Conductix-Wampfler 91012-411-3090871 User manual

Operation Manual
Regulator
4 kW 560 V DC 40% Duty Cycle + 24 V DC
BAL9100-0126d-EN
www.conductix.com original document page 1 of 32
Order-Number
91012
-411-3090871: 4 kW Regulator 560 V DC 40% Duty Cycle + 24 V DC, EMS
91012
-411-3090872: 4 kW Regulator 560 V DC 40% Duty Cycle + 24 V DC, AIR

Operation Manual
Regulator
4 kW 560 V DC 40% Duty Cycle + 24 V DC
BAL9100-0126d-EN
www.conductix.com original document page 2 of 32
Contents
1Symbols and Hints ......................................................................................................................................................................4
2Advisory Information for the User ...............................................................................................................................................5
3Intended Purpose........................................................................................................................................................................5
4Technical Data ............................................................................................................................................................................6
4.1 Electrical Data ................................................................................................................................................................6
4.2 Environmental Data ........................................................................................................................................................7
4.3 Protection Measures.......................................................................................................................................................8
4.4 Mechanical Integration ...................................................................................................................................................8
4.5 Electrical Connections ..................................................................................................................................................10
4.5.1 Connection of Power Input: X1.....................................................................................................................................10
4.5.2 Connection of Power Outputs: X2 ................................................................................................................................10
4.5.3 Connection of Interface: X3..........................................................................................................................................11
4.5.4 Ground Connection ......................................................................................................................................................11
4.5.5 ESD Protection .............................................................................................................................................................11
5Scope of Delivery......................................................................................................................................................................12
6Transport and Storage ..............................................................................................................................................................12
7Installation.................................................................................................................................................................................12
7.1 Who is Authorized to Carry out the Installation ............................................................................................................12
7.2 General Advice for the Installation................................................................................................................................12
7.3 Electrical Regulations ...................................................................................................................................................13
7.4 Recommended Connection ..........................................................................................................................................13
7.4.1 Connection of Pilot Pins ...............................................................................................................................................13
7.4.2 Example: Using the Interface .......................................................................................................................................14
7.4.3 Example: Interface is not used .....................................................................................................................................15
7.5 Place and Conditions of Installation .............................................................................................................................16
7.5.1 Position.........................................................................................................................................................................16
7.5.2 Air Flow Required .........................................................................................................................................................16
7.5.3 Proximity to Iron/Steel ..................................................................................................................................................17
7.5.4 Attachment Points ........................................................................................................................................................17
8Operation ..................................................................................................................................................................................18
8.1 Powering Up .................................................................................................................................................................18

Operation Manual
Regulator
4 kW 560 V DC 40% Duty Cycle + 24 V DC
BAL9100-0126d-EN
www.conductix.com original document page 3 of 32
8.2 Powering Down ............................................................................................................................................................18
8.3 Positional Tolerances ...................................................................................................................................................19
8.4 Parallel Operation of Regulators ..................................................................................................................................19
8.5 Maximum Number of Regulators on a Track................................................................................................................19
8.6 Information on Operation with Interface .......................................................................................................................20
8.7 Precautions...................................................................................................................................................................20
9Warnings and Cautions.............................................................................................................................................................21
10 Fault and Diagnosis ..................................................................................................................................................................22
10.1 Basics ...........................................................................................................................................................................22
10.2 Normal State.................................................................................................................................................................23
10.3 Signals and Meanings ..................................................................................................................................................24
10.4 Reset ............................................................................................................................................................................26
11 Maintenance .............................................................................................................................................................................27
12 Repair .......................................................................................................................................................................................27
13 Disassembly and Re-use ..........................................................................................................................................................28
13.1 Safety Advice for Disassembly and Disposal ...............................................................................................................28
13.2 Recycling ......................................................................................................................................................................28
14 Accessories...............................................................................................................................................................................29
14.1 Power Input X1 .............................................................................................................................................................29
14.2 Power Output X2 ..........................................................................................................................................................29
14.3 Interface........................................................................................................................................................................30
15 Tools .........................................................................................................................................................................................31
This Operation Manual is based on the following IPT-Technology-Documentation-No.: OM9100-0126c-EN!
Important:
This manual refers solely the appliance described. See the system description document for information about the complete IPT®
system and the interaction between components.
Company names mentioned in this manual that are registered and protected trade names by copyright remain the property of the
companies themselves. In order to improve the energy supply system and its function, we reserve the right to carry out technical
modifications of illustrations and statements in this operation manual.
Please find details related to a whole IPT®system in the system manuals. Always refer to the system documentation before starting
any work on the system or components within the system or before operating the system.
Reprint and duplication (even partially) are only allowed with permission from Conductix-Wampfler.
© Conductix-Wampfler GmbH 2016

Operation Manual
Regulator
4 kW 560 V DC 40% Duty Cycle + 24 V DC
BAL9100-0126d-EN
www.conductix.com original document page 4 of 32
1Symbols and Hints
Warning of voltage
This symbol can be found in several places of the operation manual, where special care has to be taken due
to voltage presence which is a potential danger to the life of people. Please observe these instructions and
be careful in those cases. Please carry out all health and safety regulations to other users as well.
Always disconnect the system from the main supply before working on the energy supply system.
Attention – some hints
This sign draws the attention to parts of the operation manual, 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 operation manual, where special care must be taken on account
of heating of surfaces or on account of inductive heating of ferromagnetic material and where other special
measures have to be taken.
Please pass on the corresponding advice to other users too.
To achieve fault-free operation and any rights to claim guarantee it is necessary to observe and fulfill the information given in this
manual or related documents at any time. Read the manual entirely before starting any work and operation of the device.
This manual contains operation related information. It is therefore recommendable to keep it in the vicinity of the device.

Operation Manual
Regulator
4 kW 560 V DC 40% Duty Cycle + 24 V DC
BAL9100-0126d-EN
www.conductix.com original document page 5 of 32
2Advisory Information for the User
This device contains life threatening voltages. Improper handling/operation or faulty installation can result in
electric shocks and/or burns as well as material damages. There are no user serviceable parts in the device.
Do not open, do not insert any objects inside.
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).
Qualified staff according to the safety regulations are persons that are familiar with the installation, assembly,
commissioning and operation of the energy supply system and that have the appropriate qualifications.
Conductix-Wampfler GmbH cannot be responsible for damage and breakdown that have been caused by not
observing this manual.
This manual contains exclusively details of the specified device.
Observe all instructions and technical data given in this manual. Ensure that the device is operated under the
specified conditions only.
Do not start up the device or related devices within the IPT®system until you have made sure that the
machine/system it is integrated into complies with the applicable norms, standards and directives and that
conformity is stated.
We reserve the right to carry out technical modifications of illustrations and statements in this instruction
manual. References to other IPT®documents specifying the document number do not include the revision
index. Refer to the project handbook when available for a list of relevant documents.
Unless specified differently, all data refer to the metric system, i.e. lengths are always in millimeter. Units
used are based on European standards.
3Intended Purpose
The intended purpose of this device is for use in conjunction with other IPT®components for the inductive transfer of electrical
power. A Regulator produces DC voltage from the AC magnetic field generated by an IPT®track and captured by a Pickup. The
environment of a Pickup defines which version of Regulator is suitable for order (see also chapter 7.5.3):
-electro-monorail systems (EMS) or similar installation where Pickups will evolve in close proximity to aluminum EMS version
-all other applications where Pickups do not come in close proximity with any metallic parts AIR version
The device is not suitable for standalone operation and must be used in conjunction with the appropriate IPT®components.
Qualified personnel only may operate this equipment.

Operation Manual
Regulator
4 kW 560 V DC 40% Duty Cycle + 24 V DC
BAL9100-0126d-EN
www.conductix.com original document page 6 of 32
4Technical Data
The data specified in this section are valid only if the requirements regarding the environment of the device
(position, ambient temperature etc…) are respected.
For instance, the layout of the IPT®track, the variations with respect to nominal position of a Pickup, or the
ambient temperature around a Regulator, may lead to a reduction of the peak and/or continuous power
available.
Regulators and Pickups are not designed for independent operation. Refer to both operation manuals
together.
4.1 Electrical Data
•Input 4 kW Pickup, 20 kHz (see chapter 14.1)
•Output voltage 1 560 V DC +/-25 V AC
•Output current 1 8 A DC maximum
•Peak output power 4 kW
in sum for both output 1+ 2 and under adequate
condition of operation (see chapter 7.5 and chapter 8.3).
•Continuous output power 1,6 kW at 40°C ambient = 40% duty cycle
2,5 kW at 20°C ambient
over 10 minute periods, air convection 0,1 m/s and nominal position
(see chapter 7.5).
in sum for both output 1 and 2
•Output 2 24 V DC +/-5%
5 A DC
based on the output voltage 1 (see chapter 10.2 and chapter 10.3)
do not overload
maximal short-circuit current: 11 A DC
•Heat loss Approximately 400 W at full load.
•Electrical protection Class II (reinforced internal insulation)
•Insulation Output 1 to Ground / Output 2 / Interface: production tested at 5 kV DC / 5 s.
Output 2 / Interface to Ground tested at 500 V DC / 5 s.

Operation Manual
Regulator
4 kW 560 V DC 40% Duty Cycle + 24 V DC
BAL9100-0126d-EN
www.conductix.com original document page 7 of 32
4.2 Environmental Data
•Storage temperature -20°C to +60°C
•Transport temperature -40°C to +80°C
•Ambient temperature +0°C to +40°C
Air temperature as measured in immediate vicinity of working device. Please note that
the heat loss of the Regulator will raise the ambient temperature, especially in enclosed
mounting spaces.
•Operation For indoor operation only.
•Humidity < 95%, non-condensing
•Chemical resistance For industrial use without special conditions.
Any specific influences of chemicals must be checked.
•Protection rating IP54 when plugs are in place
•EMC environment The device is designed for use in industrial environments (EN55011 Class A)
•Installation altitude Up to 1000 m; continuous output power must be de-rated for higher altitudes
The use in explosion-proof areas or in areas where the device is exposed to harmful oils, acids, vapors, dust, gases, radiation,
humidity etc. is explicitly forbidden.

Operation Manual
Regulator
4 kW 560 V DC 40% Duty Cycle + 24 V DC
BAL9100-0126d-EN
www.conductix.com original document page 8 of 32
4.3 Protection Measures
The Regulator is protected against the following events:
•Over voltage Automatic shutdown if the voltage supplied by the Regulator exceeds 610 V.
Output protected up to 850 V (no reverse polarization)
•Disconnected DC output Automatic shutdown when unplugged/disconnected:
Protection against DC contact arcing; output voltage is removed.
Unplugging under load is not recommended
(proper wiring of the pilot pins: see chapter 7.4).
•Over current Output 1 is current limited
Automatic shutdown on strong overload or short circuit of output 1 - i.e. voltage < 100 V.
A high transient over current i.e. a sudden short circuit will damage the device.
•Reverse current Output 1 is protected against reverse current flow -
but not protected against reversed polarization i.e. reverse battery connection.
•Over temperature Automatic shutdown on internal over temperature
i.e. as a consequence if maximum rated temperature and/or maximum continuous
output power are exceeded.
•Repetitive shutdowns Shutdown procedures (i.e. turning off the Regulator through the interface plug)
discharge the energy stored inside the Regulator. To avoid overheating, the number of
shutdown procedures is limited to 3 within 30 seconds. This number exceeded, the
Regulator will remain in disable mode and respond only passed a delay of 30 seconds.
4.4 Mechanical Integration
•Dimensions See drawing
Versions 91012-411-3090871 and 91012-411-3090872 are mechanically identical.
•Weight 10 kg (without cables or Pickup)
•Surface temperatures Heatsink surface temperature may reach up to 70°C depending on operating conditions
To a lesser extent the housing may also get hot.

Operation Manual
Regulator
4 kW 560 V DC 40% Duty Cycle + 24 V DC
BAL9100-0126d-EN
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Operation Manual
Regulator
4 kW 560 V DC 40% Duty Cycle + 24 V DC
BAL9100-0126d-EN
www.conductix.com original document page 10 of 32
4.5 Electrical Connections
•X1 - AC Input Refer to chapter 14 for information on Pickups
•X2 - DC Power outputs HAN Q4/2 (Harting) or CQM04/2 (Ilme)
•X3 - Interface SACC-E-M12FS-8CON (Phoenix) or series 763/8-pole (Binder)
Connection cables can be ordered separately. Refer to chapter 14.
4.5.1 Connection of Power Input: X1
The power input of the Regulator must be connected to a suitable Pickup. The use of an extension cable between the Regulator
and the Pickup is generally not allowed. Refer to paragraph 14 for information on Pickups.
4.5.2 Connection of Power Outputs: X2
(view: contact side)
PIN 1 > DC+ out
PIN 3 > DC- out
(Power output 560 V DC)
PIN 2 > 24 V DC
PIN 4 > 0 V DC
(Isolated 24 V / 5 A DC power output)
this 24V/5A output is different from the 24V/150mA available on the interface plug X3
PIN 11 > Pilot 1
PIN 12 > Pilot 2
(Pilot 1 and 2 must be shorted for the device to power up – see chapter 7.4, 8.1 and 8.2)
PIN > Ground

Operation Manual
Regulator
4 kW 560 V DC 40% Duty Cycle + 24 V DC
BAL9100-0126d-EN
www.conductix.com original document page 11 of 32
4.5.3 Connection of Interface: X3
(view: contact side)
PIN 1 > Isolated 24 VDC
PIN 2 > Isolated 0VDC
(150mA maximum. Do not distribute externally: see chapter 8.1 and 8.2).
this internal 24V/150mA is different from the 24V/5A output available on X2
PIN 3 > COM
(common to the 3 output relays “Warning”, ”Error” and “Status”)
PIN 4 > Enable
(must be connected to allow the Regulator to power up. See chapter 8.1 and 8.2.)
PIN 5 > Warning
PIN 6 > Error
PIN 7 > Status
(relays have potential free contacts, rated for 30 V DC / 5 A max.)
PIN 8 > Ground
All pins are isolated from the main power output.
4.5.4 Ground Connection
All electrical equipment must be connected together to the vehicle frame to ensure an equipotential bonding. The ground output of
each plug must therefore be connected. In the same way, make sure to connect the housing of the device to the vehicle frame
(GND) and not rely only on the connection to ground provided by the power connector. The reason is that if the connection to the
load is removed while the IPT®primary is active, then the device is still internally energized though the ground connection is
broken.
4.5.5 ESD Protection
Because the IPT®system is isolated, some electrical charges may accumulate on the vehicle depending on the surrounding
conditions and the vehicle design. An adequate solution must be foreseen using a conductive floor coating together with for
example conductive brushes, sliders, track rollers, wheels or similar methods for a connection to Earth, in order to reduce the
likelihood of static charge build up and therefore ensure protection against electrostatic discharge (ESD).

Operation Manual
Regulator
4 kW 560 V DC 40% Duty Cycle + 24 V DC
BAL9100-0126d-EN
www.conductix.com original document page 12 of 32
5Scope of Delivery
Cables and plugs, as well as material for mounting the device to a supporting structure (i.e. screws etc.) are not included in the
scope of supply. Refer to chapter 14 for more information.
6Transport and Storage
WARNING!
The transport company must be advised about any damage that has been detected after delivery. Prior to
installing or starting operation with damaged components please consult the supplier.
Refer to chapter 4 for required transport and storage conditions.
7Installation
7.1 Who is Authorized to Carry out the Installation
All installation and commissioning work as well as maintenance 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).
Qualified staff according to the safety regulations are persons who are familiar with the assembly and
installation of the energy supply system and who have the appropriate qualifications.
7.2 General Advice for the Installation
WARNING!
After receipt of the components, and prior to starting the installation work:
•Unpack the components and check carefully for damage that may have occurred during transport or
storage (damage to housings and insulation, missing parts etc.).
•Check data on the identification plate to make sure that the components meet the requirements with
regard to nominal power and voltage and that they are matching parts to the Pickup used.
•Check completeness of the documents and conformity with the delivered components.

Operation Manual
Regulator
4 kW 560 V DC 40% Duty Cycle + 24 V DC
BAL9100-0126d-EN
www.conductix.com original document page 13 of 32
Regulators have to be installed on an even surface and in a permanently safe position. An improper installation of the energy
supply system has a negative impact on the function, the efficiency and the lifetime of the device. It is therefore important to
observe the specification for the choice and place of installation. The warranty will expire if this is not observed!
Follow the instructions of chapter 7.5 for attaching a Regulator to a supporting structure. See also chapter 4.5.4 for making the
connection to ground.
7.3 Electrical Regulations
WARNING!
The general electrical operating conditions according to VDE 0100 (installation and operation of electrical
equipment up to 1000 V) have to be observed. If necessary apply the local regulations when they go beyond
or differ from these requirements.
7.4 Recommended Connection
7.4.1 Connection of Pilot Pins
Shorter pilot pins are used in the power connector (Regulator side) to provide a signal to the Regulator when the load is
connected. Breaking the pilot connection while unplugging will signal to the Regulator to shut down before the main contacts are
disconnected, thus preventing DC arcing in the connectors (protection measure presented in chapter 4.3).
If the pilot signal is shorted in the plug on the Regulator side, the Regulator will not be able to detect when the cable is
disconnected at the load side. No protection against DC contact arcing can be expected in this case, nor would the output voltage
be disabled once the cable disconnected. This could result in an unsafe situation.
In order to fully use the benefits of the pilot pins in case the power output cable is disconnected, we recommend shorting the pilot
pins on the load side. Only this way is it assured that the Regulator switches off when the cable is disconnected, be it on the
Regulator side as well as on the load side. Refer to following examples for more details.

Operation Manual
Regulator
4 kW 560 V DC 40% Duty Cycle + 24 V DC
BAL9100-0126d-EN
www.conductix.com original document page 14 of 32
7.4.2 Example: Using the Interface
Below is an example of connection when both the power output and the interface connection are used.
The interface connection allows turning on and off the Regulator even under load and provides as well an easy way to reset the
device in case a fault has been detected. These basic functions are fulfilled by the switch connected between pins 1 and 4 on the
vehicle side. Due to the low voltages involved and the isolated characteristics of the interface connections, the switch requires very
basic isolation and ratings (24 V DC / 150 mA).
Initial status of relays, please see chapter 10.

Operation Manual
Regulator
4 kW 560 V DC 40% Duty Cycle + 24 V DC
BAL9100-0126d-EN
www.conductix.com original document page 15 of 32
7.4.3 Example: Interface is not used
Even if signals available through the interface plug are not being used, it is still necessary to connect pin 1 to pin 4 for the
Regulator to start. See also chapter 8.1 for more information on this subject.
Pilot pins are not designed to be used as an ON/OFF switch and it is thus recommended not to open the pilot connection under
load. However, disconnecting the pilot pins will reset the Regulator. Therefore, this procedure can be used to reset a fault in case
of automatic shutdown. This is the purpose of the switch shown in the following illustration, connecting pins 11 and 12 on the load
side. Refer to chapter 0 for more information.
Voltage present on the pilot pins is not isolated from the main output power. Make sure to use a switch with suitable isolation to
ground. Rating between contacts is 24 V DC / 150mA.
Initial status of relays, please see chapter 10.

Operation Manual
Regulator
4 kW 560 V DC 40% Duty Cycle + 24 V DC
BAL9100-0126d-EN
www.conductix.com original document page 16 of 32
7.5 Place and Conditions of Installation
WARNING!
Install the Regulator in an environment and under conditions as specified in this document only. The
Regulator is to be attached to a solid base, mounted with the heatsink fins in a vertical position.
Ensure free space around Regulator to provide sufficient cooling air circulation.
The available output power as specified in this document strongly depends on the ambient conditions of the
device. Refer to chapter 4.1 for more information.
7.5.1 Position
WARNING!
A vertical position of the heatsink cooling fins is required to maximize the efficiency of convection cooling. If
the Regulator is positioned differently, the maximum continuous power available may be reduced.
7.5.2 Air Flow Required
The heat power of the Regulator is dissipated by convection and radiated cooling only. Ensure that free flow of air is guaranteed
around the device at all times. It is essential to make sure that the air flow is not hindered in any way by objects and that the device
is protected from additional heating, i.e. exposure to sun light or hot air flow from inverters, proximity to brake resistors.
Confined areas should be adequately ventilated, allowing also for the heat generated by the Regulator which
can reach about 400 W under full load conditions.
Positions where free air flow around the device and more specifically around the heatsink is not sufficiently
provided, i.e. close or directly against an obstacle, will lead to higher local temperature and therefore cannot
be allowed generally.
Failure to satisfy these requirements may result in reduced performance, damage and/or reduction in
lifetime.

Operation Manual
Regulator
4 kW 560 V DC 40% Duty Cycle + 24 V DC
BAL9100-0126d-EN
www.conductix.com original document page 17 of 32
7.5.3 Proximity to Iron/Steel
There are no special requirements regarding the proximity of the Regulator itself to ferromagnetic material. However special care
should be taken regarding the presence of ferromagnetic material near the Pickup (refer to chapter 14.1 for more information) and
near the IPT®track itself (Refer to the entire documentations related to the installation of your IPT®system).
We strongly recommend to respect the specifications for areas free of ferromagnetic material as specified in the document
mentioned above, and even to go beyond these requirements whenever possible.
7.5.4 Attachment Points
Attaching a Regulator to a supporting structure must be done without opening the lid. For that purpose, four holes are accessible
from the top of the device.
Warranty seals are placed on the housing in order to forbid the opening of the lid and therefore preventing accidental soiling or
insertion of foreign parts. Breaking a seal will terminate the warranty.

Operation Manual
Regulator
4 kW 560 V DC 40% Duty Cycle + 24 V DC
BAL9100-0126d-EN
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8Operation
8.1 Powering Up
The primary track being switched on, once a suitable magnetic field is detected, and if the pilot pins (pins 11 and 12 of the power
output connector) are shorted, the Regulator will be ready to be switched on. The output voltage will however appear at the power
output of the shrouded pin connector only if the Regulator is enabled at the interface plug. Enabling the Regulator can be done in
two different ways:
by making a connection between pin 1 (internal isolated 24 V) and pin 4 (enable),
by connecting an external 24 V supply. 0V to pin 2 and 24V to pin 4.
Note that when the Regulator is in the disable mode (pin 1 and 4 disconnected), the internal isolated 24 V supply is only suitable to
supply a starting signal to the Regulator itself; do not distribute externally! When the Regulator is enabled and the “status” relay is
closed (between pins 3 and 7), the maximum current allowed is 150 mA.
When the interface is not used:
Even if signals available through the interface plug are not being used, it is still necessary to connect pin 1 to pin 4 for the
Regulator to start.
An optional “enable plug” is available for that matter, see chapter 14.3.
8.2 Powering Down
Turning off the primary track will immediately turn off all Regulators present on the track unless they are enabled. If a Regulator is
in an enable mode, the output voltage will decrease according to the load connected to it. This behavior allows continued function
(the length in time depends on the load needed at that point) even in the case where the IPT®power is temporarily interrupted (i.e.
the Track Supply was briefly turned off, a Pickup runs over an area where the magnetic field from the track is shielded… etc.)
Turning off a Regulator resets the error mode. It may therefore be required in the event of a fault to turn off a single Regulator,
instead of turning the track supply which would turn off all vehicles. Please, refer to chapter 10.4 to find out more on how to reset
Regulators.
If the need of turning on and off a Regulator exists even under load, using the interface plug is the best way to proceed; simply
break the contact with pin 4. It is not recommended to use the pilot pins to turn off a Regulator under load.
When a Regulator is turned off, the energy stored internally is discharged to reduce the output voltage to a minimum. For this
reason, the number of times a Regulator can be turned off (number of shutdown procedures) is limited to 3 within 30 seconds.
Exceeding this limit causes the Regulator not to respond and it will remain disabled (off) for the next 30 seconds.

Operation Manual
Regulator
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BAL9100-0126d-EN
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8.3 Positional Tolerances
The data concerning Regulators specified in this documentation strongly depend on the interaction with the attached Pickup. The
validity of these specifications depends on the respect of nominal positions as defined for the Pickup itself. Always refer to both the
operating instructions of a Regulator and of its designated Pickup.
The power ratings - peak power as well as continuous power - of the combination Pickup and Regulator will be affected by the
relative position of the Pickup to the IPT®Track and therefore the layout of the track, i.e. bifurcations, curves, influence of
ferromagnetic material, etc. See also chapter 7.5.
8.4 Parallel Operation of Regulators
Up to five Regulators can be connected together in parallel (more upon request). By parallel operation it is understood that only the
main voltage output X2 of several Regulators are connected together (exception made of the ground connection see chapter
4.5.4). In other words, connections with pins 2, 4, 11 and 12 of X2, as well as all connections with X3 must remain separate for
each Regulator.
WARNING!
When several Regulators are directly connected to a common bus, voltage will be present if a plug is
disconnected on the Regulator side. Please note that the interface makes it possible to detect when a
power plug is disconnected while other Regulators are still powered up, see below.
When the interface is used:
Due to their isolated properties, it is possible to interconnect the M12 interfaces together. However, we recommend to wire each
signal separately to determine precisely which signal comes from which Regulator and therefore to be able to take corresponding
action independently (i.e. if a Regulator entered an error mode, it can be reset without having to completely stop the vehicle).
As mentioned above, the detection of a disconnected power plug is possible. A closed “Warning” relay and open “Status” relay,
while the controls of the vehicle still provide an “enable” (or ON) signal, is characteristic of such a case and therefore of a possibly
unsafe situation if other Regulators are still powered up.
8.5 Maximum Number of Regulators on a Track
WARNING!
When the primary track is first turned on, Regulators shortly draw a certain amount of energy, energy which
is proportional to the number of Regulators (enabled) present on the Track during start-up. In the same way,
the peak power and continuous power required during operation are determining factors of the maximum
number of Regulators allowed on a Track. Make sure that the Track Supply specifications and the maximum
number of Regulators possibly present on this primary Track are compatible.
This parameter is defined during project planning by Conductix-Wampfler and may be critical for the
reliability of the whole IPT®system. Therefore, the extension or the modification of an existing system is
only allowed upon acceptance of the new parameters by Conductix-Wampfler.

Operation Manual
Regulator
4 kW 560 V DC 40% Duty Cycle + 24 V DC
BAL9100-0126d-EN
www.conductix.com original document page 20 of 32
8.6 Information on Operation with Interface
The signals that are available through the M12 interface plug are described hereafter, including their initial state (open or closed).
For more details on available information and diagnosis see chapter 0.
•Error relay (pins 3 - 6)
Closes when a magnetic field acceptable to ensure the minimum function is detected and when no error occurs. This is however
no guarantee for the deliverable output power (refer to chapter 7.5). Opens when an error is detected.
•Warning relay (pins 3 - 5)
Is normally open. Closes when approaching limits of operations (i.e. temperature, overload) to give the user the opportunity to take
the signal into account and prevent an automatic shutdown which could cause the vehicle to stop in a critical zone and/or at a
critical moment. Provides also some information on the status of the pilot pin function. See also chapter 8.4.
•Status relay (pins 3 - 7)
Is normally open. Closes when the main output has been enabled and the regulation functions are fully ready for operation with
load. The state of this relay is no guaranty for the accuracy of the voltage output i.e. in case of overload the voltage will be lower
than the nominal value specified.
8.7 Precautions
Regulators are not designed for independent operation. They have to be operated in conjunction with
corresponding IPT®Rail components.
Never operate a device showing damage or that is in a non-touch proof state. Do not perform any work on
the device while in operation. Life threatening danger of electrical shock!
During or after operation surfaces of the Regulator may be hot. Use caution! Prevent access to hot surfaces
if necessary. Refer to chapter 4.4 for more information.
Never short circuit the power output 1 or discharge it into a resistance of less than 20 ohms.
Do not overload the power output 2.
These may result in high discharge currents and therefore severe damage may occur.
Do not connect or switch a charged or powered Regulator directly on to any batteries. Connection should
only take place when the Regulator is in a powered down state. Never connect a battery load in reverse
polarity, damage will occur. Regulators will draw a small amount of power from batteries even if switched off;
batteries will discharge.
Ensure adequate ventilation. Refer to chapter 7.5.