Conductix-Wampfler 91112-310-3090986 User manual

Operation Manual
4 kW E-Pickup
40% Duty Cycle, 1150 mm Cable, Q4/2 Plug
BAL9100-0125b-EN
www.conductix.com Page 1 of 20
Order-Number
91112
-310-3090986: 4 kW E-Pickup, 40% Duty Cycle, 1150 mm Cable, Q4/2 Plug
(Regulators must be ordered separately)

Operation Manual
4 kW E-Pickup
40% Duty Cycle, 1150 mm Cable, Q4/2 Plug
BAL9100-0125b-EN
www.conductix.com Page 2 of 20
Index Page
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 Mechanical Integration ...................................................................................................................................................7
4.4 Electrical Connections ....................................................................................................................................................8
4.4.1 Power Output..................................................................................................................................................................8
4.4.2 Ground Connection ........................................................................................................................................................8
5Scope of Delivery........................................................................................................................................................................8
6Transport and Storage ................................................................................................................................................................8
7Installation...................................................................................................................................................................................9
7.1 Who is Authorized to Carry out the Installation ..............................................................................................................9
7.2 General Advice for the Installation..................................................................................................................................9
7.3 Electrical Regulations .....................................................................................................................................................9
7.4 Place and Conditions of Installation .............................................................................................................................10
7.4.1 Position.........................................................................................................................................................................10
7.4.2 Air Flow Required .........................................................................................................................................................11
7.4.3 Proximity to Iron / Steel ................................................................................................................................................11
7.4.4 Attachment Points ........................................................................................................................................................12
8Positional Tolerances................................................................................................................................................................13
9Warnings and Cautions.............................................................................................................................................................14
10 Maintenance .............................................................................................................................................................................15
11 Repair .......................................................................................................................................................................................15
12 Disassembly and Re-use ..........................................................................................................................................................16
12.1 Safety Advice for Disassembly and Disposal ...............................................................................................................16
12.2 Recycling ......................................................................................................................................................................16
13 Accessories...............................................................................................................................................................................17
14 Tools .........................................................................................................................................................................................17

Operation Manual
4 kW E-Pickup
40% Duty Cycle, 1150 mm Cable, Q4/2 Plug
BAL9100-0125b-EN
www.conductix.com Page 3 of 20
Important:
This document describes the components specified on the cover only. The manual does not include details about their
interaction with other components within a system.
Document subject to change without prior notice.
Conductix-Wampfler GmbH 2009

Operation Manual
4 kW E-Pickup
40% Duty Cycle, 1150 mm Cable, Q4/2 Plug
BAL9100-0125b-EN
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1Symbols and Hints
Warning of voltage
This symbol can be found in several places of the operating instructions 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 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 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
4 kW E-Pickup
40% Duty Cycle, 1150 mm Cable, Q4/2 Plug
BAL9100-0125b-EN
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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 Pickup.
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 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 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 components for the inductive transfer of electrical power.
A Pickup produces an AC voltage output from the AC magnetic field generated by a Track.
The device is not suitable for stand alone operation and must be used in conjunction with the appropriate components.
Qualified personnel only may operate this equipment.

Operation Manual
4 kW E-Pickup
40% Duty Cycle, 1150 mm Cable, Q4/2 Plug
BAL9100-0125b-EN
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4Technical Data
The data specified in this section are valid only if the requirements regarding the environment of the device
(nominal position, ambient temperature etc…) are respected.
For instance, the layout of the 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 Track 125 A, 20 kHz
•Peak output power 4 kW
under adequate condition of operation (see chapter 7.4 and chapter 8).
•Continuous output power 1,6 kW at 40°C ambient = 40% duty cycle
2,5 kW at 20°C ambient
within 10 minute periods, air convection 0,1 m/s and nominal position
(see chapter 7.4)
•Output voltage 380 V AC at 40% duty cycle
100 V AC open circuit (disconnected from Regulator)
•Output current 32 A AC at 40% duty cycle
•Heat loss Approximately 150 W at full load
•Electrical protection Class II (reinforced internal insulation)
•Insulation to Ground Output to Ground tested at 5 kV DC / 5 s

Operation Manual
4 kW E-Pickup
40% Duty Cycle, 1150 mm Cable, Q4/2 Plug
BAL9100-0125b-EN
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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 Pickup 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 plug is in place
•EMC environment Pickups are designed for use in industrial environments (EN55011 Class A)
•Installation altitude Up to 1000 m; continuous output power must be derated for higher altitudes
The use in explosion-proof areas or in areas where the Pickup is exposed to harmful oils, acids, vapors, dust, gases, radiation,
humidity, etc. is explicitly forbidden.
4.3 Mechanical Integration
•Dimensions See drawing. L = 1150 mm.
•Weight 4,2 kg
•Surface temperatures Surface temperature may reach up to 70°C depending on operating conditions

Operation Manual
4 kW E-Pickup
40% Duty Cycle, 1150 mm Cable, Q4/2 Plug
BAL9100-0125b-EN
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4.4 Electrical Connections
4.4.1 Power Output
The output of the Pickup must be connected to a suitable Regulator. The use of an extension cable between the Regulator and the
Pickup is generally not allowed.
For minimal interference and maximum electromagnetic compatibility, route the Pickup cable away from other cables, and at a
minimum distance of 15 millimeters – one time the cable diameter – away from any metal structure.
4.4.2 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 with the
Regulator is removed while the primary is active, then the device is still internally energized though the ground connection is
broken.
5Scope of Delivery
Mounting elements (screws…etc…) are not included in the scope of supply. No other parts are necessary for the connection of a
Pickup to a Regulator.
6Transport and Storage
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 “Technical data” for required transport and storage conditions.

Operation Manual
4 kW E-Pickup
40% Duty Cycle, 1150 mm Cable, Q4/2 Plug
BAL9100-0125b-EN
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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
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 Regulator used.
•Check completeness of the documents and conformity with the delivered components.
Pickups 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 guarantee will expire if this is not observed.
Follow the instructions of chapter 7.4 for attaching a Pickup to a supporting structure. See also chapter 4.4.2 for making the
connection to ground.
7.3 Electrical Regulations
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.

Operation Manual
4 kW E-Pickup
40% Duty Cycle, 1150 mm Cable, Q4/2 Plug
BAL9100-0125b-EN
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7.4 Place and Conditions of Installation
Install the Regulator in an environment and under conditions as specified in this document only. The Pickup is
to be attached to a solid base, ensuring free space around the device 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.
7.4.1 Position
Maximum tolerances are given in the illustration below in the case of an installation in nominal position over a
straight Track.
Tolerances must be defined taking into account the whole system design, i.e. curves, bifurcations or obstacles
in order to avoid any risk of collision.
Technical data stated in this manual are given for Pickups when
mounted in their nominal position:
-horizontal: ………….. 110 mm*
-vertical: ………….. centered between the Track cables
-parallel to the primary Track (see below)
Tolerances:
-horizontal: ………….. +20 / -10 mm
-vertical: ………….. ± 5 mm
The vertical tolerance is for mechanical purpose only, in order to
avoid collision. The horizontal tolerance will strongly affect the
output characteristic; refer to chapter 8 for more information.
The non variable parameter is understood to be at nominal value.
*: between the supporting structure for the cable holders and the
aluminum plate of the Pickup (see illustration).
The nominal position of a Pickup on a straight Track as well as in curves is parallel to the Track cables.

Operation Manual
4 kW E-Pickup
40% Duty Cycle, 1150 mm Cable, Q4/2 Plug
BAL9100-0125b-EN
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7.4.2 Air Flow Required
The heat power of the Pickup 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 must be adequately ventilated, allowing also for the heat generated by the Pickup which can
reach about 150 W under full load conditions.
Failure to satisfy these requirements may result in reduced performance, damage and/or reduction in lifetime.
7.4.3 Proximity to Iron / Steel
Ferromagnetic material (iron, steel…) will influence the characteristics of the Pickup, i.e. lower output power,
production of additional heat/losses, etc. We strongly recommend to respect the specifications for areas free
of ferromagnetic material as shown in the illustration below for Pickups, and even to go beyond these
requirements whenever possible.
For recommended areas free of ferromagnetic material around the Track cables, please refer to the entire documentation related
to the installation of an system.
For use with Regulator “EMS” version. For use with Regulator “AIR” version.

Operation Manual
4 kW E-Pickup
40% Duty Cycle, 1150 mm Cable, Q4/2 Plug
BAL9100-0125b-EN
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7.4.4 Attachment Points
Use the four holes available on the plate to attach the Pickup to a supporting structure. We recommend the use of washers on both
sides of the plate. The positions and dimensions of the holes are shown in chapter 4.3 “Mechanical Integration”.

Operation Manual
4 kW E-Pickup
40% Duty Cycle, 1150 mm Cable, Q4/2 Plug
BAL9100-0125b-EN
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8Positional Tolerances
The data concerning Pickups specified in this documentation strongly depend on the interaction with the attached Regulator. The
validity of these specifications depends on the respect of the nominal position of a Pickup and its environment (see chapter 7.4),
but also relies on the adequate environment of the Regulator attached to it. Always refer together to 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 Track and therefore by the layout of the Track, i.e. bifurcations, curves, influence of
ferromagnetic material, etc. See chapter 7.4.
The following curve shows the typical output power over a straight Track as a function of displacement for use with both:
-Regulator 91012-411-3090871 for electrified monorail systems or similar EMS
-Regulator 91012-411-3090872 for other systems without aluminum or ferromagnetic structure in close proximity AIR
The nominal position is taken as reference and is shown as 0 mm. A positive displacement i.e. +20 mm is when the Pickup is
further away from the Track cables. A negative displacement is when the Pickup is closer. Please refer to chapter 7.4.1 for the
definition of the nominal position.
2,0
2,5
3,0
3,5
4,0
4,5
-10 010 20
Horizontal Displacement (in mm)
Maximum Peak Output Power (in kW)

Operation Manual
4 kW E-Pickup
40% Duty Cycle, 1150 mm Cable, Q4/2 Plug
BAL9100-0125b-EN
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9Warnings and Cautions
All electric work has to be carried out by qualified staff (IEC 364 respectively ENELEC HD 384 or DIN VDE
0100 and IEC 664 or DIN VDE 0110 and national safety rules).
Qualified staff, according to safety regulations, are persons that are familiar with the installation,
commissioning and operation of the energy supply systems and that have the appropriate qualifications.
The devices are only foreseen to be operated in conjunction with matching components. If you are not sure
whether components match, contact Conductix-Wampfler. Do not put into operation before.
Do not use the output of the Pickup for any other reason than to connect it to a corresponding Regulator.
Connecting the Pickup to a Regulator should only take place when the Track is not under power.
Route power and control cables separately so that no interference can occur.
Do not install an obviously damaged device. Do not take damaged devices into operation. Severe damage
may result. Ensure that protection device and other preventive measures taken comply with the applicable
regulations. Make sure that all connected circuits fulfill at least the same safety standards as the Pickup and
fulfill requirements for safe operation.
During or after operation surfaces of Pickups may be hot. Use caution! Prevent access to hot surfaces if
necessary. Refer to chapter 4.3 “Mechanical Integration” for more information.
Ensure adequate ventilation. Refer to chapter 7.4 “Place and Conditions of Installation”.
Do not open Pickups, do not insert any objects inside, do not touch connection terminals. The only safe
means of working on circuits connected to the device is to ensure that the primary Track is switched off and
then to disconnect physically the plug. Make sure that connections are not removed under dangerous
conditions, i.e. under load. Improper handling can result in electric shocks or burns as well as damage to the
devices!
Do not perform any work on or around the device while in operation. Life threatening danger of electrical
shock!

Operation Manual
4 kW E-Pickup
40% Duty Cycle, 1150 mm Cable, Q4/2 Plug
BAL9100-0125b-EN
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10 Maintenance
There is no specific maintenance required other than checking regularly that a free air flow for cooling is given
and that there are no damages visible from the outside which could indicate collisions.
Strong soiling or obstacles that would prevent sufficient cooling conditions must be avoided.
Caution: metallic parts may be heated by induction. The presence of small ferromagnetic parts must be
avoided along the travelling path of the Pickup.
Any repair work is only possible at Conductix-Wampfler.
11 Repair
If a fault cannot be attributed to external conditions of operation the device needs to be repaired by a
specialist.
Unless otherwise arranged return parts to your nearest Conductix-Wampfler facility or to Conductix-Wampfler GmbH for repair.
Before returning any parts contact Conductix-Wampfler for specific instructions. Be sure to include the following information when
returning parts to Conductix-Wampfler:
•Product name
•Material number
•Serial number
•Application/Installation, in case with a brief description
•Wiring schematic of overall system, if at hand
•Fault description
•Circumstances the fault occurred at, especially if any unusual events preceded the fault
•Presumption what could have caused the fault
•Photo, if available

Operation Manual
4 kW E-Pickup
40% Duty Cycle, 1150 mm Cable, Q4/2 Plug
BAL9100-0125b-EN
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12 Disassembly and Re-use
If it is necessary to exchange a Pickup due to damage or to install it in another place, verify that no damage
will occur during disassembly.
For installation in another place observe the described mounting and commissioning instructions. Improper
application, installation or operation involve the danger of severe injuries to persons and damage to objects.
All electric work has 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.
12.1 Safety Advice for Disassembly and Disposal
1. Disconnect the system from the mains voltage.
2. Make sure the system cannot be powered up again accidentally.
3. After disconnecting the Track Supply from the supply voltage wait at least 5 minutes for internally stored energy to discharge.
4. Dismount the device.
5. Dispose of components in a specific way Recycling.
12.2 Recycling
The unit contains components that have to be disposed of in a specific way. If it is not used any longer, it will have to be recycled
properly.
Dispose of the materials separately in accordance with the current regulations, i.e. separate, aluminum plate, copper, plastic
housing etc. or hand over the unit to a recycling specialist.

Operation Manual
4 kW E-Pickup
40% Duty Cycle, 1150 mm Cable, Q4/2 Plug
BAL9100-0125b-EN
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13 Accessories
The output of a Pickup must be connected to a suitable Regulator. The use of an extension cable between the Regulator and the
Pickup is generally not allowed.
Both Regulator and Pickup strongly depend on each others. Please refer to both operation manuals together. Limiting conditions
for one device limit the operation of the other, i.e. if the ambient temperature around a Regulator is higher than the one specified,
the maximum continuous power available will be decreased even if the Pickup itself is sufficiently cooled.
Corresponding Regulators must be ordered separately through Conductix-Wampfler, i.e. typically:
EMS Version is material number: 91012-411-3090871
AIR Version is Material number: 91012-411-3090872
For details on the version to order, please refer to the product documentation or contact
Conductix-Wampfler.
14 Tools
There are no special tools required.

Operation Manual
4 kW E-Pickup
40% Duty Cycle, 1150 mm Cable, Q4/2 Plug
BAL9100-0125b-EN
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Operation Manual
4 kW E-Pickup
40% Duty Cycle, 1150 mm Cable, Q4/2 Plug
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Operation Manual
4 kW E-Pickup
40% Duty Cycle, 1150 mm Cable, Q4/2 Plug
BAL9100-0125b-EN
www.conductix.com Page 20 of 20
Conductix-Wampfler GmbH
Rheinstraße 27 + 33
79576 Weil am Rhein – Märkt
Germany
Phone: [phone]
Fax: [phone]
[email protected]
www.conductix.com
Importer for the United Kingdom:
Conductix-Wampfler Ltd.
1, Michigan Avenue
Salford
M50 2GY
United Kingdom
Phone: [phone]
Fax: [phone]
[email protected]
www.conductix.com