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Conductix-Wampfler 91008-111-3130923 Operating Instructions Manual

Track supply 16 kw ip54
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Operating Instructions
Track Supply 16 kW IP54
80 A/125 A at 400 V/480 V
Order Number
91008-111-3130923 ( 80 A, 400 V, RAL 7035 - light gray)
91012-111-3130924 (125 A, 400 V, RAL 7035 - light gray)
91008-111-3130925 ( 80 A, 480 V, RAL 7035 - light gray)
91012-111-3130926 (125 A, 480 V, RAL 7035 - light gray)
91000-111-3130914 (configurable version)
Figure shows conditioned variant
BAL9100-0138i-EN
www.conductix.com
translated document
page 1 of 56

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Summary of Contents for Conductix-Wampfler 91008-111-3130923

  • Page 1 80 A/125 A at 400 V/480 V Order Number 91008-111-3130923 ( 80 A, 400 V, RAL 7035 - light gray) 91012-111-3130924 (125 A, 400 V, RAL 7035 - light gray) 91008-111-3130925 ( 80 A, 480 V, RAL 7035 - light gray)

  • Page 2: Table Of Contents

    Operating Instructions Track Supply 16 kW IP54 80 A/125 A at 400 V/480 V Contents page General Advice ................................. 5 Information about these Operating Instructions ...................... 5 Limitation of Liability ............................. 5 Copyright ................................6 Spare Parts ................................6 Material Defects..............................6 Technical Support ..............................
  • Page 3 Operating Instructions Track Supply 16 kW IP54 80 A/125 A at 400 V/480 V 5.8.1 Design Standards for 400 V Versions ........................21 5.8.2 Additional Design Standards for 480 V Versions ....................21 Safety Features of the Track Supply Module......................21 5.10 Grounding ................................
  • Page 4 For system details please see the respective documentation. Always observe the system documentation for any works at the system or for the operation of the system. Reprinting and copies, even in excerpt, only with our approval. © Conductix-Wampfler GmbH 2018 BAL9100-0138i-EN www.conductix.com...

  • Page 5: General Advice

    Operating Instructions Track Supply 16 kW IP54 80 A/125 A at 400 V/480 V General Advice 1.1 Information about these Operating Instructions This document facilitates safe and efficient handling and use of the equipment. It is an integral part of the equipment and must be kept in its immediately vicinity to allow access by personnel at any time. Prior to commencing any work, the personnel must have carefully read and understood these operating instructions.

  • Page 6: Copyright

    - Use only original spare parts of the manufacturer! The product warranty expires with the use of unauthorized spare parts. Spare parts must be ordered from your licensed dealer or directly from Conductix-Wampfler. Address see last page of these instructions.

  • Page 7: Safety Advice

    Operating Instructions Track Supply 16 kW IP54 80 A/125 A at 400 V/480 V Safety Advice 2.1 Explication of Symbols Safety and hazard information is identified in this document by symbols. Signal words are used to indicate the degree of hazard. Always observe safety instructions and work carefully to avoid accidents, personal injury or property damage! …...

  • Page 8: Personnel Requirements

    Operating Instructions Track Supply 16 kW IP54 80 A/125 A at 400 V/480 V 2.2 Personnel Requirements 2.2.1 Qualification Risk of injury due to insufficient qualification! Improper use can result in serious injury to persons or property damage. - All activities may only be performed by qualified personnel! WARNING! The following qualifications are listed in these operating instructions for different areas of operation: Trained personnel/operators...

  • Page 9: Intended Use

    Operating Instructions Track Supply 16 kW IP54 80 A/125 A at 400 V/480 V 2.3 Intended Use The equipment is exclusively designed and built for the intended use described here. Danger due to improper use! Any application that deviates from or goes beyond the intended use of the devices can result in a hazardous situation.

  • Page 10: Specific Hazards

    Operating Instructions Track Supply 16 kW IP54 80 A/125 A at 400 V/480 V 2.5 Specific Hazards These operating instructions exclusively contain notes regarding the specified Track Supply. Please note all data and advice listed in this document. Ensure that the device is operated under the specified conditions only. Do not start up the device until you have made sure that the machine/system into which it has been integrated, complies with the applicable norms and directives! We must point out that we will not accept any liability for damage and breakdown that have been caused...

  • Page 11: Short Technical Description

    Please note that in some cases the above figure is not exactly in conformity with the supplied Track Supply (e.g. the color could be different or the cable connections could be at another place). If you are not sure that you have been delivered the right part, please contact a person at Conductix-Wampfler. ADVICE! BAL9100-0138i-EN www.conductix.com...

  • Page 12: Track Supply Ip54 (Air-Conditioned)

    Operating Instructions Track Supply 16 kW IP54 80 A/125 A at 400 V/480 V 4.2 Track Supply IP54 (Air-Conditioned) Device configurable via 91000-111-3130914 Outlet air from air conditioning unit Status-LEDs Manual operation Door main switch Air conditioning unit Inlet air to air conditioning unit Fig.

  • Page 13: Technical Data

    Operating Instructions Track Supply 16 kW IP54 80 A/125 A at 400 V/480 V Technical Data 5.1 Electrical Power Data Nominal power (cont.) 16 kW ◼ ◼ Power reduction -3% / °C to 50 °C with air cooling: from 35 °C on with air conditioning: from 40 °C on ◼...

  • Page 14: Electrical Input Values | Specifications For Versions With 480 V

    Operating Instructions Track Supply 16 kW IP54 80 A/125 A at 400 V/480 V 5.3 Electrical Input Values | Specifications for Versions with 480 V ◼ Input voltage 480 V / 60 Hz, 3 phases symmetrically, with grounded neutral conductor ◼...

  • Page 15: Environmental Conditions

    Operating Instructions Track Supply 16 kW IP54 80 A/125 A at 400 V/480 V 5.5 Environmental Conditions ◼ Storage temperature: -20 °C to +60 °C ◼ Transport temperature -20 °C to +70 °C Ambient temperature + 5 °C to +35 °C (with ventilator) / + 5 °C to +50 °C (with air conditioning) ◼...
  • Page 16 Operating Instructions Track Supply 16 kW IP54 80 A/125 A at 400 V/480 V Air out Air in Fig. 4 Variant without air conditioning Fig. 5: Variant with air conditioning Room around the housing: Sufficient air supply must be secured! Recommended distances: 400 in front of the Track Supply with ventilator ◼...

  • Page 17: Mechanical Specifications

    ~ 240 kg ◼ Weight (with air-conditioning) ~ 300 kg ◼ 91008-111-3130923 (80 A, 400 V, …) 91012-111-3130924 (125 A, 400 V, …) 91008-111-3130925 (80 A, 480 V, …) 91012-111-3130926 (125 A, 480 V, …) Fig. 6: Dimensions variant without air-conditioning BAL9100-0138i-EN www.conductix.com...
  • Page 18 Operating Instructions Track Supply 16 kW IP54 80 A/125 A at 400 V/480 V 91000-111-3130914 (configurable version - with air-conditioning) Fig. 7: Dimensions variant with air-conditioning BAL9100-0138i-EN www.conductix.com translated document page 18 of 56...

  • Page 19: Connections | Track Supply Ip54

    Operating Instructions Track Supply 16 kW IP54 80 A/125 A at 400 V/480 V 5.7 Connections | Track Supply IP54 Connections track cables 1+2 directly in the Track Supply module (Connections according to section 10.5.2 „Connect Track Cable“) Connection Terminals Extended control switch Three-phase network...
  • Page 20 Operating Instructions Track Supply 16 kW IP54 80 A/125 A at 400 V/480 V Control and configuration (terminal 5X3) Function Voltage / Comment current +24 V 24 V DC / Start 24 V present = Start 20 mA +24 V 24 V DC / 0 V = Reset Reset...

  • Page 21: Design Standards

    Operating Instructions Track Supply 16 kW IP54 80 A/125 A at 400 V/480 V 5.8 Design Standards 5.8.1 Design Standards for 400 V Versions EN 50178 Equipment of power plants with electronic equipment; German version EN 50178: 1997 ◼ ◼ EN 61000-6-2 Electromagnetic compatibility (EMC) - part 6-2: General information Standards - interference resistance in the industrial sector EN 55011...

  • Page 22: Esd Protection

    Operating Instructions Track Supply 16 kW IP54 80 A/125 A at 400 V/480 V 5.11 ESD Protection Electrostatically endangered components! Electrostatic discharges (ESD) might damage electronic components. - Comply with the respective ESD measures before and during the complete works at the open WARNING! device, e.g.

  • Page 23: Options

    ADVICE! 6.2 Integrated Tuning Unit (only in Combination with Air Conditioning Unit) The device version with integrated tuning unit is meant for short tracks. To adjust the inductivity, contact Conductix-Wampfler. Consult BAL9100-0143 and apply it accordingly. Tuning Unit Fig. 3: View mounting plate BAL9100-0138i-EN www.conductix.com...
  • Page 24 WARNING! The tuning units are already pre-assembled by the manufacturer. No changes may be made. The configuration of the cables is to be performed by personnel of Conductix-Wampfler according to MV9100-0038. To adjust the inductivity, see BAL9100-0143 and consult Conductix-Wampfler.

  • Page 25: Track Supply Module

    Operating Instructions Track Supply 16 kW IP54 80 A/125 A at 400 V/480 V 7 Track Supply Module (1) Main air outlet (2) Air outlets (3) Access to the primary conductor (4) Mains and control connections (5) Access to the fuses (6) display status-LEDs BAL9100-0138i-EN...

  • Page 26: Indicator Circuit Board Of The Track Supply

    Operating Instructions Track Supply 16 kW IP54 80 A/125 A at 400 V/480 V 7.1 Indicator Circuit Board of the Track Supply The indicator circuit board of the Track Supply is made up of a 3 x 16 sign display with background lighting, three LEDs and two buttons for operation.
  • Page 27 Operating Instructions Track Supply 16 kW IP54 80 A/125 A at 400 V/480 V The yellow LED warns the operating personnel of critical operational states. Such warning messages do not stop the Track Supply. If, however, a warning is not noticed, this can cause an error. If more than one warning messages are existing, only the most important one will be displayed (in the following table the events are arranged from top to bottom with increasing importance.

  • Page 28: Version Number Of The Software

    Operating Instructions Track Supply 16 kW IP54 80 A/125 A at 400 V/480 V 7.3 Version Number of the Software After switching on the LCD-display a start indication will be displayed for 5 seconds with Version 1234567a 13:07 the serial number of the software version, the compile time and the compile date. May 17, 09 The Track Supply can start its function prior to the expiration of these 5 seconds.

  • Page 29: Language Setting, Time And Date

    Operating Instructions Track Supply 16 kW IP54 80 A/125 A at 400 V/480 V 7.5 Language Setting, Time and Date Below the LCD you will find two buttons, by which the operating personnel can change the basic settings. These settings can be made in each operational state, except in the RESET mode.

  • Page 30: Warning Messages

    Operating Instructions Track Supply 16 kW IP54 80 A/125 A at 400 V/480 V 7.6 Warning Messages While staying in the operational mode RESET, STANDBY and OPERATION, additional warning messages can be displayed. These are indicated by the state of the yellow LEDs. If there is more than one warning at the same time, these will be indicated one after the other at secondary frequency.
  • Page 31 Operating Instructions Track Supply 16 kW IP54 80 A/125 A at 400 V/480 V Error Description Meaning/cause code ◼ Tuning condensers damaged Axial fan defective / fan fuse triggered ◼ See E007 ◼ ◼ Fan of tuning unit defective E008 High temperature at sensor 2 HF Litz cable is loose ◼...
  • Page 32 Operating Instructions Track Supply 16 kW IP54 80 A/125 A at 400 V/480 V Error Description Meaning/cause code When switching on the device it was not possible to read out a stable ◼ E030 Intermediate circuit voltage instable voltage on the intermediate circuit due to a power supply disturbance Track tuning condenser aging, error or loose connections ◼...

  • Page 33: Fuses

    The Track Supply is equipped with several automatic fuses and protective switches. These must only be replaced after having consulted Conductix-Wampfler. In the event of the repair the Track Supply must be disconnected from the mains supply and an appropriate time must be considered for discharging processes (approx. 10 minutes to let the voltage drop to < 60 V DC).

  • Page 34: Transport, Packaging And Storage

    Operating Instructions Track Supply 16 kW IP54 80 A/125 A at 400 V/480 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, CAUTION! and observe the symbols and notes on the packaging.

  • Page 35: Packaging

    Operating Instructions Track Supply 16 kW IP54 80 A/125 A at 400 V/480 V 9.2 Packaging The individual packages have been packed according to the expected transport conditions. We have used environmentally sound packing material only. The packing shall protect the individual components up to the assembly from transport damage, corrosion and other kind of damage.

  • Page 36: Installation

    ADVICE! Settings of the inductivity are solely to be made by Conductix-Wampfler. 10.2 General Installation Recommendations After having received the component(s) and prior to starting the installation works unpack the components and check exactly ◼...

  • Page 37: Place And Conditions Of Installation

    – see chapter 6.1 „Variant with Air Conditioning Unit (Side Mounting)“. The ambient temperature should not be below 5°C and must not exceed the Conductix-Wampfler specification of 35 °C at a ventilator or 50 °C at an air conditioning unit. The relative humidity should be below 90 % and there must not be any condensation.

  • Page 38: Electrical Connection

    If you should have any doubts about that, please contact Conductix-Wampfler. 3. The nominal voltage of the cables for systems with 480 V AC must be at least 600 V.

  • Page 39: Connect Track Cable

    Operating Instructions Track Supply 16 kW IP54 80 A/125 A at 400 V/480 V 10.5.2 Connect Track Cable Connection of the Track Cable with the Option Integrated Tuning Unit With the option integrated tuning unit, the track cable is connected directly to the tuning unit and not as described in this chapter 10.5.2.

  • Page 40: Connection Of The Track Cable With The Option Integrated Tuning Unit

    Operating Instructions Track Supply 16 kW IP54 80 A/125 A at 400 V/480 V Danger of electric shock! The Track Supply is de-energized when the switch on the door is in positon OFF or if the plug is disconnected, but only if 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 The connections on the insulators are only for HF-Litz cables. Do only use stainless steel screws. WARNING! Risk of injury due to improper mounting and initial commissioning! Connections may only be installed by qualified personnel from Conductix-Wampfler. All covers are to be kept closed. WARNING!

  • Page 42: Warnings And Precautions

    The Track Supply is only intended for operation in connection with other, accordingly dimensions 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 43: Commissioning

    Operating Instructions Track Supply 16 kW IP54 80 A/125 A at 400 V/480 V 12 Commissioning 12.1 Safety Track Supplies have to be commissioned in connection with the respective components of the 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 44: System Conditions

    Operating Instructions Track Supply 16 kW IP54 80 A/125 A at 400 V/480 V 12.2 System Conditions The permissible transient fluctuation of the system 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 45: Switch Off

    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 permitted if approved by Conductix-Wampfler. ADVICE! 14 Switch Off As already described in chapter 10.5 „Electrical Connection”...

  • Page 46: Manual Operation

    Operating Instructions Track Supply 16 kW IP54 80 A/125 A at 400 V/480 V 15 Manual Operation For commissioning, tests or if an external control for the release of the Track Supply is not available, a manual start release is possible.

  • Page 47: Emergency Measures

    Operating Instructions Track Supply 16 kW IP54 80 A/125 A at 400 V/480 V 16 Emergency Measures 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 10 minutes after switch-off before starting any works at the energy supply system or its component, so that voltages of the intermediate circuit condensers can fall down...

  • Page 48: Fault Diagnosis

    Operating Instructions Track Supply 16 kW IP54 80 A/125 A at 400 V/480 V 17 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 49: Maintenance And Servicing

    All the notes listed in this document must be strictly observed. It is moreover required to observe the general national prescriptions and specific factory regulations. Adjustments concerning inductivity may only be made by qualified personnel of Conductix-Wampfler. Qualified personnel, according to the safety regulations, are persons that are familiar with the installation, assembly, commissioning and operation of energy supply systems and that have the appropriate qualifications.

  • Page 50: Maintenance Schedule Track Supply Ip54 (Air Cooling)

    6 months. ADVICE! For a qualified check of the operating parameters of the system, please contact Conductix-Wampfler. Thus you can compare the currently measured values with those obtained during commissioning or the last inspection. Here you can also check free airflow inside the housing and specific torques.

  • Page 51: Maintenance Schedule Track Supply Ip54 (Air-Conditioned Variant)

    For the maintenance of the air-conditioning system, see the documentation of the manufacturer (Rittal). ADVICE! For a qualified check of the operating parameters of the system, please contact Conductix-Wampfler. Thus you can compare the currently measured values with those obtained during commissioning or the last inspection. Here you can also check free airflow inside the housing and specific torques.

  • Page 52: 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 GmbH. Please contact our service department in this case for further information.

  • Page 53: Disassembly And Disposal

    Operating Instructions Track Supply 16 kW IP54 80 A/125 A at 400 V/480 V 20 Disassembly and Disposal 20.1 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 54: Disassembly

    Operating Instructions Track Supply 16 kW IP54 80 A/125 A at 400 V/480 V 20.3 Disassembly After the system is no longer in use, the device must be disassembled and disposed of in an environmentally friendly way. 1. Disconnect the Track Supply from the mains supply. 2.

  • Page 55: Spare Parts

    80 A/125 A at 400 V/480 V 21 Spare Parts Only the fuses and a few other components are to be replaced by the operator of the system! All other parts have to replaced or repaired by trained and qualified Conductix-Wampfler personnel. Manufacturer Conductix-...

  • Page 56: Tools

    Air conditioning unit: For tools and further details see notes of RITTAL GmbH & Co. KG. For commissioning you require further tools, a laptop with configuration software and a measuring device. Conductix-Wampfler GmbH Phone: +49 (0) 7621 662-0 Rheinstraße 27 + 33...

This manual is also suitable for:

91012-111-313092491008-111-313092591012-111-313092691000-111-3130914

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