GTS iMAPLA 13 Installation And Operating Manual Download Page 63

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Page 63

Issue 08/2013

Installation and commissioning

Delivery scope

5.2

Delivery scope

Please verify the completeness of the delivery before installation of the

system. Please get in touch with the manufacturer or the supplying agent if

any parts are missing or if you have questions.

Construction type “One Unit” and Stand-Alone MMI

MAPLA Generator with attached switch box

MMI

Connection cable, MMI switch box

Connection cable, switch box lifting magnet

Connection cable, MMI to control button

Construction type “One Unit” and MMI with radio modem

MAPLA Generator with attached switch box

MMI with radio modem

Connection cable, switch box radio modem

Connection cable, switch box lifting magnet

Connection cable MMI to the control button / voltage supply

Summary of Contents for iMAPLA 13

Page 1: ...Issue 08 2013 Modular energy supply system for load lifting magnets iMAPLA 8 iMAPLA 13 iMAPLA 17 iMAPLA 20 iMAPLA 25 iMAPLA 30 Installation and operating manual English 08 2013 iMAPLA series...

Page 2: ...bodily injury will occur if the appropriate precautionary measures are not met Warning Means that death or serious bodily injury can occur if the appropriate precautionary measures are not met Cautio...

Page 3: ...et 24 4 4 3 Overload protection iMAPLA 26 4 5 Generator drive types 28 4 5 1 Drive via belt pulley 28 4 5 2 Direct drive 28 4 5 3 Drive via direct flange 28 4 5 4 Drive via hydraulic motor 28 4 6 MMI...

Page 4: ...84 5 6 6 Assembly instructions for flange mount SAE5 86 5 6 7 Assembly instructions for hydraulic drive 87 5 7 Arrangement of the hydraulic drive 89 5 7 1 Calculation for hydro drive for GTS iMAPLA ge...

Page 5: ...Maintenance work carried out by authorised personnel 140 8 Repairs repair 141 9 Transport and storage 144 9 1 General 144 9 2 Ambient conditions for transport and storage 144 9 3 Lifting generators a...

Page 6: ...installed power generation system in excavators or material folding machine y y The GTS iMAPLA system is only for use for suitable lifting magnets with suitable rated voltage Always follow the manufac...

Page 7: ...perating manual All other uses are not as intended and are not allowed Generator Technik Systeme GmbH Co KG cannot assume any liability for the improper use or misuse of the iMAPLA system or individua...

Page 8: ...this occurs 2003 2013 Generator Technik Systeme GmbH Co KG All rights reserved 1 5 General information Technical changes after going to press are not taken into account We reserve the right to make ch...

Page 9: ...nts of VDE tests DIN and European standards All information in this operating manual has been composed and verified carefully to the best of our knowledge Before the installation commissioning and use...

Page 10: ...or use indicated in the Intended use chapters and only according to the information in the operating manuals Danger Danger to life through electric shock y y During operation the iMAPLA system generat...

Page 11: ...e and lifted material may drop in an uncontrolled fashion Run the system with an insulation fault Danger Danger to life through falling loads y y Suspended loads which fall mean an accident risk with...

Page 12: ...e operation of active implants pacemakers Persons with pacemakers are not allowed to remain in the vicinity of lifting magnets when switched on Always maintain a sufficient safety clearance from the l...

Page 13: ...ective coverings are not in use there is a risk of injury through electric shock moving parts and hot surfaces Only operate the iMAPLA system when protective covers have been fitted for the drive as s...

Page 14: ...ng magnet when it is not needed for the work Warning Danger to life caused by electric shock and risk of damage y y Water from a high pressure cleaner can cause damage to the iMAPLA system or electric...

Page 15: ...ther power generation systems Never connect multiple controllers systems together Important The iMAPLA system must only be operated under the indicated environmental conditions and cooling conditions...

Page 16: ...y Act GSG and the certification according to EU EEC directives The manufacturer cannot assume any liability in such a case Important As a unit generating electrical power the iMAPLA system and the mac...

Page 17: ...VDE 0701 0702 2008 06 BGV A3 Inspection after repairs changes to electrical device repeat checks General requirements on electrical safety y y GUV2 10DEmpf BR 1981 11 25 UVV Accident prevention regula...

Page 18: ...7 tests Test Ea and guidance shock IEC 60068 2 27 2008 y y DIN EN 60068 2 64 VDE 0468 2 64 2009 04 Environmental testing Part 2 64 tests Test Fh vibration broadband random and guidance IEC 60068 2 64...

Page 19: ...l Unit The switch box and generator are arranged separately Note Follow the installation instructions Installation of the switch box construction type External Unit page 92 MMI control device The MMI...

Page 20: ...and identification page 53 Generator The generator provides the electrical voltage current needed for an action to the connected lifting magnet There are a range of options for providing drive power t...

Page 21: ...itch upon request MMI control device Possible options Stand Alone version shown Radio modem Inboard version Sorting function MSF Drive Possible options Belt drive shown Direct drive Direct flange Hydr...

Page 22: ...y y Visual display of all important functions and operating states on the MMI control unit y y Integrated insulation monitor with the reporting of insulation faults y y Optional use of analogue measur...

Page 23: ...24 To accelerate the magnetisation the iMAPLA System uses quick magnetisation with impulse excitation for all subsequent magnetisations This method only works when the system knows the rated current o...

Page 24: ...of current Quick magnetisation with impulse excitation Normal magnetisation without impulse excitation Lifting Time Fig 2 Characteristic curve lifting 4 4 2 Release load switch off lifting magnet Dur...

Page 25: ...d re magnetisation in the opposite direction takes place the voltage polarity is rotated until reaching half the saved nominal current Afterwards demagnetisation takes place again This procedure is ca...

Page 26: ...tic data for the magnet are recorded and calculated The iMAPLA system verifies the connected magnetic load during the measurement and test phase If the lifting magnet exceeds the maximum rated output...

Page 27: ...nerator s rated power is exceeded significantly a switchover to the system fault takes place but not until the operator has interrupted the load on the lifting magnet MMI operating and fault displays...

Page 28: ...generator and drive unit are connected with each other directly The generator runs at the same speed as the drive unit The drive unit must have a suitable and constantly regulated speed in order to av...

Page 29: ...Interface The MMI control device intelligently controls all system functions and indicates the operating states The MMI sends the control information to the iMAPLA system The MMI is installed inside...

Page 30: ...e and MMI displays LED lit flashing 1 Operation indicator MMI 2 Operation indicator lifting magnet lift 3 Quick magnetisation running release 4 Interruption Interface fault 5 Overload limitation Syste...

Page 31: ...ING STAF 6 STI S HARTING HAN 3A GW PG11 Connection for the control button Hirschmann ELST 412 PG9 4 pole Hirschmann ELWIKA KV 4412 4 pole 5 m cable Free 1 6 3 5 2 4 1 6 3 5 2 4 1 1 BK Free UART data B...

Page 32: ...the aid of a permanently magnetised plate affixed to the reverse side Fig 8 MMI dimensions and fastening dimensions stand alone version page 32 Danger Risk of injury and risk of damage y y Opening or...

Page 33: ...rol electronics completely cast 2 iMAPLA generator controller iMAPLA series 2013 insulation monitor fully cast 3 Connection for MMI RS232 interface 4 Connection for lifting magnet 5 Cooling element fo...

Page 34: ...ectronics and generator controller 2 Connection for generator 3 Connection for MMI RS232 interface 4 Connection for lifting magnet 5 Cooling element 6 Connection cable for the switch box 7 Fan wheel c...

Page 35: ...h the generator via a plug in cable and can either be attached to the generator itself One Unit construction type or mounted separately External Unit construction type The generator is attached either...

Page 36: ...Powerboard This allows for generator variables to be controlled more efficiently and safely Modern hydraulic drives or load and torque profiles are thus more easily controlled The optional built in i...

Page 37: ...er Generator Socket connection on the generator Cable s or connection to the switch box Switch box Housing weight PE PE PE Housing weight Generator U C1 C1 1 Generator U C2 C2 2 C3 C3 3 Generator V C4...

Page 38: ...V2 Generator W1 B1 B1 Generator W1 Generator W2 B2 B2 Generator W2 Generator F1 A1 A1 Generator F1 Generator F2 A2 A2 Generator F1 Fig 12 iMAPLA 25 and 30 plug connection generator switch box The 160...

Page 39: ...potential connection is missing insulation faults may not be detected by an installed insulation monitor Always make sure that the PE PA connection potential connection usually green yellow between th...

Page 40: ...rgy supply system for load lifting magnets iMAPLA system description Generator and controller Load cable s to the magnet Lifting magnet Gray brown black blue gn ge Fig 15 Connection assignment at the...

Page 41: ...om the iMAPLA 2013 series a CAN Bus connection is also provided alongside the MMI interface y y The CAN connection has a sealed M12 5 pin socket with A encoding y y The CAN Bus is isolated from the ge...

Page 42: ...e 08 2013 Page 42 MAPLA Modular energy supply system for load lifting magnets iMAPLA system description Dimensions of the systems 4 8 Dimensions of the systems Fig 17 Dimensioned drawing iMAPLA 8 One...

Page 43: ...Page 43 Issue 08 2013 iMAPLA system description Dimensions of the systems Fig 18 Dimensioned drawing iMAPLA 8 External Unit...

Page 44: ...Issue 08 2013 Page 44 MAPLA Modular energy supply system for load lifting magnets iMAPLA system description Dimensions of the systems Fig 19 Dimensioned drawing iMAPLA 13 One Unit...

Page 45: ...Page 45 Issue 08 2013 iMAPLA system description Dimensions of the systems Fig 20 Dimensioned drawing iMAPLA 13 External Unit...

Page 46: ...Issue 08 2013 Page 46 MAPLA Modular energy supply system for load lifting magnets iMAPLA system description Dimensions of the systems Fig 21 Dimensioned drawing iMAPLA 17 One Unit...

Page 47: ...Page 47 Issue 08 2013 iMAPLA system description Dimensions of the systems Fig 22 Dimensioned drawing iMAPLA 17 External Unit...

Page 48: ...Issue 08 2013 Page 48 MAPLA Modular energy supply system for load lifting magnets iMAPLA system description Dimensions of the systems Fig 23 Dimensioned drawing iMAPLA 25 External Unit...

Page 49: ...Page 49 Issue 08 2013 iMAPLA system description Dimensions of the systems 178 278 306 104 60 32 k6 10 5 27 216 12 253 162 132 354 513 M12 4x 528 5 258 Fig 24 Dimensioned drawing iMAPLA 20...

Page 50: ...Issue 08 2013 Page 50 MAPLA Modular energy supply system for load lifting magnets iMAPLA system description Dimensions of the systems Fig 25 Dimensioned drawing iMAPLA 30 One Unit...

Page 51: ...switch box EMC directives followed DIN EN 13309 ISO 7637 2 DIN EN 55011 VDE 0875 11 2011 04 and other EMC norms referenced in the named norms References to standards and directives page 17 Operating c...

Page 52: ...nd other EMC norms referenced in the named norms References to standards and directives page 17 Operating conditions Free cooling air feed unrestricted cooling air discharge max temperature of the suc...

Page 53: ...ase keep the serial numbers of the controller and or the generator to hand The type designation or order number is also useful for service requests 4 10 1 Rating plate generator Each GTS generator has...

Page 54: ...hine exciter unit BL4 model 132 BL model 160 DGGM DWG WG AC generator for lifting magnet applications MAPLA iMAPLA Three phase generator for mains power replacement applications not MAPLA Alternator f...

Page 55: ...4 pole 13 programmed power class of iMAPLA in kW INT iMAPLA indicator INT 1234 Serial number of electronic controller 4 digits for iMAPLA hardware ID switch box newer version not used for iMAPLA seri...

Page 56: ...heating of the generator Note 2 pole and 4 pole version iMAPLA controllers are only compatible with the connectors on the appropriate generator Note For test purposes or temporary use controllers with...

Page 57: ...new MMI which is independent of the power class B g MMI software version program variant 13 g programmed power class in kW Note The power class is not used for the new MMI For this reason this MMI ca...

Page 58: ...uring installation depending on the generator model rated power Reference is made to these deviations in the corresponding chapters of this manual Carefully read the safety instructions before install...

Page 59: ...specialists Only use the iMAPLA system according to the information in this operating manual and only for the applications included in the intended use chapter Danger Danger to life through modificat...

Page 60: ...ration never connect or disconnect plug connections Danger Danger to life y y Strong permanent magnetic fields can impair the operation of active implants pacemakers Persons with pacemakers are not al...

Page 61: ...Risk of injury and risk of damage y y Shutting off the drive motor counts as a general EMERGENCY STOP function In the event of an emergency shutting down the drive machine can switch off the system sa...

Page 62: ...ot be used for supplying distribution units on building sites or other fixed distribution systems e g domestic installations Never connect the iMAPLA system to the public electricity supply network Ne...

Page 63: ...on type One Unit and Stand Alone MMI y y iMAPLA Generator with attached switch box y y MMI y y Connection cable MMI switch box y y Connection cable switch box lifting magnet y y Connection cable MMI t...

Page 64: ...ble switch box lifting magnet y y Connection cable MMI to the control button voltage supply 5 3 Installation of MMI For information about the MMI installation see the description of the MMI used MMI p...

Page 65: ...rements for supply cables and Information for Han modular connectors Requirements on the connection cables page 66 Information for Han modular connector cables switch box lifting magnet page 67 The co...

Page 66: ...lay them over edges with direct mechanical contact It is important that you observe the specified minimum bending radius when installing the cables Minimum bending radius y y With flexible installati...

Page 67: ...x 6 mm Cu y y iMAPLA 25 and 30 5 x 10 mm Cu y y Maximum line length 30 m Information for Han modular connector cables switch box lifting magnet Note Only use the Han axial screw on module in articula...

Page 68: ...E Rated current max 40 A Rated voltage 1000 V Test voltage Ueff 4 kV Contamination level 3 C Insulation resistance 1010 MegaOhm Material Polycarbonate Temperature range 40 C 125 C Flammability to UL 9...

Page 69: ...uction types The graphics for the generator installation apply to the One Unit construction type A notice is included in the text where installation for the One Unit and the External Unit construction...

Page 70: ...e main fan of the engine y y In each case the generator switch box must be outside of the engine compartment y y The iMAPLA generator is protected against spray water according to IP54 and may also be...

Page 71: ...tor can also be ordered with a switch box and plug connectors attached at an angle of 45 Other installation positions are not permitted 5 5 3 Assembly Note when assembling the generator in a rotated p...

Page 72: ...x 2 000 N for iMAPLA 8 and 13 Frmax 3 000 N for iMAPLA 17 and 20 measured in a 50 mm axial clearance from the point where the shaft exits the bearing plate Famax 200 N for iMAPLA 8 and 13 Famax 380 N...

Page 73: ...in extreme cases it can cause damage to the generator The temperature of the supplied cooling air should not exceed 40 C y y A maximum underpressure of Pmax 4 Pa is allowed in the suction path of the...

Page 74: ...ot strike the pulley on the shaft Taper bushes are preferred for the attachment Secure the belt pulley to the shaft with a key Thread in a screw into the end face of the shaft to secure the belt pulle...

Page 75: ...LA 8 13 17 and 20 we generally recommend you use high performance belts V belts of types XPA or AVX13 Maximum tension force tension of drive belt on the shaft Permissible load on the shaft Frmax 2 000...

Page 76: ...mm Remove the collar 1 Unscrew and remove four screws M12 x 12 3 along with the washers 1 2 3 4x Fig 27 Preparatory disassembly of the flange mount iMAPLA 8 and 13 Assembly Assembly of flange mount SA...

Page 77: ...inserting twist slightly until the gearing locks Secure the flange 1 to the drive unit 4b M12x30 DIN912 DIN128 A 12 6 5 4a 4x 4b 1 2 4a 4a M12 x 30 DIN 912 4b DIN 128 A 12 Fig 28 Assembly of flange m...

Page 78: ...shaft at the generator and prevent it from twisting on the shaft using with a key Mount the washer 6 onto the hydraulic motor 8 Place the second half of the coupling 5 to the hydraulic motor Place the...

Page 79: ...ion types The graphics for the generator installation apply to the One Unit construction type A notice is included in the text where installation for the One Unit and the External Unit construction ty...

Page 80: ...in fan of the engine y y The generator switch box must be situated outside the engine compartment y y The iMAPLA generator is protected against spray water according to IP54 and may also be secured to...

Page 81: ...orizontal surface standing on the attachment brackets as shown The controller iMAPLA 30 or terminal box iMAPLA 25 attached to the generator must always be on top Appropriate special variants with side...

Page 82: ...undone by themselves e g via a tension ring according to DIN 128 y y Tightening torque for mounting screws M 87 Nm y y Permissible load of the shaft Frmax 5 000 N measured in 60 mm axial clearance fr...

Page 83: ...extreme cases it can cause damage to the generator The temperature of the supplied cooling air should not exceed 40 C y y A maximum underpressure of Pmax 4 Pa is allowed in the suction path of the co...

Page 84: ...Important Do not strike the pulley on the shaft Taper bushes are preferred for the attachment Secure the belt pulley to the shaft with a key Thread in a screw into the end face of the shaft to secure...

Page 85: ...type XPB a 2x belt is needed for the iMAPLA 25 and 30 systems Maximum tension force tension of the drive belt on the shaft Fmax 5 000 N at a max 60 mm axial clearance from the point where the shaft ex...

Page 86: ...MAPLA 25 and 30 page 86 Unscrew and remove four grub screws M12 x 20 1 1 4x Fig 30 Preparatory disassembly of the flange mount SAE5 iMAPLA 25 and 30 Assembly Fig 31 Assembly of flange mount SAE5 iMAPL...

Page 87: ...ve unit 2a 2b M12x35 DIN912 DIN128 A 12 4 3 2a 2b 1 4x 2a M12 x 35 DIN 912 2b A 12 DIN 128 Fig 31 Assembly of flange mount SAE5 iMAPLA 25 and 30 5 6 7 Assembly instructions for hydraulic drive Prepara...

Page 88: ...the shaft using with a key Mount the washer 4 onto the hydraulic motor 6 Place the second half of the coupling 3 to the hydraulic motor Place the hydraulic motor 6 with washer 4 and second half of the...

Page 89: ...rioritised flow rate y y If the speed drops strongly in the loaded state or if the power control on the hydraulic system reduces the flow rate it will no longer be possible to supply the magnet with n...

Page 90: ...ficiency of the engine in 100 Conversion of torque into output in Watt with the speed revs min and torque in Nm Operating a GTS iMAPLA at SunFab Hydro Motors GTS offers options in the arrangement of t...

Page 91: ...20 25 3300 2500 65 117 89 162 122 146 269 150 198 108 143 120 18 230 28 09 20 25 30 3300 2500 117 89 162 122 146 158 209 115 151 127 19 230 29 65 20 25 30 3300 2500 117 89 162 122 146 167 221 121 160...

Page 92: ...nor must air be allowed to flow through it e g air blown out of the engine compartment y y The switch box must be mounted so that the cooling vanes are vertical and to ensure unobstructed air convect...

Page 93: ...her installation positions are not permitted 5 8 3 Installing the generator connection cable The connection cable must be installed between the switch box and generator in accordance with the instruct...

Page 94: ...enerator is mounted correctly and firmly Generator installation for iMAPLA 8 13 17 and 20 page 69 Generator installation for iMAPLA 25 and 30 page 79 Make sure that the protection covers of the genera...

Page 95: ...er Danger to life through electric shock y y During operation the power generation system generates voltages that are potentially fatal Work on the electrical installations and equipment must only be...

Page 96: ...gnetic fields can impair the operation of active implants pacemakers Persons with pacemakers are not allowed to remain in the vicinity of lifting magnets when switched on Always maintain a sufficient...

Page 97: ...e optionally built in insulation monitor must trip in the self test Refrain from using the power generation system if the insulation monitor does not trip In this case send the power generation system...

Page 98: ...y a higher acceleration on the lifting magnet is compacted higher Procedures when switching the lifting magnet on and off Function description page 23 Follow the operating conditions and only operate...

Page 99: ...tor lifting magnet lift 3 Quick magnetisation running release 4 Interruption Interface fault 5 Overload limitation System fault 6 Underspeed Overspeed 7 Cyclic duration factor lifting magnet 8 Light s...

Page 100: ...e LED only indicates the supply voltage to the MMI not the functioning of the generator LED 2 Yellow Operation indicator lifting magnet The LED is lit y y The lifting magnet is switched on lift The LE...

Page 101: ...d not indicated on the MMI LED 4 Orange The LED is lit interruption y y The connection cable to the lifting magnet is not connected or the connection is broken After switch on a check is run to see wh...

Page 102: ...t time the lifting magnet is switched off Note Overload limiter active is a warning On newer iMAPLA systems this message is not displayed until significant overloads 110 apply However you should check...

Page 103: ...uced The LED goes out once the speed is within the tolerance limits again The LED is flashing overspeed y y The generator is operating at an overspeed After releasing the load it is not possible to sw...

Page 104: ...ween the switch on switch off time Continuous running when the cyclic duration factor is too high can cause damage to or overheating of the lifting magnet follow the data sheet for the lifting magnet...

Page 105: ...herwise provided by the system is no longer effective If another fault occurs potentially fatal contact voltages on metal parts may arise LED 4 5 6 lit up 100 LED flashes Temperature warning control e...

Page 106: ...ure as a system fault LED 5 flashes On iMAPLA systems the control electronics will not switch off the magnet for safety reasons Nevertheless this message should be considered as a very critical operat...

Page 107: ...ing work Press the check button for the insulation monitor on the left side of the MMI If the insulation monitor is working correctly LED 4 5 6 flashes at the same time when the check button is presse...

Page 108: ...al connection PE PA of the lifting magnet to the controller is correct 6 6 Set operating modes normal mode and jog mode machine handling and sorting operation Note y y There are MMI versions without a...

Page 109: ...esponding to the demagnetisation Briefly pressing the control button repeatedly and releasing it creates a separation of the material suspended from the lifting magnet 6 6 3 Other optional modes GTS o...

Page 110: ...agnetisation with impulse excitation is not used yet This first magnetisation process lasts approx 2 seconds than the next magnetisation processes When using a new iMAPLA system the characteristic val...

Page 111: ...he operator can also preselect the tension force of the lifting magnet on a wide range of MMI variants e g INT MSF The selection and separation of materials can thus be handled with greater sensitivit...

Page 112: ...normal speed i e the demagnetisation takes considerably longer Alternatively on newer MMI variants you can choose whether during the automatic demagnetisation procedure pressing on the joystick again...

Page 113: ...to normal material handling as the lifting magnet only remains switched on for as long as the control button remains pressed If the control button is released the lifting magnet is switched off Note...

Page 114: ...itched off y y The load parts of the load drop Once the necessary volume of material has dropped off the lifting magnet press the control button again and keep it pressed down Briefly press and releas...

Page 115: ...the generator Establish the system s readiness for use page 106 Switch off the drive unit Wait until the MMI displays goes out but for at least 45 seconds It is only now that it is assumed that the M...

Page 116: ...may only be opened by the manufacturer or a party authorised by it Only carry out the work described in this manual Danger Danger to life through electric shock y y During operation the power generati...

Page 117: ...LA system insufficiently qualified persons put themselves at risk and can damage the system The assembly connection and commissioning of the iMAPLA system and work on the electrical systems may only b...

Page 118: ...y lights up immediately after pressing the button when the switch on command is issued and goes out automatically once a magnet is connected Troubleshooting measures Switch off the drive unit and secu...

Page 119: ...e IMAPLA generator and MMI for MMIs with a radio modem check the connection cables between the generator and radio modem where necessary and also check the aerial connections on the modules for visibl...

Page 120: ...nificant overloads 110 apply However you should check that the lifting magnet is suitable for the system Overload protection iMAPLA page 26 Troubleshooting measures Switch off the drive unit and secur...

Page 121: ...ng Troubleshooting system fault blink codes page 132 Troubleshooting measures Read the error blank code on the MMI control unit Troubleshooting system fault blink codes page 132 This is only possible...

Page 122: ...result in an automatic shut down of the lifting magnet Troubleshooting measures Operate the generator at a speed within the permissible tolerances Generator drive types page 28 Danger Danger to life t...

Page 123: ...d is within the tolerance limits again Troubleshooting measures Operate the generator at a speed within the permissible tolerances Generator drive types page 28 Important Mechanical damage y y The gen...

Page 124: ...rises in the system this can lead to uncontrolled shut downs of the machine due to short circuits This message will not clear until after a system restart System restart iMAPLA controller page 115 Tro...

Page 125: ...ve the ignition key and keep it in a safe place Have the system checked and the insulation fault fixed Note It is possible that no optional insulation monitor is fitted in the controller on familiar s...

Page 126: ...trol electronics has reduced further and the overtemperature pre warning goes out If the iMAPLA system is used under load despite the overtemperature pre warning the temperature increases further and...

Page 127: ...ystem is switched off immediately without further warning Any raised loads will be released by the lifting magnet After the system has been switched off automatically a restart block prevents the lift...

Page 128: ...or is faulty any insulation faults which may arise can no longer be detected and reported by the system In this case action must be taken to see whether an insulation fault would really apply The oper...

Page 129: ...nge between 50 and 70 Unlike the older versions of the iMAPLA system no automatic switch off takes place and no re engaging lock when the relative switch on time exceeds 80 Troubleshooting measures To...

Page 130: ...lifting magnet is switched off i e the load is released this LED will go out 3 Quick magnetisation release switch off This operating mode only applies for material handling mode A mode The LED lights...

Page 131: ...tem is operating at reduced voltage or material handling performance lifting output LED is flashing Overspeed generator The generator is operating at an overspeed It will not be possible to switch the...

Page 132: ...rated load of the machine was exceeded The re engaging lock is active Check the load connect smaller load where necessary 4 Short circuit type 1 Conductance monitor triggered 5 Short circuit type 2 L...

Page 133: ...lifting magnet and load cable internal system fault Category 2 critical short circuit present check the lifting magnet and load cable if this fault continues contact customer service external system f...

Page 134: ...m Visual inspection cleaning work by the user page 138 Important y y As well as the work described here inspections of the drive system may be required according to the requirements and provisions of...

Page 135: ...it Only carry out the work described in this manual Danger Danger to life through electric shock y y During operation the power generation system generates voltages that are potentially fatal Work on...

Page 136: ...hock and risk of damage y y Water from a high pressure cleaner can cause damage to the iMAPLA system or electric shock Never expose the iMAPLA system to the water jets of a high pressure cleaner Warni...

Page 137: ...y no longer be able to detect an insulation fault Caution Burn hazard y y Parts of the iMAPLA system can get very hot during and after operation Allow the iMAPLA System and parts to cool down before t...

Page 138: ...instructions in the Safety instructions chapter as well as the information given here Safety instructions page 135 Danger Danger to life through electric shock y y Never carry out visual inspections...

Page 139: ...Generator and switch box Caution Burn hazard y y Parts of the iMAPLA system can get very hot during and after operation Allow the iMAPLA System and parts to cool down before touching y y Check the ge...

Page 140: ...cially trained personnel Carry out all connection work according to applicable national regulations in Germany these include VDE specifications Read and observe the safety instructions in the Safety i...

Page 141: ...r the machine Danger Risk of injury and risk of damage y y Opening or disassembling the iMAPLA system puts the system at risk and compromises the safety of the user Do not open or dismantle the iMAPLA...

Page 142: ...yellow between lifting magnet and generator controller is connected to the electricity supply Without this the detection of external ISO faults in the lifting magnet will not be possible y y If this...

Page 143: ...ut by authorised personnel Warning Danger to life caused by electric shock and risk of damage y y Water from a high pressure cleaner can cause damage to the iMAPLA system or electric shock Never expos...

Page 144: ...red condition with packaging and protection devices fitted Close the protective covers provided for this purpose attach the sealing caps and seal correctly 9 2 Ambient conditions for transport and sto...

Page 145: ...External Unit An eyebolt is attached to the top of the generator for attachment for the lifting equipment The lifting devices are only allowed to be secured to the generator using this eyebolt Weight...

Page 146: ...to the valid legal regulations and send for recycling The next information is available from the relevant environmental authorities or manufacturer Disposal instructions Generator and switch box Housi...

Page 147: ...I is installed inside the cab within the driver s field of vision to allow him her to monitor the indicated operating states It contains the system intelligence display elements and the connection for...

Page 148: ...an external supply source from the on board power supply because there is no cable connection between the MMI and the generator system Radio modem in the vicinity of the generator MMI in the driver s...

Page 149: ...nterface to switch box HARTING STAF 6 STI S HARTING HAN 3A GW PG11 STAF 6 FE L MMI Connection for the control button and voltage supply Hirschmann ELST 412 PG9 4 pole Hirschmann ELWIKA KV 4412 4 pole...

Page 150: ...ith radio modem Socket on MMI 1 12 24 V INPUT Power supply 2 Joystick S1 INPUT 3 GND INPUT Power supply 4 12 V OUTPUT Connection assignment control button 1 brown Power supply 12 24 V 2 white Joystick...

Page 151: ...g dimensions MMI and radio modem page 153 CAUTION Where necessary the transparent cover can be removed for the attachment and assembly of the wireless MMI Danger Risk of injury and risk of damage y y...

Page 152: ...ally excavators have their own terminal for such purposes behind the ignition lock this is separately fused and is switched via the ignition lock The supply voltage is also transmitted in the cable fo...

Page 153: ...ry configured radio channel does not need to be changed To ensure safe wireless transmission when running multiple systems at the same time keep to a mutual channel clearance between systems of at lea...

Page 154: ...additional specifications Possible special functions through the use of MMIs with quickcouplers or INT MSF version are explained in separate additional brief descriptions enclosed with the MMI The ba...

Page 155: ...0 001 5 0000 5512 110 001 5 0000 5512 110 001 Load cable 8 30 kW 20 30 m compl with connector 0 0100 5502 020 001 0 0100 5502 020 001 0 0100 5503 030 001 Joystick cable 4 pole 10 m straight angled con...

Page 156: ...mpl with connector 0 0100 5503 030 001 0 0100 5504 030 001 0 0100 5504 030 001 Joystick cable 4 pole 10 m straight angled connector 0 0100 5512 110 001 0 0100 5512 110 001 0 0100 5512 110 001 DS3 DS 6...

Page 157: ...ber of the generator Assembly SK Serial number switch box Installed magnetic plate Manufacturer Type Rated current A Nominal voltage V Permissible cyclic duration factor MMI version Standard version S...

Page 158: ...press approval Manufacturer representative GTS GmbH Co KG Generator Technik Systeme Ziegelfeldstra e 62 65 73563 M gglingen Germany Tel 49 0 71 74 8 98 00 0 Description of system components y y functi...

Page 159: ...ousing IP Code DIN EN 61557 Electrical safety in low voltage distribution systems DIN EN ISO 12100 Safety of machinery General principles of design risk assessment DIN EN 60204 32 Safety of machinery...

Page 160: ...Issue 08 2013 Page 160 MAPLA Modular energy supply system for load lifting magnets Block circuit diagram 15 Block circuit diagram Fig 38 Block circuit diagram 8 17 kW...

Page 161: ...Page 161 Issue 08 2013 Block circuit diagram Fig 39 Block circuit diagram 20 kW...

Page 162: ...Issue 08 2013 Page 162 MAPLA Modular energy supply system for load lifting magnets Block circuit diagram Fig 40 Block circuit diagram 30 kW...

Page 163: ...A 8 One Unit 42 Fig 18 Dimensioned drawing iMAPLA 8 External Unit 43 Fig 19 Dimensioned drawing iMAPLA 13 One Unit 44 Fig 20 Dimensioned drawing iMAPLA 13 External Unit 45 Fig 21 Dimensioned drawing i...

Page 164: ...Generator drive types 28 Generator installation for iMAPLA 8 13 17 and 20 69 Generator installation for iMAPLA 25 and 30 79 GTS spare parts list iMAPLA 155 GTS type designation and identification 53...

Page 165: ...load switch off lifting magnet 24 112 Releasing load 114 Repairs 141 Requirements for the connection cables between generator and lifting magnet 67 Requirements on the connection cables 66 Requirement...

Page 166: ...Issue 08 2013 Page 166 MAPLA Modular energy supply system for load lifting magnets...

Page 167: ...Page 167 Issue 08 2013...

Page 168: ...Ziegelfeldstra e 62 65 D 73563 M gglingen T 49 0 7174 89800 0 F 49 0 7174 89800 25 E info gts generator com W www gts generator com...

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