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Conductix-Wampfler 91008-111-3090673 Operation Manual

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Operation Manual
Track Supply 16 kW Module
80 A/125 A at 400-415 V/440 V/480 V/277 V
Part Number
91008-111-3090673 ( 80 A, 400-415 V, RAL 7016)
91012-111-3090674 (125 A, 400-415 V, RAL 7016)
91008-111-3090675 ( 80 A, 480/277 V, RAL 7016)
91012-111-3090676 (125 A, 480/277 V, RAL 7016)
91000-111-3090677 (configurable version)
BAL9100-0123g-EN
www.conductix.com
translated document
page 1/56

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Summary of Contents for Conductix-Wampfler 91008-111-3090673

  • Page 1 Track Supply 16 kW Module 80 A/125 A at 400-415 V/440 V/480 V/277 V Part Number 91008-111-3090673 ( 80 A, 400-415 V, RAL 7016) 91012-111-3090674 (125 A, 400-415 V, RAL 7016) 91008-111-3090675 ( 80 A, 480/277 V, RAL 7016) 91012-111-3090676 (125 A, 480/277 V, RAL 7016)

  • Page 2: Table Of Contents

    Operation Manual Track Supply 16 kW Module 80 A/125 A at 400-415 V/440 V/480 V/277 V Index General Advice ................................... 5 1.1. Information to these Operating Instructions ......................... 5 1.2. Limitation of Liability ..............................5 1.3. Copyright ..................................6 1.4. Spare Parts ..................................
  • Page 3 Operation Manual Track Supply 16 kW Module 80 A/125 A at 400-415 V/440 V/480 V/277 V 6.9. Grounding .................................. 20 Control Board Hardware and Fault Indication ........................... 20 7.1. Track Supply Control Board (for specially trained personnel only) ................20 7.1.1.
  • Page 4 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 BAL9100-0123g-EN www.conductix.com...

  • Page 5: General Advice

    Operation Manual Track Supply 16 kW Module 80 A/125 A at 400-415 V/440 V/480 V/277 V General Advice 1.1. Information to these Operating Instructions This document 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.

  • Page 6: Copyright

    Operation Manual Track Supply 16 kW Module 80 A/125 A at 400-415 V/440 V/480 V/277 V 1.3. Copyright These installation and operating instructions are subject to copyright and intended for customer internal use only. Providing third parties with the installation and operating instructions, duplications in any form - even in extracts - as well as reuse and/or disclosure of the contents are not permitted without written approval of the manufacturer, except for customer internal purposes.

  • Page 7: Symbols And Hints

    Operation Manual Track Supply 16 kW Module 80 A/125 A at 400-415 V/440 V/480 V/277 V Symbols 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.

  • Page 8: Requirements Regarding Personnel

    Electrician When the cables have been terminated correctly by authorized personnel having received instruction exclusively from Conductix-Wampfler, further work may be performed by an electrician. Instructed personnel/operators have been instructed by the operator about the tasks assigned to them and the possible dangers in case of improper behaviour.

  • Page 9: Application In Accordance With The Regulations

    Operation Manual Track Supply 16 kW Module 80 A/125 A at 400-415 V/440 V/480 V/277 V 2.2. Application in Accordance with the Regulations The equipment has been exclusively designed and constructed for the intended purpose. Danger caused by application not in accordance with regulations! Each application of the equipment not in accordance with and/or different from the regulations can result in dangerous situations.

  • Page 10: Advisory Information For The User

    ADVICE! Conductix-Wampfler 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.

  • Page 11: Brief Technical Description

    Operation Manual Track Supply 16 kW Module 80 A/125 A at 400-415 V/440 V/480 V/277 V Brief 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 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.

  • Page 12: Technical Data

    Operation Manual Track Supply 16 kW Module 80 A/125 A at 400-415 V/440 V/480 V/277 V Technical Data 6.1. Electrical Data | Specifications 6.1.1. Electrical Power Data | Specifications for all Versions Output power (cont.) 16 kW  at max. 40 °C for 400-415 V and 480 V versions at max.

  • Page 13: Electrical Input Data | Specifications For Versions With 440 V

    Operation Manual Track Supply 16 kW Module 80 A/125 A at 400-415 V/440 V/480 V/277 V 6.1.3. Electrical Input Data | Specifications for Versions with 440 V Input nominal supply voltage 440 V / 50 Hz, 3-phase symmetric, neutral grounded ...

  • Page 14: Environmental Data

    Operation Manual Track Supply 16 kW Module 80 A/125 A at 400-415 V/440 V/480 V/277 V 6.3. Environmental Data Ambient temperature +5 °C to +55 °C, see chapter 6.1.1 “Electrical Power Data |  Specifications for all Versions“ regarding power de-rating Damage due to extreme differences in temperature! Frozen and very cold internal components might be the cause for damage of the device or its components at the moment of switch-on or with fast/strong loads.
  • Page 15 Operation Manual Track Supply 16 kW Module 80 A/125 A at 400-415 V/440 V/480 V/277 V Air out The Track Supply requires a sufficient air flow for correct cooling. Ensure free air flow at all times and, if Track Supply is mounted in a cabinet, inspect filters for dust and oil blockage regularly.

  • Page 16: Mechanical Data

    Operation Manual Track Supply 16 kW Module 80 A/125 A at 400-415 V/440 V/480 V/277 V 6.4. Mechanical Data Cabinet Sheet Metal housing  Dimensions See the following drawing  Nom. color housing (outside) RAL XXXX; delivered color see type plate on Track Supply ...
  • Page 17 Operation Manual Track Supply 16 kW Module 80 A/125 A at 400-415 V/440 V/480 V/277 V BAL9100-0123g-EN www.conductix.com translated document page 17/56...

  • Page 18: Interfaces

    Operation Manual Track Supply 16 kW Module 80 A/125 A at 400-415 V/440 V/480 V/277 V 6.5. Interfaces X1: Track connection (all versions) – Screwed connections Function Remarks Track cable 1 20 mm² (80 A) – 35 mm² (125 A) IPT HF litz cables Cable lugs with M8 opening –...

  • Page 19: General Features

    Operation Manual Track Supply 16 kW Module 80 A/125 A at 400-415 V/440 V/480 V/277 V 6.6. General Features Input line chokes Will drop 4% from the mains voltage at rated load  EMC filtering Built in line filter included ...

  • Page 20: Grounding

    Operation Manual Track Supply 16 kW Module 80 A/125 A at 400-415 V/440 V/480 V/277 V 6.9. Grounding The Track Supply has to be grounded professionally at the installation place and connected preferably to a symmetrical neutral grounded three-phase WYE supply. Although the Track Supply may well function in supply systems with other grounding, such as grounded delta, the electromagnetic compatibility and reliability may be compromised.

  • Page 21: Control Board Led Indication

    Operation Manual Track Supply 16 kW Module 80 A/125 A at 400-415 V/440 V/480 V/277 V 7.1.1. Control Board LED Indication The control board LEDs are only visible when the front cover is removed. Risk of injury due to insufficient qualification! The front cover must only be removed by trained personnel.

  • Page 22: Led Indication

    Operation Manual Track Supply 16 kW Module 80 A/125 A at 400-415 V/440 V/480 V/277 V 7.2.1. LED Indication The behavior of the three display board LEDs is as follows: LED green Status Cause Track Supply not powered or Possible causes: error Track Supply is disconnected from the mains power ...
  • Page 23 Operation Manual Track Supply 16 kW Module 80 A/125 A at 400-415 V/440 V/480 V/277 V LED yellow Status Cause No warnings Real Time Clock has stopped due to weak battery and may 1 brief be out of date. Track Supply will continue to operate, flash every Real Time Clock warning however, errors will no longer be time stamped correctly.

  • Page 24: Software Version Number

    Operation Manual Track Supply 16 kW Module 80 A/125 A at 400-415 V/440 V/480 V/277 V 7.2.2. Software Version Number After switching on the LCD displays, a welcome screen with software revision number Version 1234567a 13:07 and compilation time and date is visible for 5 seconds. 17-Mai-09 The Track Supply may start operation prior to the expiry of 5 s delay depending on the START input!

  • Page 25: Setting Language, Time And Date

    Operation Manual Track Supply 16 kW Module 80 A/125 A at 400-415 V/440 V/480 V/277 V 7.2.4. Setting Language, Time and Date There are two buttons located beneath the LCD that allow the user to change basic settings. Settings may be changed in any mode, except in RESET mode.

  • Page 26: Warning Messages

    Operation Manual Track Supply 16 kW Module 80 A/125 A at 400-415 V/440 V/480 V/277 V 7.2.5. Warning Messages While in modes RESET, STANDBY and RUN, additional warning messages may be displayed. These are reflected in the status of the yellow LED. If more than one warning is present at a time, warning messages will alternate every second. The following warning messages are available: No warnings ...
  • Page 27 Operation Manual Track Supply 16 kW Module 80 A/125 A at 400-415 V/440 V/480 V/277 V Error code Description Meaning/Cause Defect sensor  E009 Temperature sensor 1 defect Loose connection  Defect sensor  E010 Temperature sensor 2 defect Loose connection ...
  • Page 28 Operation Manual Track Supply 16 kW Module 80 A/125 A at 400-415 V/440 V/480 V/277 V Error code Description Meaning/Cause At power up no stable DC bus voltage could be detected E030 DC bus voltage unstable due to a mains supply disturbance Track tuning capacitor aging, failure or loose ...

  • Page 29: Fuses

    Operation Manual Track Supply 16 kW Module 80 A/125 A at 400-415 V/440 V/480 V/277 V Fuses Danger of electric shock! The Track Supply is de-energized only if the voltage supply has been interrupted for at least 20 minutes by switching off or unplugging the power plug. DANGER! - Wait at least 20 minutes after switch-off, so that voltages of the intermediate circuit condensers can fall down to <...

  • Page 30: Transport, Packaging And Storage

    Operation Manual Track Supply 16 kW Module 80 A/125 A at 400-415 V/440 V/480 V/277 V Transport, Packaging and Storage 9.1. Transport 9.1.1. Safety Instructions for Transport Damage from improper transport! Improper transport can result in substantial property damage. - Proceed with care when unloading packaged parts upon delivery or during internal transport, and CAUTION! observe the symbols and notes on the packaging.

  • Page 31: Packaging

    Operation Manual Track Supply 16 kW Module 80 A/125 A at 400-415 V/440 V/480 V/277 V 9.2. Packaging The individual packages must be packed according to the transport conditions to be expected. Only environmentally friendly materials have been used for packaging. The packaging must protect the individual components from transport damage, corrosion and other damage until the installation will be made.

  • Page 32: Installation

    Ensure and verify completeness of the documents, if the documents comply with the supplied component(s).  If several Track Supplies are applied in one single system, they might need to be synchronized. Conductix-Wampfler provides  the documentation with the synchronization components.

  • Page 33: Place And Conditions Of Installation

    Operation Manual Track Supply 16 kW Module 80 A/125 A at 400-415 V/440 V/480 V/277 V 10.3. Place and Conditions of Installation Install the Track Supply in a dry and ventilated space. The Track Supply must be installed in a vertical position and mounted onto a solid subsoil.

  • Page 34: Electrical Connection

    The Track Supply is designed for connection to a neutral grounded 3-phase supply system. While operation on alternative supply systems such as corner grounded Delta maybe possible, it is unadvisable and may void the warranty. Please discuss with Conductix-Wampfler if in doubt. The nominal voltage of the cables must be at least 600 V.

  • Page 35: Configuration Of Control Plug (X3)

    10.5.5. ADVICE! Sync For synchronizing Track Supplies together to the same frequency and phase. Use only Conductix-Wampfler approved equipment. When using several Track Supplies synchronization may be required. Both Start and /Reset inputs are optically isolated and may be connected to an external 24 V DC supply or the provided 24 V output.

  • Page 36: Connection Track Cable (X1)

    Operation Manual Track Supply 16 kW Module 80 A/125 A at 400-415 V/440 V/480 V/277 V Reference for input and output Start + Start – /Reset + /Reset – Error relay Output 24 V Output 0 V Harting HAN-10E Synchronization Attention at 480/277 V version: min.

  • Page 37: Layout Of The External Connections (X1, X2, X3, X4, X5)

    (3) Control / Synchronization (X3) (4) RS232 – Only for commissioning (X4) (5) Only for commissioning (X5) Housing bottom Ensure that the cable ends are long enough to make connections. Conductix-Wampfler recommends to use a flexible cable. ADVICE! BAL9100-0123g-EN www.conductix.com...

  • Page 38: Wiring Of The Track Supply

    Operation Manual Track Supply 16 kW Module 80 A/125 A at 400-415 V/440 V/480 V/277 V 10.5.5. Wiring of the Track Supply Delivery state: not wired Controls Type: refer to chapter 6.5 AC mains supply Location: refer to chapter 10.5.4 IPT Track Type: refer to chapter 6.5 Note: X3 has to be wired adequately in order...
  • Page 39 Operation Manual Track Supply 16 kW Module 80 A/125 A at 400-415 V/440 V/480 V/277 V X3 connection example 2 X3 connection example 1 with internal supply only with external supply Cable length must not be longer than 2 meters. Refer to chapter 10.5.2 BAL9100-0123g-EN www.conductix.com translated document...
  • Page 40 Operation Manual Track Supply 16 kW Module 80 A/125 A at 400-415 V/440 V/480 V/277 V Danger of electric shock! The Track Supply is de-energized only when the plug or the power supply is disconnected for more than 20 minutes. DANGER! - Prior to opening the Track Supply wait at least 20 minutes! - Observe the safety regulation and ensure that nobody else has access to the open Track Supply.

  • Page 41: Warnings And Precautions

    ® components. DANGER - If you are not sure that this is the case, contact Conductix-Wampfler. Do not start operation of the Track Supply/system in this case! Interference of the operation by intrusion of dirt and dust! Operation of the Track Supply without its covers may allow the intrusion of dirt and dust, thereby reducing the functioning and reliability according to the specification.

  • Page 42: Commissioning

    Operation Manual Track Supply 16 kW Module 80 A/125 A at 400-415 V/440 V/480 V/277 V 12 Commissioning 12.1. Safety Track Supplies have to be commissioned in connection with the respective components of the IPT rail systems. For ® commissioning it is necessary to mount the secondary components (Pickups and Regulators) on all vehicles. Access to secondary Pickups and Regulators on all vehicles is necessary.

  • Page 43: System Conditions

    Operation Manual Track Supply 16 kW Module 80 A/125 A at 400-415 V/440 V/480 V/277 V 12.2. System Conditions The permissible transient fluctuation of the mains supply voltage is between -10% and +10% of the nominal voltage. If the values are lower or higher than these, the technical data of the Track Supply cannot be guaranteed any longer and destruction of some components may be the consequence.

  • Page 44: Start And Operation

    Operation Manual Track Supply 16 kW Module 80 A/125 A at 400-415 V/440 V/480 V/277 V 13 Start and Operation The Track Supply is not designed for independent operation. It has to be operated in conjunction with corresponding IPT rail components. Therefore no specific details about the operation are given in this ®...
  • Page 45 Operation Manual Track Supply 16 kW Module 80 A/125 A at 400-415 V/440 V/480 V/277 V 1. Connect the device to the mains supply 2. At Start+ (Pin1) and Start- (Pin 2) 24 V DC are to be applied (X3). For information on the LED indication, see chapter 7.2.1.

  • Page 46: Switching-Off

    Operation Manual Track Supply 16 kW Module 80 A/125 A at 400-415 V/440 V/480 V/277 V 14 Switching-off As described in chapter 10.5 “Electrical Connection” first switch-off the Track Supply by switching the START-input to “OFF” and after this disconnect the line voltage (i.e. by a load switch) Danger of electric shock! The Track Supply is de-energized only if the voltage supply has been interrupted for at least 20 minutes by switching off or unplugging the power plug.

  • Page 47: Fault Diagnosis

    Operation Manual Track Supply 16 kW Module 80 A/125 A at 400-415 V/440 V/480 V/277 V 16 Fault Diagnosis In case of faults at the Track Supply, e.g. no energy supply to the secondary components, check the display for indication of a possible cause.

  • Page 48: Maintenance And Servicing

    Operation Manual Track Supply 16 kW Module 80 A/125 A at 400-415 V/440 V/480 V/277 V 17 Maintenance and Servicing Danger of electric shock! The Track Supply is de-energized only if the voltage supply has been interrupted for at least 20 minutes by switching off or unplugging the power plug.

  • Page 49: Repair

    Conductix-Wampfler technician, but the relevant safety regulations must be observed. If fault analysis or repair is not possible on site, it is required to send the faulty part to Conductix-Wampfler. Please contact our service department in this case for further information.

  • Page 50: Disassembly And Disposal

    Operation Manual Track Supply 16 kW Module 80 A/125 A at 400-415 V/440 V/480 V/277 V 19 Disassembly and Disposal 19.1. Safety Danger of injury due to improper disassembly! Stored residual energies, sharp components, points, and edges on and in the device or the tools needed can cause injury.

  • Page 51: Disassembly

    Operation Manual Track Supply 16 kW Module 80 A/125 A at 400-415 V/440 V/480 V/277 V 19.3. Disassembly When the device has reached the end of its useful life, disassemble it and dispose of it in an environmentally compatible way. Disconnect Track Supply from the mains voltage.

  • Page 52: Spare Parts

    80 A/125 A at 400-415 V/440 V/480 V/277 V 20 Spare Parts Only the fuses are to be changed by the operator of the plant! All other parts have to be changed or repaired by trained and qualified Conductix-Wampfler personnel. Conductix-Wampfler Designation...

  • Page 53: Tools

    Operation Manual Track Supply 16 kW Module 80 A/125 A at 400-415 V/440 V/480 V/277 V 21 Tools Descriptions Size / Specification Remarks Connection track cable Open ended or ring spanner wrench 13 mm (20 and 35 mm Litz cable) Flat Screw driver 5 - 7 mm Plug HAN-6HSB earth screw...

  • Page 54: Commissioning Report

    Operation Manual Track Supply 16 kW Module 80 A/125 A at 400-415 V/440 V/480 V/277 V 22 Commissioning Report Track Supply ____ A _____ V @ _____ Hz Material-No.: ____________________________ Serial number .............. Name of the project or line .............. Environmental conditions on the place ..............

  • Page 55: Inspection Report

    Operation Manual Track Supply 16 kW Module 80 A/125 A at 400-415 V/440 V/480 V/277 V 23 Inspection Report Inspection Report ______________________________ Track Supply ____ A _____ V @ _____ Hz Material-No.: ____________________________ Serial number .............. Name of the project or line ..............
  • Page 56 Operation Manual Track Supply 16 kW Module 80 A/125 A at 400-415 V/440 V/480 V/277 V Conductix-Wampfler GmbH Phone: +49 (0) 7621 662-0 Rheinstrasse 27 + 33 Fax: +49 (0) 7621 662-0-144 info.de@conductix.com 79576 Weil am Rhein - Maerkt Germany www.conductix.com...

This manual is also suitable for:

91012-111-309067491008-111-309067591012-111-309067691000-111-3090677

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