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Conductix-Wampfler 91008-111-3090873 Operation Manual

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Operation Manual
Track Supply 6 kW
80 / 125 A at 400 / 480 V
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)
BAL9100-0124c-EN
www.conductix.com
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Summary of Contents for Conductix-Wampfler 91008-111-3090873

  • Page 1 Track Supply 6 kW 80 / 125 A at 400 / 480 V 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)

  • Page 2: Table Of Contents

    Operation Manual Track Supply 6 kW 80 / 125 A at 400 / 480 V Index Page Understanding ..................................5 Symbols and hints ................................. 5 Advisory information for the user ............................6 Brief technical description ..............................7 Appearance .................................... 7 Technical data ..................................
  • Page 3 Operation Manual Track Supply 6 kW 80 / 125 A at 400 / 480 V 7.2.5 Warning Messages ................................19 7.2.6 Error Codes .................................... 19 Fuses ..................................... 22 Transport and storage ................................. 22 Installation .................................... 23 10.1 Who is authorized to carry out the installation? ........................23 10.2 General advice for the installation ............................
  • Page 4 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 BAL9100-0124c-EN www.conductix.com...

  • Page 5: Understanding

    Operation Manual Track Supply 6 kW 80 / 125 A at 400 / 480 V 1 Understanding 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.

  • Page 6: Advisory Information For The User

    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.

  • Page 7: Brief Technical Description

    Operation Manual Track Supply 6 kW 80 / 125 A at 400 / 480 V 4 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 400 V 50 Hz or 480/277 V 60 Hz mains voltage to a constant 20 kHz sinusoidal current.
  • Page 8 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. BAL9100-0124c-EN www.conductix.com...

  • Page 9: Technical Data

    Operation Manual Track Supply 6 kW 80 / 125 A at 400 / 480 V 6 Technical 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 •...

  • Page 10: Electrical Input Data - Specifications For 480 V Versions

    Operation Manual Track Supply 6 kW 80 / 125 A at 400 / 480 V 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.

  • Page 11: Environmental Data

    Operation Manual Track Supply 6 kW 80 / 125 A at 400 / 480 V 6.3 Environmental data • Ambient temperature +5°C to +40°C, power de-rating 3% / °C between 40°C and 55°C • Humidity < 90% non-condensing • Ambient air No salt water, no conductive dry or wet dust! (e.g.

  • Page 12: Mechanical Data

    Operation Manual Track Supply 6 kW 80 / 125 A at 400 / 480 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 13: Interfaces

    Operation Manual Track Supply 6 kW 80 / 125 A at 400 / 480 V 6.5 Interfaces Track connection (X1) Pin Function Remarks Track cable 1 20 (80 A) - 35 (125A) mm² lug HF Litz cable * Track cable 2 * = cable shoes with M8 hole, Soldered only! Connection to AC mains supply (X2);...

  • Page 14: Design Standards

    Operation Manual Track Supply 6 kW 80 / 125 A at 400 / 480 V 6.7 Design standards 6.7.1 Design standards for 400 V versions • EN 50178 • EN 61000-6-2 • EN 55011 6.7.2 Additional design standards for 480 V versions •...

  • Page 15: Control Board Hardware And Failure Indication

    Operation Manual Track Supply 6 kW 80 / 125 A at 400 / 480 V 7 Control board hardware and failure indication 7.1 Track Supply Control Board The control board is located in the upper part of the Track Supply and is visible if the door of the cabinet is open. There are two PCB’s: •...

  • Page 16: Track Supply Display Board

    Operation Manual Track Supply 6 kW 80 / 125 A at 400 / 480 V 7.2 Track Supply Display Board 3x16 LCD The Track Supply display board has a backlit 3x16 character display, 3 LEDs and two push buttons for user interaction assembled.

  • Page 17: Software Version Number

    Operation Manual Track Supply 6 kW 80 / 125 A at 400 / 480 V important one will be shown (in the table below importance increases from top to bottom). Example: if tuning and overload warning both are present, the warning LED will be on. The LCD, however, will display both warnings (see section 7.2.5). Cause LED yellow Status...

  • Page 18: Modes Of Operation

    Operation Manual Track Supply 6 kW 80 / 125 A at 400 / 480 V 7.2.3 Modes of Operation During operation the LCD provides basic information about the operating mode of the Track Supply. The following modes have been defined: The Track Supply is powered but does not receive a high level signal on its RESET -----RESET------ input.

  • Page 19: Warning Messages

    Operation Manual Track Supply 6 kW 80 / 125 A at 400 / 480 V The date is displayed in dd.mm.yy format. The keys function as follows: SET DATE 26:05.09 • Pressing or holding the SET key will increase the setting marked by the cursor. dd:mm:yy •...
  • Page 20 Operation Manual Track Supply 6 kW 80 / 125 A at 400 / 480 V Error code Description Meaning/Cause • Isolation of Track Supply or track installation damaged. • Water present on track E004 Ground fault • Ground fault level set too low. •...
  • Page 21 Operation Manual Track Supply 6 kW 80 / 125 A at 400 / 480 V • Track not connected E026 Track Supply output open circuited • Track cable damaged or cut • Mains overvoltage, e.g. lightning or other disturbance E027 DC bus voltage high •...

  • Page 22: Fuses

    Operation Manual Track Supply 6 kW 80 / 125 A at 400 / 480 V 8 Fuses Used fuses see chapter 20. Attention: The Track Supply is without any voltage inside only when the plug or the power supply is disconnected for at least 20 minutes. After 10 minutes however, the internal voltages on the dc bus capacitors has dropped to <...

  • Page 23: Installation

    • When operating several track supplies in one plant the control board may need to be synchronized. Conductix-Wampfler provides documentation with the synchronization components. For the installation of the Track Supply make sure that it is mounted safely. It has to be secured on site so that...

  • Page 24: Place And Conditions Of Installation

    The ambient temperature should not be lower that 5°C and must not exceed the Conductix-Wampfler specification of 40°C. The relative air humidity should be below 90% and there must not be any condensation.

  • Page 25: Electrical Connection

    Delta maybe possible, it is unadvisable and may void the warranty. Please discuss with Conductix-Wampfler if in doubt. 3. The nominal voltage of the cables for systems of 480 V AC must be at least 600 V.

  • Page 26: Configuration Of Control Plug

    Operation Manual Track Supply 6 kW 80 / 125 A at 400 / 480 V 10.5.2 Configuration of control plug Inputs: /Reset Reset+ (Pin 3) must be taken 24 V DC above Reset - (Pin 4), otherwise the Track Supply remains in a reset state.

  • Page 27: Connection Track Cable (X1)

    Operation Manual Track Supply 6 kW 80 / 125 A at 400 / 480 V 10.5.3 Connection track cable (X1) Torque for the track cable connections X1.1 and X1.2: 9 - 10 Nm. Connection terminals Track cable (X1.1 and X1.2) Cable outlets Track cable 10.5.4 Arrangement external connections (X2, X3, X4)

  • Page 28: Wiring Of The Track Supply

    Operation Manual Track Supply 6 kW 80 / 125 A at 400 / 480 V 10.5.5 Wiring of the Track Supply 400 V version: HAN 6HSB 480/277 V version: HAN-K12/2 400 V version is shown 480/277 V version: PE L1 L2 L3 BAL9100-0124c-EN www.conductix.com Page 28 of 44...

  • Page 29: Wiring Of The Track Supply

    Operation Manual Track Supply 6 kW 80 / 125 A at 400 / 480 V 10.5.6 Wiring of the Track Supply Attention: The Track Supply is without any voltage > 60 VDC inside only when the plug or the power supply is disconnected for longer than 10 minutes. For absolute safety please wait 20 minutes.

  • Page 30: Warnings And Cautions

    If you are ® not sure whether components match, contact Conductix-Wampfler. Do not put into operation beforehand. Operation of the Track Supply without all provided covers may allow the ingress of dirt and dust, thereby reducing the ability to function reliably and within specification. Avoid operation with removed cover(s) and / or opened door.

  • Page 31: Commissioning

    Operation Manual Track Supply 6 kW 80 / 125 A at 400 / 480 V 12 Commissioning Prior to commissioning pay attention to warnings and hints in chapter 11 “Warnings and cautions”. Track supplies have to be commissioned in conjunction with other corresponding IPT Rail components.

  • Page 32: Start And Operation

    Reconstruction or modifications at the energy supply system or its components on one’s own authority are excluded from the guarantee. Any necessary reconstructions or modifications - especially on electrical components - are only allowed if they have been approved by Conductix-Wampfler. BAL9100-0124c-EN www.conductix.com...

  • Page 33: Switching-Off

    Operation Manual Track Supply 6 kW 80 / 125 A at 400 / 480 V 14 Switching-off As described earlier (see 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). After disconnection of the energy supply system from the supply voltage, components or power terminals must not be touched immediately afterwards, because capacitors might be charged.

  • Page 34: Fault Diagnosis

    Operation Manual Track Supply 6 kW 80 / 125 A at 400 / 480 V 16 Fault diagnosis If the Track Supply faults - e.g. no energy supply to the secondary components, check the LED display for indication of possible cause. Refer section 7 “Control board hardware and failure indication” for LED status. Attempts to repair or restart should be avoided! Do not use the system anymore as long as the error is not located and repaired or defect components are replaced by trained personal! After conclusion of the failure analysis, the Track Supply has to be protected against touching of live parts by...

  • Page 35: Maintenance

    6 months at maximum. • Consult Conductix-Wampfler to have qualified personnel check the operating parameters of the IPT ® System. Have them compare measured values in the system with those obtained during commissioning or during the last system check.

  • Page 36: Repair

    If repair action or replacement of faulty parts is necessary and possible on site these works have to be carried out by trained personnel or by a Conductix-Wampfler technician, both while considering the relevant safety regulations. If no failure analysis or repair is possible on site the faulty part has to be sent to Conductix- Wampfler GmbH.

  • Page 37: Disassembly / Re-Use

    Operation Manual Track Supply 6 kW 80 / 125 A at 400 / 480 V 19 Disassembly / Re-use If it is necessary to exchange the Track Supply due to damage or to install it in another place, verify that no damage can occur during disassembly.

  • Page 38: Spare Parts

    80 / 125 A at 400 / 480 V 20 Spare parts Only the fuses and a few other parts 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. Producer Conductix-...

  • Page 39: Tools

    Operation Manual Track Supply 6 kW 80 / 125 A at 400 / 480 V 21 Tools Size / Description Remarks specification Connection track cable Open ended or ring spanner wrench SW 13 (35 mm Litz cable) Flat Screw driver 5 - 7 mm Plug HAN-6HSB earth screw Flat Screw driver...

  • Page 40: Adjustments During The Commissioning And Start-Up

    Operation Manual Track Supply 6 kW 80 / 125 A at 400 / 480 V Adjustments during the commissioning and start-up Track Supply ____ A _____ V @ _____ Hz Material-No.: _______________________________ Serial number ..................Name of the project or line ..................

  • Page 41: Inspection Report

    Operation Manual Track Supply 6 kW 80 / 125 A at 400 / 480 V Inspection report _____________________ Track Supply ____ A _____ V @ _____ Hz Material-No.: _______________________________ Serial number ..................Name of the project or line ..................Environmental conditions on the place ..................

  • Page 42: Inspection Report

    Operation Manual Track Supply 6 kW 80 / 125 A at 400 / 480 V Inspection report _____________________ Track Supply ____ A _____ V @ _____ Hz Material-No.: _______________________________ Serial number ..................Name of the project or line ..................Environmental conditions on the place ..................

  • Page 43: Inspection Report

    Operation Manual Track Supply 6 kW 80 / 125 A at 400 / 480 V Inspection report _____________________ Track Supply ____ A _____ V @ _____ Hz Material-No.: _______________________________ Serial number ..................Name of the project or line ..................Environmental conditions on the place ..................
  • Page 44 Operation Manual Track Supply 6 kW 80 / 125 A at 400 / 480 V Conductix-Wampfler GmbH Telefono: +49 ( 0) 7621 662-0 Rheinstrasse 27 + 33 Fax: +49 ( 0) 7621 662-144 79576 Weil am Rhein - Maerkt info.de@conductix.com Germany www.conductix.com...

This manual is also suitable for:

91012-111-309087591008-111-309087691012-111-309087891000-111-3090877

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