Conductix-Wampfler 91008-111-3090873 User manual

Operation Manual
Track Supply 6 kW
80 / 125 A at 400 / 480 V
BAL9100-0124c-EN
www.conductix.com Page 1 of 44
Order Number
91008
-111-3090873 ( 80 A, 400 V, RAL 7016)
91012
-111-3090875 (125 A, 400 V, RAL 7016)
91008
-111-3090876 ( 80 A, 480 V, RAL 7016)
91012
-111-3090878 (125 A, 480 V, RAL 7016)
91000
-111-3090877 (Configurable version)

Operation Manual
Track Supply 6 kW
80 / 125 A at 400 / 480 V
BAL9100-0124c-EN
www.conductix.com Page 2 of 44
Index Page
1Understanding........................................................................................................................................................................5
2Symbols and hints.................................................................................................................................................................5
3Advisory information for the user........................................................................................................................................6
4Brief technical description....................................................................................................................................................7
5Appearance ............................................................................................................................................................................7
6Technical data........................................................................................................................................................................9
6.1 Electrical data - specifications..................................................................................................................................................9
6.1.1 Electrical output data – specifications for 400 V and 480 V versions ......................................................................................9
6.1.2 Electrical input data – specifications for 400 V versions ..........................................................................................................9
6.1.3 Electrical input data – specifications for 480 V versions ........................................................................................................10
6.2 Physical data..........................................................................................................................................................................10
6.3 Environmental data ................................................................................................................................................................11
6.4 Mechanical data.....................................................................................................................................................................12
6.5 Interfaces ...............................................................................................................................................................................13
6.6 General features ....................................................................................................................................................................13
6.7 Design standards...................................................................................................................................................................14
6.7.1 Design standards for 400 V versions.....................................................................................................................................14
6.7.2 Additional design standards for 480 V versions.....................................................................................................................14
6.8 Safety features of Track Supply.............................................................................................................................................14
6.9 Grounding ..............................................................................................................................................................................14
7Control board hardware and failure indication.................................................................................................................15
7.1 Track Supply Control Board...................................................................................................................................................15
7.1.1 Control board LED indication.................................................................................................................................................15
7.2 Track Supply Display Board...................................................................................................................................................16
7.2.1 LED indication........................................................................................................................................................................16
7.2.2 Software Version Number......................................................................................................................................................17
7.2.3 Modes of Operation ...............................................................................................................................................................18
7.2.4 Setting Language, Time and Date .........................................................................................................................................18

Operation Manual
Track Supply 6 kW
80 / 125 A at 400 / 480 V
BAL9100-0124c-EN
www.conductix.com Page 3 of 44
7.2.5 Warning Messages ................................................................................................................................................................19
7.2.6 Error Codes............................................................................................................................................................................19
8Fuses.....................................................................................................................................................................................22
9Transport and storage.........................................................................................................................................................22
10 Installation............................................................................................................................................................................23
10.1 Who is authorized to carry out the installation? .....................................................................................................................23
10.2 General advice for the installation..........................................................................................................................................23
10.3 Place and conditions of installation........................................................................................................................................24
10.4 Electrical regulations..............................................................................................................................................................24
10.5 Electrical connection ..............................................................................................................................................................25
10.5.1 Mains connection ...................................................................................................................................................................25
10.5.2 Configuration of control plug..................................................................................................................................................26
10.5.3 Connection track cable (X1)...................................................................................................................................................27
10.5.4 Arrangement external connections (X2, X3, X4)....................................................................................................................27
10.5.5 Wiring of the Track Supply.....................................................................................................................................................28
10.5.6 Wiring of the Track Supply.....................................................................................................................................................29
11 Warnings and cautions .......................................................................................................................................................30
12 Commissioning....................................................................................................................................................................31
12.1 System conditions..................................................................................................................................................................31
12.2 System protection ..................................................................................................................................................................31
13 Start and operation..............................................................................................................................................................32
14 Switching-off ........................................................................................................................................................................33
15 Actions in case of emergency ............................................................................................................................................33
16 Fault diagnosis.....................................................................................................................................................................34
17 Maintenance .........................................................................................................................................................................35
18 Repair....................................................................................................................................................................................36
19 Disassembly / Re-use..........................................................................................................................................................37
19.1 Safety advice for disassembly and disposal ..........................................................................................................................37
19.2 Recycling ...............................................................................................................................................................................37
20 Spare parts ...........................................................................................................................................................................38

Operation Manual
Track Supply 6 kW
80 / 125 A at 400 / 480 V
BAL9100-0124c-EN
www.conductix.com Page 4 of 44
21 Tools .....................................................................................................................................................................................39
Adjustments during the commissioning and start-up..................................................................................................................40
Inspection report _____________________ ...................................................................................................................................41
Inspection report _____________________ ...................................................................................................................................42
Inspection report _____________________ ...................................................................................................................................43
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 2009

Operation Manual
Track Supply 6 kW
80 / 125 A at 400 / 480 V
BAL9100-0124c-EN
www.conductix.com Page 5 of 44
1Understanding
This document (BAL) describes the component specified on the cover only. The manual does not include details about the
interaction of this component with other IPT®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).
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 6 kW
80 / 125 A at 400 / 480 V
BAL9100-0124c-EN
www.conductix.com Page 6 of 44
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. 56 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 IPT®documents specifying the document number do not include the revision
index. Refer to the project handbook for a list of relevant documents.

Operation Manual
Track Supply 6 kW
80 / 125 A at 400 / 480 V
BAL9100-0124c-EN
www.conductix.com Page 7 of 44
4Brief technical description
The Track Supply serves to supply energy to the secondary components of the IPTsystem in a defined
segment.
The Track Supply converts the 400 V 50 Hz or 480/277 V 60 Hz mains voltage to a constant 20 kHz
sinusoidal current. The alternating output current into the primary track of an IPT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
Display-Window
Status-LED’s
Access fuses
Main air outlet
Air outlets
Access Track Cable
Power and Control Plugs

Operation Manual
Track Supply 6 kW
80 / 125 A at 400 / 480 V
BAL9100-0124c-EN
www.conductix.com Page 8 of 44
View without front lid
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.
Display Board
Bolt terminals for track (max. 10 Nm)
Track Cable
Transformer
24 V Supply
Control Plug
RS232 Diagnosis Plug
Power Plug
AC line fuse disconnect
Control Board

Operation Manual
Track Supply 6 kW
80 / 125 A at 400 / 480 V
BAL9100-0124c-EN
www.conductix.com Page 9 of 44
6Technical data
6.1 Electrical data - specifications
6.1.1 Electrical output data – specifications for 400 V and 480 V versions
•Continuous output power 6 kW
•Overload capability 137% (8 kW) for max. 1 minute / 10 minute at 40°C,
with average load derating to 4.9kW
•Output current 80 A or 125 A ±2A @ 20 kHz ±50 Hz
•Optimal load track inductance 58 µH +2 µH for 80 A Track Supplies
26 µH +2 µH for 125 A Track Supplies
•Nominal output voltage range 560 - 665 V rms (80 A), 380 - 475 V rms (125 A). Overloads will increase the voltage.
•Impedance output to PE 180 Ohm (center capacitively referenced)
•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 nominal supply voltage 400 V / 50 Hz, 3-phase symmetric, neutral grounded
•Supply voltage tolerance -10% to + 10%, with proportional cont. power de-rating for input
voltages other than nominal value
•Efficiency at rated load 94%
•Power factor (cos ϕ) 0.78
•Supply current 12 A at rated power / voltage
•Input connector Supplied HAN-6HSB in Han-16B connector with PG 21 or M25
cable gland. Maximum outside cable diameter is 18 mm. Use
flexible cable 6 mm2.
•Input leakage current 16 mA rms in standby. Occasional 200 mA peak pulses for 250 µsec
at rated load. Ground leakage equipment must be rated accordingly if
used.
•Internal fuses 16 A gS or gRL. Semiconductor and wiring protection.
•Harmonic currents (rated load) 5th -4.5dB, 7th -9dB, 11th -21.6dB, 13th -21.7dB (on fundamental)

Operation Manual
Track Supply 6 kW
80 / 125 A at 400 / 480 V
BAL9100-0124c-EN
www.conductix.com Page 10 of 44
6.1.3 Electrical input data – specifications for 480 V versions
•Input nominal supply voltage 480 V / 60 Hz, 3-phase symmetric, neutral grounded
•Supply voltage tolerance -10% to + 10%, with proportional cont. power de-rating for input
voltages other than nominal value
•Efficiency at rated load 94%
•Power factor (cos ϕ) 0.78
•Supply current 10 A at rated power / voltage
•Input connector Supplied HAN-6HSB in Han-16B connector with PG 21 or M25
cable gland. Maximum outside cable diameter is 18 mm. Use
flexible cable 6 mm2.
•Input leakage current 19 mA rms in standby. Occasional 200 mA peak pulses for 250 µsec
at rated load. Ground leakage equipment must be rated accordingly if
used.
•Internal fuses 12A JKS, HSJ, DFJ Fast Class J
•Harmonic current (rated load) 5th -4.3dB, 7th -9.1dB, 11th -18.7dB, 13th -19.7dB (on fundamental)
6.2 Physical data
•Noise levels During operation 65 dBA at 1m distance in front
•Air volume moved 50 m³ / hour (air recirculation)
•Fan 3 axial fans