units.

Figure 1
VAHLE
POWERCOM® 485

1.1.1 Safety
Note
We point out that the contents of these operating instructions are not part of a for-
mer or existing agreement, promise or legal relationship or intended to modify any
such relationship. All obligations of Vahle result from the respective purchase
contract which also contains the complete and sole warranty conditions. These
contractual warranty conditions are neither extended nor restricted by the infor-
mation contained in this operating instructions document.
We furthermore point out that for clarity it is not possible to describe every con-
ceivable problem or situation which could arise in connection with the use of this
device. If you require any further information or encounter special problems not
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dealt with in sufficient detail in the operating instructions, please request such in-
formation through your local Vahle branch. This device is operated with electricity.
You must strictly comply with the safety precautions stipulated in the operating in-
structions with regard to the voltages which may be applied!

1
Powercom 485 3

Description and operating instuctions

Warning
Failure to observe the warning instructions can lead to severe injuries and/
or material damage. Only properly qualified personnel should work on or in
the vicinity of this device. These personnel must be thoroughly familiar with
all warnings and maintenance tasks according to these operating instruc-
tions. Correct and safe operation of this device is subject to proper trans-
portation, storage and installation as well as careful operation and
maintenance.

1.1.2 General

Figure 2
Overview of Einspeisung CONNECTION
400V/50Hz (480V/60Hz)
Einspeisung CONNECTION
230V/50Hz max. 6A (115V/60Hz)
L N PE VAHLE
connection from -X10 L1 L2 L3 PE
DOPPELFILTER
DUAL FILTER -X1 1 2 3
POWERCOM®485
-PC

VAHLE 230 VAC / 50 Hz / 6A -DF

/1.3
/1.4

L L N N PE XN XL
SPS/PLC

POWERCOM® -X2:4 5 6 7

XL XL XN XN
components
6-polige Schleifleitung
CONDUCTOR RAILS

Steuerung SPS/PLC Steuerung SPS/PLC

CONTROL CONTROL
RC VAHLE VAHLE RC
POWERCOM®485 POWERCOM®485

-L -N -PE -XN -XL -L -N -PE -XN -XL

The connection to the data transmission path must be established via an in line
fuse.
To protect the VAHLE POWERCOM transmission against external disturbances,
such as control signals of the electric power supply companies, a dual filter must
always be installed at the input.
VAHLE POWERCOM units can only operate safely and without problems in an
EMC suitable environment (see also "EMC-suitable installation and configuration
of VAHLE electronic components”).
The cable and devices in the switch cabinet must comply with the relevant regu-
lations and must not be installed together with the electric power cables.
The instructions of the equipment suppliers must be complied with in plants with
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frequency converters, in particular with regard to interference suppression

measures, separation distances and cable shielding.
Data transmission has been tested and approved only with VAHLE conductor rail.
The feed via vehicles must always be made with dual current collectors. Special
measures are required for heated conductor rail.
Any consumer devices connected via the data conductor rails must be equipped
with a dual filter.

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 Powercom 485 4

Description and operating instuctions

Note
At inspections at connection trolleys without data communication it must be se-
cured that electrical lines which are originally used for the data communication
must be disconnected at the connection trolleys and be layed under safety-critical
aspects.

1.1.3 Technical Data

Type Length of transmission Devices/Segment Description Order-Nr.

VAHLE POW- up to 5000m 64 Additional interface: 910 108
ERCOM® 485 Allen-Bradley DH 485,
230V MODBUS
VAHLE POW- up to 5000m 64 Power supply+-10% 910 109
ERCOM® 485 Weight: 1100g
115V

Parameter Dimension
Gewicht [g] 1100
Dimension (HxWxD) [mm] 117x85x110
Operation temperature [°C] -20...+50
Storage temperature [°C] -20...+50
Operation voltage [VDC] 230 (115 option)
Power demand [W] max. 20
Current consumption [A] 0,08 (230VDC) / 0,18 (115VDC)
Protection class IP20

Voltage drop: 10% max.

The VAHLE POWERCOM® 485 devices support only one of the data transmissi-
on rates defined in the DIN 19 245 specification: 9.6 kbit/s or 19.2 kbit/s depend-
ing on the device type.
The VAHLE POWERCOM® 485 devices regenerate the signal form and ampli-
tude of the received data.
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Note:
VAHLE POWERCOM®,Kom.-Nr. 00000nnnnn

Due to the complexity and versatility of switching power supplies a custo-

mer's check in connection with Vahle - electronic components is recom-
mended.

1.1.4 Wiring the conductor rails

Some special features must be observed when wiring the conductor rails.

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Powercom 485 5

Description and operating instuctions

In contrast to the wiring of power rails there should always be a feed point or ter-
mination point at the ends of the data rails. VAHLE POWERCOM® cables should
always be separate from power or other data conductors.
The configuration of the terminating circuit is determined by the length and type
of the conductor rails and feeder cable, and must be determined when designing
the system.

Figure 3
Wiring the SPS/PLC Eins peisung
230V/50Hz max.6A
conductor rails L N

VPC 485 DF

SPS/PLC

VPC 485

1.1.5 Preparation for installation

You can mount the VAHLE POWERCOM® 485 devices on a tophat rail.
The VAHLE POWERCOM® 485 device can be mounted only horizontally.
Comply with the following directives when designing your device configuration:
– The VAHLE POWERCOM® 485 device is designed for heat removal by natu-
ral convection. Therefore leave a clear space of at least 30 mm above and be-
low the device to ensure heat removal. (see Figure 4).

Figure 4
Space for heat dissi-
pation VAHLE
POWERCOM® M INI MU M
SPAC E F OR
H EAT DISSI PATIO N
P OW ER
R X- SIG N AL
C O M M U N IC AT I O N S YS T E M S
TX -S IGNAL
VA HL E
PO W ERC O M ®
RS 485 48 5
PR O FIB US

POW ER SIGN AL
1 2 3 4 5 6 7
L L N N PE Xn Xl

1 2 3 4 5 6 7
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– A mounting depth of at least 175 mm is required for installing the VAHLE

POWERCOM® COM 485 device in a switch cabinet.
– Set up the devices such that adequate space is available for wiring the con-
nections.
– Choose the installation location such that the climatic limit conditions speci-
fied under the technical data are maintained.

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 Powercom 485 6

Description and operating instuctions

– Make sure that there is sufficient space for connecting the bus and power sup-
ply lines.
– Mount the modules only on a low-resistance low- inductance
– grounded top-hat rail or mounting plate.

1.1.6 Installing a VAHLE POWERCOM® 485 device

Warning
If the supply voltage for the VAHLE POWERCOM® 485 devices and all con-
nected devices is not switched off when installing or removing the devices,
this could lead to fatal accidents, severe injuries and/or material damage.

Before installing or removing the VAHLE POWERCOM® 485 devices, take all ne-
cessary safety precautions and make sure that the supply voltage is switched off.
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Powercom 485 7

Description and operating instuctions

1.1.7 Mounting a VAHLE POWERCOM® 485 device on a top-

hat-rail
Proceed as follows for mounting a VAHLE POWERCOM® 485 device on a top-
hat rail:

Figure 5
Mounting a VAHLE
POWERCOM® 485
device on a top-hat-
rail

– screw the top-hat rail onto the mounting plate at intervals of 75 mm.
– Hook the upper latch hook of the module into the top-hat-rail and then press
the underside onto the bus rail until it latches audibly.
– Make sure that the device is securely attachedon the rail.
– To remove it press the device downwards.
Note
In environments subject to strong vibration, it may be necessary to secure the de-
vice on the top-hat rail with grounding terminals to prevent slipping.

Warning
Control systems may fail in unsafe conditions and thus cause uncontrolled
operation of the controlled devices. Such dangerous events can lead to fa-
tal accidents, severe injuries and/or material damage. Therefore provide an
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EMERGENCY SHUT OFF SWITCH, electromechanical or other redundant

VAHLE POWERCOM®,Kom.-Nr. 00000nnnnn

safety device which is independent of your automation system.

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 Powercom 485 8

Description and operating instuctions

1.1.8 Installation the field wiring

Observe the following directives when installing and wiring the VAHLE
POWERCOM® 485 device:
– Make sure that all valid and mandatory standards are complied with when wi-
ring the VAHLE POWERCOM® 485 device.
– Comply with the relevant national and regional regulations for installation and
operation of the devices. Ask the local government authorities, which stan-
dards and regulations apply for your particular case.
– Use wires with appropriate conductor size for the current amperage required.
– The VAHLE POWERCOM® 485 devices can be wired with lines having a con-
ductor cross section area between AWG 20 -14.
– Do not over tighten the terminals. The maximum torque is 0.56 Nm.
– The bridges between the power connection and the data connection must be
wired with the same cross section and type as the feeder lines.
– Separate the AC and the DC wiring with quick operating sequences from low
voltage signal wiring.
– The minimum spacing between cables from different categories is shown in
the table. In general, the hazard of interferences caused by cross-talk is the
lower the further the cables are apart from one another.

Figure 6 POWER SIGNAL

Connection VAHLE L L N N PE Xn Xl
POWERCOM® 485 1 2 3 4 5 6 7

device

L N PE
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Powercom 485 9

Description and operating instuctions

Cables for ... and cables for ... routing ...

VAHLE POW- Bus signals, shielded (PROFI- in separate bundles or cable
ERCOM® BUS, Ethernet) Bus signals, ducts (no minimum distance
unshielded (AS-Interface) required)
Data signals, shielded (PG,
counting inputs etc.) Analog
signals, shielded Direct vol-
tage (=60 V),
unshielded
process signals (=25 V),
shielded alternating voltage
(=25 V), unscreened
Direct voltage (>60 V and Within cabinets:
=400 V), unscreened
In separate bundles or cable
Alternating voltage 50 / 60 Hz
ducts (no minimum distance
(>25 V and =400 V), un-
required)
screened
Outside cabinets:
On separate cable tracks with
a spacing of at least 10 cm
VAHLE conductor rails:
Phase spacing of the relevant
system
Direct and alternating voltage In separate bundles, cable
with fast switching sequences with ducts or on separate ca-
such as e.g. converter cables. ble tracks with a spacing of at
least 10 cm.
Conductor rails:
separate system with a spa-
cing of at least 50 cm

If you wish to know how two different types cable need to be routed, then proceed
as follows:
1. Look up cable type of first cable in column 1 (Cables for ...).
2. Look up cable type of second cable in the associated section of column 2 (and
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cables for...).
VAHLE POWERCOM®,Kom.-Nr. 00000nnnnn

3. In column 3 (routing ...): read off the routing guidelines to be observed.

– Mark all lines leading to the VAHLE POWERCOM® 485 device.
– Provide suitable surge arrestors for all lines which may be exposed to lightning
strikes.

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 Powercom 485 10

Description and operating instuctions

1.1.9 Connecting the electric Profibus line

• Use only shielded twisted two-wire lines complying with the Profibus specifi-
cation as Profibus line
• Electrical isolation exists between the Profibus lines RxD/TxD-N and RxD/
TxD-P, the supply voltage and the casing (ground potential).
Therefore observe the following safety instructions:
• Do not connect the VAHLE POWERCOM® 485 devices via PROFIBUS lines
to plant components which are connected to a different ground potential. The
voltage differences arising could lead to destruction of the devices!
• Do not connect any PROFIBUS lines which are installed partly or completely
out of doors, otherwise lightning strikes in the environment could lead to des-
truction of the modules.
• Make bus connections which come out of buildings with optical waveguide
cables!
The PROFIBUS connection is designed as 9-pole subminiature D plug connec-
tor.
The pin assignment corresponds to the PROFIBUS standard configuration. A
short circuit proof 5 Volt output is available at pin 5 and 6 for connecting external
pull-up/pull-down resistors. This supply is not able to feed active units.
– Use a plugging line fitted with 9-pole subminiature D connectors (male) on
both ends for connecting a terminal device.
– Connect a bus connecting plug (loop-through of the Profibus line) for connec-
ting a RS 485 bus segment.
– If the module is at the beginning or end of a bus segment, connect an external
terminating resistor combination (use a bus connecting plug with integrated
connectable terminating resistor combination).

1.1.10 LED indicators

LED Farbe Funktion

POWER Green Supply voltage ok.
POWER not lit Supply voltage missing or internal voltage
supply defective
RX-Signal Red Data received by the VAHLE POWERCOM
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interface.
RX-Signal not lit No data being received.
TX-Signal Red Data transmitted by the VAHLE POWER-
COM interface.
TX-Signal not lit No data being sended.

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Powercom 485 11

Description and operating instuctions

If all indications are without fault but communication is nevertheless disturbed

(e.g. no acknowledgement is received, unexpected telegrams), check the moni-
toring times set on the PROFIBUS subscriber devices (e.g. the slot time). For
further details, please consult the description in the PROFIBUS terminal device
documentation.

1.1.11 Instructions for parameterisation

In large PROFIBUS networks with many modules and long line lengths, the trans-
mission delay caused by network components and lines must be taken into ac-
count when setting the monitoring times.
For this purpose determine the transmission delay time TTD:
– The transmission delay time is the maximum time which elapses for the trans-
mission of a telegram on the transmission medium from the transmitter to the
receiver.
Note
If the project software you are using to configure your PROFIBUS network does
not support the PROFIBUS parameter TTD, increase instead both two times min.
RSDR and max. TSDR by 2 x TTD in each case (the reaction time of the respon-
der is extended by the transmission delay time for the outgoing and return path).
Calculation of the transmission delay time TTD:
– First of all determine the transmission path with the longest propagation time
between the transmitter and the receiver of a telegram.
– PROFIBUS subscribers which do not communicate with each other (e.g. DP
slave with DP slave) should not be taken into consideration.
Indications for long transmission times are:
– Long fiber optic or copper lines.
– Great cascade depth of active components
– Delay time of RS 485 lines The delay time is approx. 5 :s per km line length.
Converted to bit times this gives:

Transmission rate in kBit/s Time delay in tBIT pro km

9,6 0,05
19,2 0,10
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To calculate the line delay time, multiply the maximum line length in km with the
delay time corresponding to the transmission rate as read from the table.
1. The delay time of the VAHLE POWERCOM® 485 devices is 1.5 bit times.
2. The total transmission delay time is given by the number of modules passed
through from the transmitter of a telegram to the receiver, multiplied by 1.5 bit
times.

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 Powercom 485 12

Description and operating instuctions

3. Please determine the transmission delay times from the respective product do-
cumentation for other active PROFIBUS network components.
4. Transmission Delay Time TTD
The total delay time is the sum of the values determined in 1., 2. and 3.
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Powercom 485 13

Description and operating instuctions

1.1.12 Adjustment of the Retry-Level (Number of repeats at the

Profibus transmission)
Following steps in the HW Config
– Opening of the tab „General” and select properties > „Network settings” tab in
the DP Master system.
– Set of „User defined” in the profile.
– Select the bus parameters and increase the „Retry Limit” from „1” to „3”.
– Exit the bus parameter dialog with „OK”.
– Open the bus parameters again.
– Click on the Recalculate button.
– Exit the bus parameter dialog with „OK”.

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 Powercom 485 14

Description and operating instuctions

1.1.13 Error description

Item Error description Possible cause Measure

1 Vehicle comes to a halt or will Contamination of the conduc- Clean the conductor rails ac-
not move on the open road tor rails cording to the corresponding
information from the related
Vahle documentation for con-
ductor rails
2 Vahle RC closures are not cor- Check closures according to
rectly connected the Powercom documentation
3 Closures at the profibus cables Check the stationary and mo-
are not correctly configured bile profibus connectors
4 Faults on the conductor rails Check installation of Vahle
are too figh double filter and configuration
of sensitivity (the latter only
with Vahle Powercom 485 HD)
5 Vehicle-side third party use of Use of a vehicle-side double
the Powercom power supply filter to avoid faults;
without an additional double fil- ATTENTION: Power supply
ter may only be used for control
units! Motors, frequency con-
verters or similar may not be
connected!
6 No double current collector Mount double current collector
used according to the relevant
Vahle documentation for con-
ductor rails.
ATTENTTION: Only current
collectors approved by Vahle
are permitted.
7 Vehicle sporadically reports Contamination of the conduc- Clean the conductor rails ac-
faults at a segment transition tor rails cording to the corresponding
information from the related
Vahle documentation for con-
ductor rails
8 Conductor is no longer correct- Orientation of the conductor
ly aligned (vertical offset of the rails
conductor rails for data trans-
fer)
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9 Segment filtes are not correct- Check the segment filters ac-
ly connected (only affects cording to the Powercom doc-
Vahle Powercom 485 HD) umentation.
10 Accumulation of undefinable Current collectors have worn Exchange of the current col-
faults lectors according to the rele-
vant Vahle documentation for
conductor rails

13
Powercom 485 15

Description and operating instuctions

11 SPS call repetition too low SPS programming with call

repetition (after consultation
with the customer program-
mer)
12 Powercom on the vehicle only EMC problems on the road Check insulation of Vahle dou-
shows data reception (Rx LED ble filter and EMC suitable ca-
lights up) bling of the system (see also
guidlines for EMC-suitable ca-
bling by Vahle)
13 Profibus cabling on the vehicle Check the profibus cables or
out of order closures at the profibus con-
nectors
14 Programming error (e.g. wrong Unprogram the SPS
address or wrong data rate) Comment: Consult the cus-
tomer programmer

1.1.14 Maintenance
The inlet openings for cooling, on the equipment unit, must be inspected from
time to time for accumulated dirt and cleaned when necessary.

Injury cause of electric shock!

When operating the VAHLE POWERCOM 485 systems, certain parts in the
device are necessarily energised. Incorrect handling of this device can lead
to fatal accidents, or severe injuries or material damage.

Maintenance of this device may be carried out only by personnel of the manufac-
turer. The device must be disconnected from power before commencing any
tasks. We recommend to request the support and services of the nearest compe-
tent VAHLE Office when a device is suspected defective.

1.1.15 Service / customer service, repairs, replacement parts

In all cases of disturbance arising in connection with the data transmission, in par-
ticular when the described test steps do not lead to success, please contact the
manufacturer
Please send all defective parts to the manufacturer for checking.
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Replace defective components only to original VAHLE-replacement parts.

VAHLE POWERCOM®,Kom.-Nr. 00000nnnnn

14
Paul Vahle GmbH & Co. KG
Westicker Str. 52
59174 Kamen
Germany

Tel.: +49 2307 704-0

Fax: +49 2307 704-444
info@vahle.de

www.vahle.com