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MOZELT CoolGen 4, Technical Manual

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MOZELT CoolGen 4 Technical Manual Download Page 14

MOZELT GmbH & Co. KG

Load lifting magnet devices

Technical manual:

 

CoolGen 4

Copyright:  

MOZELT GmbH & Co. KG, D-47269 Duisburg 

 

 

Edition:

  August 2014   

 

Rev.:

   00

Page 14 

 

English

3.11  Dimensional Drawings Power Generator 

Fig.: 14 | Power generator CG4 30 kW

Zahnwelle:  W 30x2x30x14x9g DIN 5480

Spline Shaft: W 30x2x30x14x9g DIN 5480

Fig.: 15 | Power generator CG4 20 kW

Fig.: 16 | Power generator CG4 13 kW

Summary of Contents for CoolGen 4

Page 1: ...Technical Manual CoolGen 4 Please observe the following safety information and recommendations before start up ...

Page 2: ...re if applicable also hot surfaces In the case of inadmissible removal of the required cover inappropriate use wrong installation or operation there is the risk of death or severe injury or material damage All work concerning the transport installation and start up as well as maintenance are to be carried out by qualified technical personnel IEC 364 and or CENELEC HD 384 or DIN VDE 0100 and IEC Re...

Page 3: ...h additional monitoring and protection devices The manufacturer s documentation is to be observed After separating the generators from the drive unit live components and line connections must not be touched when the generator spindle is running due to the voltage All covers are to be kept closed during operation In the electronics there are intermediate circuit capacitors Their discharge may take ...

Page 4: ...Drives 8 3 Assembling 9 3 1 Assembling instructions 9 3 2 Installation of BELL CLUTCH Coupling 9 3 3 EMC Notes Electromagnetic Compatibility 10 3 3 1 Interference Immunity 10 3 3 2 Interference Radiation 10 3 4 Magnet Connection 10 3 5 LED Functions 10 3 6 Control cable 11 3 7 Terminal Box 11 3 8 Terminal Block 12 3 8 1 Start command via switch line on the MFD display 12 3 8 2 Start Command via Te...

Page 5: ...ional devices can lead to a change of the technical specification and the content of the documentation and manual and therefore leads to an exclusion of our liability also from the guarantee CAUTION CAUTION CAUTION CAUTION The rated speed of a generator of the CG 4 series is around 3000 rpm In this connection the range from 2700 rpm to 3400 rpm is to be regarded as the tolerance range It is partic...

Page 6: ...d the LED Ready for operation extinguishes The following monitoring functions are integrated Overload protection Insulation monitoring Overtemperature protection Overspeed protection Open magnetic circuit Short circuit 1 6 Safety regulations magnet operation The operation of a load lifting magnet on a mobile excavator represents a special mode of operation and an increased safety risk In contrast ...

Page 7: ...ng or under a cover the temperature of the air used for cooling should not be more than 50 C max maximum internal temperature of the casing cover CAUTION 1 2 3 4 5 Fig 1 General view CG4 Display The different operating conditions of the generator are indicated in the function display MFD via LEDs An additional 6 LEDs indicate the working loading utilization of the magnet On Off ratio within the ra...

Page 8: ... supplied with a priority flow of hydraulic oil This means the supply flow should not be adversely affected by motor fluctuations lifting travelling or other movements Depending on the manufacturer of the construction machine this is implemented in various technical designs Please ask the respective manufacturer for information on this matter or contact us for the alternative solution of the Hydra...

Page 9: ...er Clamping bushing on the power generator Shaft end shield on the power generator 5 Coupling half Fig 4 Explosion drawing BELL CLUTCH coupling Fig 5 Distance drawing coupling halves 1 CAUTION The environmental atmosphere must be free of aggressive dust corrosive vapours gases and liquids The generator is to be protected against moisture according to IP 55 Synchronous generators with integrated el...

Page 10: ...es etc are to be interference suppressed using suitable components e g RC elements 3 3 2 Interference Radiation To avoid unallowable interference radiation it is absolutely necessary to observe the given wiring instructions Non line related interference radiation is directly emitted by the integrated electronics and wiring within a frequency range of 30 MHz to 1 GHz It is mainly generated by the f...

Page 11: ...bserved The discharge time begins after final shutdown of the power generator Fig 8 Connection control line on the power generator 5 1 Magnet connection 230 V DC 2 3 4 5 Protective earth conductor connection Terminal block USB connection Screw terminal control line Fig 7 Terminal box Steuerelektronik 1 4 2 3 5 6 6 Control card WARNING In the electronics there are intermediate circuit capacitors Th...

Page 12: ...c control HydraBrain Pushbutton wiring Temperature sensor generator Bridge Internal Temperature sensor MFD Display Keying signal Keying signal on the display deactivated 3 9 USB Connection On the control card and MFD there is an USB port Both USB connections are identical and allow the following functions via the DriveSoft service software see Annex DriveSoft Changing of the output voltage Changin...

Page 13: ...NYE BK BN GY BU GNYE 1 2 3 N 1 2 3 N P1 P2 P1 P2 BK BN GY BU GNYE P1 P2 Black Brown Grey Blue Green Yellow Protective earth cond Pole 1 Pole 2 Adherent sleeves Ring cable lugs Legend Plug in connection on the strut Magnet connection line beam line Optional additional plug in connection on the beam Terminal box on the generator Terminal box at the magnet P1 P2 P1 P2 Fig 13 Cable allocation magnet s...

Page 14: ...ELT GmbH Co KG D 47269 Duisburg Edition August 2014 Rev 00 Page 14 English 3 11 Dimensional Drawings Power Generator Fig 14 Power generator CG4 30 kW Zahnwelle W 30x2x30x14x9g DIN 5480 Spline Shaft W 30x2x30x14x9g DIN 5480 Fig 15 Power generator CG4 20 kW Fig 16 Power generator CG4 13 kW ...

Page 15: ... magnet with the drive motor in operation Stand on an isolating mat suitable for electrostatically sensitive devices and make sure that this mat is not earthed before performing commissioning work on the switch on unit WARNING Before start of work verify isolation from power supply Make sure that no voltage is applied to the magnet connection If this note is not observed severe or even fatal bodil...

Page 16: ...gain only 1 x The already illuminated green LED Power on now goes out and a red LED with Power off lights up After the load has been dropped this goes out automatically The permanently illuminated LED Ready during the shifting processes indicates that a renewed procedure is now possible and that the power can be switched on Breakdowns are indicated by illuminated red LEDs The meaning and eliminati...

Page 17: ...erator running in the working range Fig 17 MFD signals Ready for operation Indication LED 1 yellow Ready LED 2 green Power on Note Magnet lifting material 1 After switching on command given via operating switch the magnet lifts Fig 18 MFD signals an activated magnet 2 Indication LED 1 yellow Ready LED 3 red Power off Note Magnet releases the material 1 After switching off command given via operati...

Page 18: ...tion August 2014 Rev 00 Page 18 English Indication LED 1 yellow Ready LED 2 green flashing Power on Note Magnet lifts material The power generator operates in the sorting mode 1 After the start command has been given via the operating pushbutton the magnet lifts Fig 20 MFD signals an activated magnet in the sorting mode 2 ...

Page 19: ...LED 4 red Line interrupt Possible cause Line interruption in the 230V circuit Magnet not or incorrectly connected Magnet line or plug and socket device defective Note The power generator is to be immediately shut down until the fault has been corrected The fault indication can only be cancelled by shutdown of the power generator After giving the shutdown command via the operating pushbutton LEDs 1...

Page 20: ...ssible cause LED 1 yellow Ready LED 5 red flashing R P M not o k The display R P M not o k flashes and the indication Ready is on 5 Fig 25 MFD signals R P M not o k Indication Possible cause The power generator runs at overspeed Shut down motor immediately and have the speed checked to prevent damage to the power generator WARNING The display R P M not o k lights up Fig 26 MFD signals underspeed I...

Page 21: ...otor immediately and have the speed checked to avoid damage to the power generator 5 Fig 27 MFD signals shutdown due to overspeed WARNING Fig 28 MFD signals overtemperature Fig 29 MFD signals insulation fault LED 1 yellow flashing Ready Power generator overheated and cannot be started The power generator operates at an unallowable ambient temperature The fresh air supply to the power generator is ...

Page 22: ...nents are 3 2 1 4a 4b 5 6 7 9 4b Variant B switch line After the start stop command has been given LEDs 3 4 flash Anzeige LED 3 red flashing Power off LED 4 red flashing Line open Possible cause Due to speed fluctuations the internal intermediate circuit voltage rises above the allowable value Note The power generator is to be immediately shut down until the fault has been corrected Contact the MO...

Page 23: ...amage to property cannot be ruled out 4 6 Mechanical Speed Measurement While the BELL CLUTCH coupling bells for power generators with a rating of 13 kW and 20 kW are provided with recesses for mechanical speed measurement the hydraulic motor with splined shaft is directly flanged to the power generator for ratings of 30 kw For this purpose one service flap each is arranged on the left and right si...

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