Conductix-Wampfler RAL7035 User manual

Operation Manual
Track Supply i40 kW
80 / 125 A at 400 / 480 V
BAL9100-0149-EN
www.conductix.com original document page 1 of 52
Order Numbers Air-Conditioned Units / RAL7035
91008-111-3298726 ( 80 A, 400 V, RAL 7035 – light grey, Air Condition)
91012-111-3297751 (125 A, 400 V, RAL 7035 – light grey, Air Condition)
91008-111-3298727 ( 80 A, 480 V, RAL 7035 – light grey, Air Condition)
91012-111-3297752 (125 A, 480 V, RAL 7035 – light grey, Air Condition)
Order Numbers Forced Air Cooled Units / RAL7035
91008-111-3298724 ( 80 A, 400 V, RAL 7035 – light grey, Forced Air Cooling)
91012-111-3297749 (125 A, 400 V, RAL 7035 – light grey, Forced Air Cooling)
91008-111-3298725 ( 80 A, 480 V, RAL 7035 – light grey, Forced Air Cooling)
91012-111-3297431 (125 A, 480 V, RAL 7035 – light grey, Forced Air Cooling)
Shown 91012-111-3297751
Air conditioned
Shown 91012-111-3297749
Forced Air Cooling

Operation Manual
Track Supply i40 kW
80 / 125 A at 400 / 480 V
BAL9100-0149-EN
www.conductix.com original document page 2 of 52
Contents
1Understanding...........................................................................................................................................................................5
1.1 Limitation of Liability .......................................................................................................................................................5
1.2 Copyright ........................................................................................................................................................................5
1.3 Replacement parts .........................................................................................................................................................6
1.4 Material defects ..............................................................................................................................................................6
1.5 Technical support ...........................................................................................................................................................6
2Symbols and Hints....................................................................................................................................................................7
3Advisory Information for the User...........................................................................................................................................8
4Brief Technical Description .....................................................................................................................................................9
5Appearance and Structure .......................................................................................................................................................9
5.1 Type with Air Conditioning..............................................................................................................................................9
5.2 Type with Forced Air Cooling .......................................................................................................................................11
6Technical Data.........................................................................................................................................................................13
6.1 Electrical Data - Specifications .....................................................................................................................................13
6.1.1 Electrical Output Data – Specifications for 400V and 480V Versions...........................................................13
6.1.2 Electrical Input Data – Specifications for 400 V Versions .............................................................................13
6.1.3 Electrical Input Data – specifications for 480 V Versions..............................................................................13
6.2 Physical Data................................................................................................................................................................14
6.2.1 Type without Air Conditioning .......................................................................................................................14
6.2.2 Type with Air Conditioning ............................................................................................................................14
6.3 Environmental Data ......................................................................................................................................................14
6.4 Mechanical Data...........................................................................................................................................................16
6.4.1 Dimensions of units with forced air cooling...................................................................................................16
6.4.2 Dimensions of units with air conditioning ......................................................................................................17
6.5 Connectors ...................................................................................................................................................................17
6.5.1 Track connection (X1)...................................................................................................................................18
6.5.2 Connection to AC mains supply (X2); Harting HAN K6/6..............................................................................18
6.5.3 Control and synchronization (X3); Harting HAN 10.......................................................................................18

Operation Manual
Track Supply i40 kW
80 / 125 A at 400 / 480 V
BAL9100-0149-EN
www.conductix.com original document page 3 of 52
6.6 General Features..........................................................................................................................................................18
6.7 Safety Features of Track Supply ..................................................................................................................................19
6.8 Grounding.....................................................................................................................................................................19
7Configuration Options............................................................................................................................................................20
7.1 Configuration with Air Conditioning Unit (mounted on the Side) ..................................................................................20
7.2 Configuration Operating Frequency .............................................................................................................................21
7.2.1 Configuration DIP-switches to change the Operating Frequency .................................................................21
7.2.2 DIP-Switch Setting Examples .......................................................................................................................22
8Control Board Hardware and Failure Indication ..................................................................................................................23
8.1 Track Supply Display....................................................................................................................................................23
8.1.1 Display ..........................................................................................................................................................23
8.1.2 Keypad..........................................................................................................................................................23
8.2 Track Supply Display Message ....................................................................................................................................24
8.3 Track Supply Error Reset .............................................................................................................................................24
8.4 Track Supply Error Codes ............................................................................................................................................25
9Door Switch .............................................................................................................................................................................26
10 Mains Fuses ............................................................................................................................................................................27
11 Transport and Storage ...........................................................................................................................................................28
12 Installation ...............................................................................................................................................................................29
12.1 Who is authorized to carry out the Installation?............................................................................................................29
12.2 General Advice for the Installation................................................................................................................................29
12.3 Place and Conditions of Installation .............................................................................................................................30
12.4 Electrical Regulations ...................................................................................................................................................30
12.5 Electrical Connection....................................................................................................................................................31
12.5.1 Mains Connection .........................................................................................................................................31
12.5.2 Configuration of control plug X3....................................................................................................................32
12.5.3 Connection Track Cable (X1)........................................................................................................................33
12.5.3.1 Routing of the Connection Track Cable (X1) ...........................................................................................33
12.5.3.2 Adding an extra C-Box (to order separately.............................................................................................34
12.5.3.3 Arrangement external Connections (X1, X2, X3).....................................................................................35
12.5.4 Wiring of the Track Supply X2 and X3 ..........................................................................................................36

Operation Manual
Track Supply i40 kW
80 / 125 A at 400 / 480 V
BAL9100-0149-EN
www.conductix.com original document page 4 of 52
13 Warnings and Cautions..........................................................................................................................................................37
14 Commissioning.......................................................................................................................................................................38
15 Start and Operation! ...............................................................................................................................................................39
16 Switching-Off...........................................................................................................................................................................40
17 Actions in case of emergency ...............................................................................................................................................40
18 Fault diagnosis........................................................................................................................................................................41
19 Maintenance ............................................................................................................................................................................42
19.1 Safety ...........................................................................................................................................................................42
19.2 Maintenance Schedule Track Supply...........................................................................................................................42
20 Repair.......................................................................................................................................................................................44
21 Disassembly/Re-use ...............................................................................................................................................................45
21.1 Safety advice for disassembly and disposal.................................................................................................................45
21.2 Recycling ......................................................................................................................................................................45
22 Spare parts ..............................................................................................................................................................................46
23 Tools ........................................................................................................................................................................................47
24 Adjustments during the commissioning and start-up.........................................................................................................48
25 Inspection Report ...................................................................................................................................................................49
Important:
Company names mentioned in this manual that are registered and protected trade names by copyright do remain the
property of the companies themselves.
We reserve the right to carry out technical modifications of illustrations and statements in these operating instructions, in
order to improve the energy supply system and its function.
System related details please find in the system manuals. Refer always to the system documentation before starting any
work on the system or components within the system or before operating the system.
Reprint and duplication (as well as extracts) are only allowed with permission from Conductix-Wampfler GmbH.
Conductix-Wampfler GmbH 2023

Operation Manual
Track Supply i40 kW
80 / 125 A at 400 / 480 V
BAL9100-0149-EN
www.conductix.com original document page 5 of 52
1Understanding
This document describes the component specified on the cover only. The manual does not include details about the interaction of
this component with other matching Conductix-Wampfler GmbH components within a system
For information relating to the system please read the system and project documentation. Follow these instructions during any
work on the system or operation of the system.
All given values are based on the metric system. Given dimensions without any measuring unit are generally in millimeters (mm).
The unit supplied may vary of the figures shown depending on the configuration. Please check the version delivered selectively
from the operation manual!
1.1 Limitation of Liability
All data and information in these operating instructions have been compiled while taking the valid standards and regulations as
well as the state-of-the art and our many years of experience and knowledge into consideration.
Conductix-Wampfler accepts no liability for damage resulting from:
Failure to comply with operating instructions
Improper use
Use by untrained personnel
Unauthorized modifications
Technical changes
Use of unauthorized replacement parts or accessories
The actual scope of delivery may differ 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.
The obligations agreed upon in the delivery agreement and our general terms and conditions of business apply, as do the delivery
conditions of Conductix-Wampfler and the legal regulations applicable at the time the contract was concluded.
All products are subject to technical modifications, within the context of improvement of function and further development.
1.2 Copyright
These operating instructions are subject to copyright, and exclusively intended for internal use by the customer.
Provision of the operating instructions to third parties, reproductions in any form – even in part – as well as the reuse and/or
disclosure of their content are not permitted without the written approval of the Conductix-Wampfler, except for the customer's
internal use.
Breach or infringement will result in liability for damages. Our right to further claims remains unaffected.

Operation Manual
Track Supply i40 kW
80 / 125 A at 400 / 480 V
BAL9100-0149-EN
www.conductix.com original document page 6 of 52
1.3 Replacement parts
WARNING!
Incorrect replacement parts are a safety hazard!
Incorrect or faulty replacement parts can impair safety and result in damage, malfunctions or
complete failure.
→Only use original Conductix-Wampfler replacement parts!
Replacement parts can be ordered an authorized dealer or directly from Conductix-Wampfler.
1.4 Material defects
The terms governing material defects can be found in the General Terms and Conditions of business.
1.5 Technical support
Our customer support staff is available for technical support. See the last page of these operating instructions for
contact information.
We are also always interested in new information, experiences and feedback from the field that can help us improve our products.

Operation Manual
Track Supply i40 kW
80 / 125 A at 400 / 480 V
BAL9100-0149-EN
www.conductix.com original document page 7 of 52
2Symbols and Hints
Warning of voltage
This symbol can be found in several places in the operating instructions where special care has to be taken
due to a voltage presence which is hazardous to people. Please observe these instructions and be careful in
those cases. Please apply all health and safety regulations to other users as well. Always disconnect the
system from the main supply prior to carrying out any work on the energy supply system.
Attention - some hints
This sign draws the attention to parts of the operating instructions where the regulations, advice and correct
operational sequence must be observed to avoid any damage or destruction to the energy supply system
and its components.
Temperature
This sign draws the attention to parts of the operating instructions, where special care must be taken
because of hot surfaces or where inductive heating of ferromagnetic material may occur and where special
measures have to be taken.
Please pass on the advice to other users as well.

Operation Manual
Track Supply i40 kW
80 / 125 A at 400 / 480 V
BAL9100-0149-EN
www.conductix.com original document page 8 of 52
3Advisory Information for the User
When the Track Supply is open it can contain live voltage and hot surfaces, depending on its protection class
and state of operation.
Non-permissible removal of required covers, improper operation, faulty installation or operation involve risk
of severe injuries to a person and damage to components.
The Track Supply has a weight of approx. 280 kg (Type with Air Cond. approx. 370 kg) and must not be lifted
or moved by an individual person. To move and position it use only suitable equipment and follow the
according instructions (see chapter 6 “Technical Data”).
All electric installation and commissioning work as well as repair work and disassembly have to be carried
out by qualified staff (IEC 364 respectively CENELEC HD 384 or DIN VDE 0100 and IEC 664 or DIN VDE
0110 and national safety rules).
All installation and commissioning work as well as repair work and disassembly have to be done according to
the present operation manual. The specifications of this document have to be strictly observed. In addition,
national regulations and whenever they apply regulations specific to the industry are to be taken into
account.
Qualified staff according to the safety regulations are persons who are familiar with the installation,
assembly, commissioning and operation of the energy supply system and who have the appropriate
qualifications.
Conductix-Wampfler GmbH cannot be responsible for damage or breakdowns that have been caused by not
observing the instruction manual.
These operating instructions contain exclusively details of the Track Supply component.
We reserve the right to carry out technical modifications of illustrations and statements in this instruction
manual. References to other documents specifying the document number do not include the revision index.
Refer to the project handbook for a list of relevant documents.
NOTE!
Tips and recommendations:
This symbol denotes useful tips and recommendations as well as information for efficient and trouble-free
operation.

Operation Manual
Track Supply i40 kW
80 / 125 A at 400 / 480 V
BAL9100-0149-EN
www.conductix.com original document page 9 of 52
4Brief Technical Description
The Track Supply serves to supply energy to the secondary components in system in a defined segment of a
i.e., material handling system.
The Track Supply converts the 400 50 Hz or 480 V 60 Hz mains voltage, depending on type, to a constant
20 kHz sinusoidal current. The alternating output current into the primary track of a system produces a local
magnetic field over which power is transferred. So the galvanically isolated power transfer to the consumers
is possible (e.g. to the pickups).
5Appearance and Structure
5.1 Type with Air Conditioning
Figure 1: Appearance and main components of Track Supply with air conditioning (Example 91012-111-3297751)
1
Air out Air conditioning unit
2
Door Lock
3
Air ir in Air conditioning unit
4
Display Window
5
Status-LEDs
6
Main Switch

Operation Manual
Track Supply i40 kW
80 / 125 A at 400 / 480 V
BAL9100-0149-EN
www.conductix.com original document page 10 of 52
Regarding the installation place and distances pay attention to the chapter 7.1 “Configuration with Air Conditioning Unit
(mounted on the Side)”!
Figure 2: Components inside (photo shows optional C-Box (to order separately))
1
Air out
2
Air in
3
Power Module
4
Control Board
5
Fan, inside
6
480 V Version shown
7
Track Cable entry (Litz Cable)

Operation Manual
Track Supply i40 kW
80 / 125 A at 400 / 480 V
BAL9100-0149-EN
www.conductix.com original document page 11 of 52
5.2 Type with Forced Air Cooling
Figure 3: Appearance and main components of Track Supply with Forced Air Cooling
1
Display-Window
2
Status-LED’s
3
Main switch
4
Door lock

Operation Manual
Track Supply i40 kW
80 / 125 A at 400 / 480 V
BAL9100-0149-EN
www.conductix.com original document page 12 of 52
Figure 4: Components inside (photo shows optional C-Box (to order separately))
1
Control Board
2
Power Module
3
Fan inside
4
Air in – via Front Door
5
Version with 480 V transformer shown
6
Track Cable entry (Litz Cable)
Note that the picture above may not in some cases correspond exactly to the delivered component (for example color or wiring
positions). If you have concerns, you have not been delivered the correct item please contact a Conductix-Wampfler representative.

Operation Manual
Track Supply i40 kW
80 / 125 A at 400 / 480 V
BAL9100-0149-EN
www.conductix.com original document page 13 of 52
6Technical Data
6.1 Electrical Data - Specifications
6.1.1 Electrical Output Data – Specifications for 400V and 480V Versions
Continuous output power
40 kW
Overload capability
50 kW for max. 1 minute at 40°C
Output current
80A or 125A ±2 @ 20 kHz ±50 Hz/60 Hz
Track inductance for 80 A Track Supply: 3,1 µH +2% of the total track inductance measured
for 125 A Track Supply:1,6 µH +2% of the total track inductance measured
Nominal output voltage range 80 A systems: 500 V (625 V)
125 A systems: 320 V (400 V)
Output capacitance to PE
200 nF
Connection to primary cable Stainless Steel M8 bolts for 35 mm² and 20 mm² HF Litz cables.
Torque range 9-10 Nm.
6.1.2 Electrical Input Data – Specifications for 400 V Versions
Input supply voltage
400 V / 50 Hz, 3 Phase symmetric, neutral grounded
Protection Class
I, grounding mandatory/PE
Overvoltage Class
III
Supply voltage tolerance
+/-10% to + 10%
Input connector Supplied HAN K6/6 connector with M 40 x 1,5 cable gland.
Maximum outside cable diameter is 25 mm. Use flexible cables recommended.
Internal fuses mains supply
80 A NH 1
6.1.3 Electrical Input Data – specifications for 480 V Versions
Input supply voltage
480 V / 60 Hz, 3 Phase symmetric, neutral grounded.
Protection Class
I, grounding mandatory/PE
Overvoltage Class
III
Supply voltage tolerance
+/-10% to + 10%
Input connector Supplied HAN K6/6 connector with M 40 x 1,5 cable gland.
Maximum outside cable diameter is 25 mm. Use flexible cables recommended.
Internal fuses
80 A NH 1

Operation Manual
Track Supply i40 kW
80 / 125 A at 400 / 480 V
BAL9100-0149-EN
www.conductix.com original document page 14 of 52
6.2 Physical Data
6.2.1 Type without Air Conditioning
Noise levels
During operation 57 dBA at 2 m distance in front
Air volume moved
500 m³ / hour (air recirculation)
Fan
1 axial fan
6.2.2 Type with Air Conditioning
Air Conditioning
Air cond. unit Type Rittal TopTherm Blue e
Fan
1 axial fan (internal air circulation)
Noise Levels Air. Cond.
During operation 65 dBA at 2 m distance in front
6.3 Environmental Data
Ambient temperature Forced Air Cooling: +10°C to +40°C, power de-rating 3% / °C between 40°C and 55°C
Air Conditioned: +10°C to +45°C, power de-rating 3% / °C between 40°C and 55°C
Humidity
< 90% non-condensing
Ambient air No salt water, no conductive dry or wet dust! (e. g. carbon fibers). Avoid extreme
environment conditions (e. g. very dusty, Oily and/or chemical influences)!
Altitude de-rating
1% of power / 100 m above 1000 m, up to a max. of 3000 m above sea level
IP classification Forced Air Cooling: IP34 (limited by exhaust vents on top)
Air Conditioned: IP34/54 (limited by AC-unit specification)
Storage temperature
-20°C to +60°C
Transport temperature
-20°C to +70°C
Maximum Vibration
3 mm at 2 - 9 Hz, max. acceleration 0,5 g at 9 - 200 Hz
Maximum operating shock
8 g, 11 ms
Maximum shipping shock
15 g, 11 ms in packaging / transport box

Operation Manual
Track Supply i40 kW
80 / 125 A at 400 / 480 V
BAL9100-0149-EN
www.conductix.com original document page 15 of 52
The Track Supply requires for the correct cooling a sufficient air flow.
Figure
5: Air flow with Air Conditioning
Figure
6: Air flow with Forced Air Cooling
Recommended clearances:
400 mm over the Track Supply
Minimum 1000 mm in front of the Track Supply to access the door
100 mm sides and back of the Track Supply
Ensure free air flow at all times and let inspect filters for dust and oil blockage regularly.
The Track Supply has to be fixed on the floor. Follow the instructions of the cabinet producer (Rittal GmbH & Co. KG, Type VX25).
Shielded control cables are not strictly required but to improve the EMC they are recommended.
In order to avoid induced voltages at 20 kHz, the control cables and other cables should not be run close to the track cable and
especially not over distances > 5 m. Shielded twisted pair cable will help reduce the capacitive coupling effect. The shield should
be grounded at one end only.

Operation Manual
Track Supply i40 kW
80 / 125 A at 400 / 480 V
BAL9100-0149-EN
www.conductix.com original document page 16 of 52
6.4 Mechanical Data
Cabinet
Rittal VX25 with right-hand hinged front door
Locking
Standard locking for Rittal cabinets Rittal VX25
Hinges
130° opening angle
Dimensions
see the following drawing
Color cabinet (outside)
RAL 7035 “lightgrey”
Color cabinet (inside)
RAL 7035 “lightgrey”
Color base
RAL 7022 “umbragrey”
Weight (400 V Forced Air C.)
~ 270 kg
Weight (480 V Forced Air C.)
~ 340 kg
Weight (400 V with Air Cond.)
~ 365 kg
Weight (480 V with Air Cond.)
~ 435 kg
6.4.1 Dimensions of units with forced air cooling
Figure 7: Dimensional drawing (forced air cooling)

Operation Manual
Track Supply i40 kW
80 / 125 A at 400 / 480 V
BAL9100-0149-EN
www.conductix.com original document page 17 of 52
6.4.2 Dimensions of units with air conditioning
Figure 8: Dimensional drawing (air conditioning, side mounted)
6.5 Connectors
Figure 9: connectors (bottom view)
1
Track connection (X1), see chapter 6.5.1
2
Connection to AC mains supply (X2), see chapter 6.5.2
3
Control and synchronization (X3), see chapter 6.5.3

Operation Manual
Track Supply i40 kW
80 / 125 A at 400 / 480 V
BAL9100-0149-EN
www.conductix.com original document page 18 of 52
6.5.1 Track connection (X1)
Pin
Function
Remarks
1
Track cable 1
Up to 35 mm² lug soldered
HF Litz cable *
2
Track cable 2
* = cable shoes with M8 hole!
6.5.2 Connection to AC mains supply (X2); Harting HAN K6/6
Pin
Function
Rating
Remarks
1
L1
80 A
I depend on load
2
L2
80 A
I depend on load
3
L3
80 A
I depend on load
PE
PE
6.5.3 Control and synchronization (X3); Harting HAN 10
Pin
Function
Rating
Remarks
1
Enable +
24 V
24 V present = ready start
2
Enable -
0 V
3
Status +
24 V
0 V = reset
4
Status NC -
0 V
5
Status NO -
0 V
6
7
8
9
10
For more details on X1, X2, X3 and their connection refer to chapter 12.5 “Electrical Connection”.
6.6 General Features
EMC filtering
Built in line filter included
Start-up inrush current
< 10 A
Mains to output isolation
High frequency isolation transformer
Internal cooling fans
1 axial fan

Operation Manual
Track Supply i40 kW
80 / 125 A at 400 / 480 V
BAL9100-0149-EN
www.conductix.com original document page 19 of 52
6.7 Safety Features of Track Supply
Over temperature
In-built temperature sensors and switches
Overload
Output load monitoring
Over current
Internal current monitoring
Overvoltage on output
Output voltage control
Input to output isolation
2500 V AC for 1 min
Fuses
80 A NH1 (see chapter 22)
6.8 Grounding
The Track Supply must be grounded by technicians at the installation location, to a three-phase grid center earthed. Other
connection variants, such as delta grounding, will lead to excessive EMC values and should therefore not be used.
Metal structures which run close and parallel to the primary track cable over significant distances have to be grounded
professionally too. For best results multiple grounding should be applied. In order to avoid induced voltages at 20 kHz, the control
cables and other cables should not be run close to the track cable and especially not over distances > 5 m. Shielded twisted pair
cable will help reduce the capacitive coupling effect, but the shield should be grounded at one end only.

Operation Manual
Track Supply i40 kW
80 / 125 A at 400 / 480 V
BAL9100-0149-EN
www.conductix.com original document page 20 of 52
7Configuration Options
7.1 Configuration with Air Conditioning Unit (mounted on the Side)
The Air Conditioning unit is located on the left side of the track supply. Pay attention to the recommended distances to the
neighboring equipment or walls (min. 400 mm) to ensure a free air flow. See chapters:
•5 „Appearance and Structure
•6.3 “Environmental Data”
•12.3 “Place and Conditions of Installation”.
Regarding the operation and maintenance of the Air Conditioning Unit follow the producer documentation. Refer to chapter 22 for
the manufacturer's designation.
Recommended adjustment of the temperature for the operation – according to the specified operation conditions: 35 °C
In case an exchange of the Air Conditioning Unit is needed follow the producer documentation and attend to the correct polarity of
the connections.