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T r o u b l e s h o o t i n g  

Power Module  DN 

Version 09.2019  

Page 33/43 

9.6  False triggering of the RCCB, ELCB 

If a RCCB or ELCB is used it needs to be a Type B, suitable for protecting frequency 
inferters. 

 
Due to the built in frequency inverter, higher than normal leakage currents can occur at ~450 
Hz.  These can falsely trigger the RCCB.  A leakage compensation

2

 can compensate leakage 

currents at frequencies typical for frequency inverters und thus prevent false triggering.  

9.7  Insufficient demagnetization 

Demagnetization process 

•

  Check demagnetization process according to chapter demagnetization in coil module 

manual 

•

  Is object in coil during the entire pulse duration? 

Have objects to be demagnetized changed?  

•

  Material,  treatment,  magnetization,  supplier  (Material  changes  within  supplier 

tolerances are not communicated but can affect demagnetization) 

•

  Has the amount of objects changed? 

•

  Has the container changed?  Ferromagnetic containers have a shielding effect. 

Machine inspection: 

Attention:  maximum  coil  current  and  maximum  field  strength  flow  only  during 
~0.1…0.7s. 

 

•

  Inspection of contact pins 

Coil module connector 

(HAN) 

•

  Measurement of (reference measurements according to enclosed inspection protocol): 

•

  Electric resistance coil module 

•

  Inductivity coil module 

•

  Maximal coil current: with suitable current clamp

3

 on 

Coil module connector

 

•

  Maximal field strength: Mean value of corner and centre measurement  

•

  Demagnetization pulse check with oscilloscope see below 

 

 

 

2 

Suitable type: LEAKCOMP HP, EPA GmbH

 

3 

Suitable current clamps: Fluke 80i-110s AC/DC Current Clamp, Fluke i1000s AC Current Probe

 

Содержание DN1100

Страница 1: ...Translation from German manual Power modules DN150 DN750 DN1100 DN1850 ...

Страница 2: ...utput 0 1DC 0V Additions to the process monitoring level 1 Chapter 6 5 3 05 2014 New interface module 08 2015 General revision manual Safety Instructions Intended use Installation and Commissioning Operation Demagnetization Maintenance Troubleshooting Specifications 10 2015 Troubleshooting with Fault 03 2016 Fault at Overtemperature 05 2016 Prefusing RCCB ELCB leakage compensation 08 2017 Junction...

Страница 3: ...t information on the last page Liability Liability is restricted to the intended use Any other liability is explicitly excluded Improper installation operation maintenance or use of the machine can lead to body injury and property damage Maurer Magnetic AG cannot be held liable for losses consequential damages or cost resulting from or linked with improper installation operation maintenance or use...

Страница 4: ...nnector 16 4 4 1 Fan connector DN150 optional 16 4 4 2 Fan connector DN750 1850 16 4 5 Control signals 16 4 5 1 Coil module monitoring M8 16 4 5 2 Sensor connector M12 16 4 5 3 D Sub15 Control Interface 16 4 5 4 D Sub9 power setting interface DN750 1850 optional 16 4 6 Modification 17 5 Commissioning 18 5 1 Power on 18 5 2 Trigger demagnetization pulse 18 5 3 Demagnetisation test with intended obj...

Страница 5: ... 2 3 Maintenance 29 8 3 Yearly maintenance interval 29 8 3 1 Functional check 29 8 4 Spare and wear parts 30 8 4 1 Fuse protection 30 8 4 2 Inverter replacement 30 8 5 Decommissioning 31 8 5 1 Disassemble 31 8 5 2 Disposal 31 9 Troubleshooting 32 9 1 Ready lamp dark no Ready signal 32 9 2 Active lamp flashing Active Signal flashing 5 Hz 32 9 3 Fault lamp flashing Fault Signal flashing 5 Hz 32 9 4 ...

Страница 6: ...er must not use the device Operate device only in premises with limited access Modification repairs and opening of the device only by skilled personell Wait 10 minutes for capacitor discharge before opening The supply line to the power module up to the main switch always carries voltage High voltages can lead to lethal electric shock and burns Opening of the device only by skilled personell No phy...

Страница 7: ...ualified personnel may connect the machine 3 Operation 3 1 Persons in the coil area Electromagnetic radiation Illegal exposure to electromagnetic radiation If a person stays in the exposure area it may cause damage to health Applying warning glue Perform and include exposure measurement A shielding chamber is recommended to reduce the exposure radius The operator of the system is recommended to in...

Страница 8: ...S a f e t y i n s t r u c t i o n s Power Module DN Version 09 2019 Page 8 43 1 4 Safety electromagnetic fields See manual coil module ...

Страница 9: ...tization coil modules such as the MM CT U MM SE MM RE MM KE MM VE series or custom built coil modules MM DN modules feature the following functionality A C source for demagnetization coils User interface Monitoring of demagnetization coil modules External control interface 24VDC 2 1 Compatibility MM coil modules Type coil modules DN150 DN750 1850 MM CT U x x MM KE x MM SE x MM RE x MM VE 2 4 x cus...

Страница 10: ...within the respective class MM DN150 MM DN750 1850 Following devices are available The addition xx indicates the installed capacity MM DN150 xx MM DN750 xx MM DN1100 xx MM DN1850 xx DN type power modules features CFT Constant Field Technology FMT Field Multiplicator Technology 3 1 Scope of delivery Power module Key for enclosure Documentation printed and digital Fixed base optional Power cable onl...

Страница 11: ...ls Figure 1 Controls DN150 3 2 2 Connectors Figure 2 Connectors DN150 Power cable Fan connector optional Coil module connector s Sensor connector M12 s Coil module monitoring M8 Control interface D Sub15 Operation Lamp Ready Lamp Fault Lamp Active Lamp Process OK lamp optional Main switch Cam Lock Start button ...

Страница 12: ... 1850 3 3 2 Connectors Figure 4 Connectors DN750 1850 Coil module connector s Power cable Fan connector Sensor connector M12 s Main switch Cam Lock 2x Operation Lamp Ready Lamp Fault Lamp Active Lamp Pulse button Power selector optional Coil module monitoring M8 Control Interface D Sub15 Power selector interface D Sub9 Process OK lamp optional ...

Страница 13: ...ce signals maximal current load 100mA D Sub15 PIN14 15 0 10 VDC Output maximal current load 1 mA Do not connect D Sub interface with computer interface verbinden Pc and power module may be damaged 4 1 Transport Do not lift components of more than 25 kg by hand Do not lift coils mounted in shielding chambers on the shielding chamber Lift with support from below Power module can be lifted and transp...

Страница 14: ...US optional For connection two phases L1 L2 and protective conductor PE are required 2P PE Colour code supply connector DN150 Labelling 1P N PE Colours 1P N PE Labelling 2P PE Colours 2P PE L1 phase brown L1 phase black N neutral blue L2 phase black PE protective conductor green yellow PE protective conductor green yellow Table 2 Colour code supply connector DN150 4 1 2 Power cable DN150 The DN150...

Страница 15: ...e black L3 phase grey or black N neutral blue PE protective conductor green yellow Table 3 Colour code supply connector DN750 1850 4 2 Prefuse For maximal and minimal prefuse see electric circuit diagram 4 2 1 Operator Protection If a RCCB or ELCB is used it needs to be a universal current sensitive RCCBs B type suitable for protecting frequency inverters In case of false triggering of the RCCB we...

Страница 16: ...the machine Connector configuration and pin assignment according to circuit diagram 4 5 2 Sensor connector M12 The Sensor connector M12 allows the connection of an external pulse trigger light barrier capacitive sensor A suitable light barrier is available at Maurer Magnetic AG Voltage range see appendix Connector configuration and pin assignment according to circuit diagram 4 5 3 D Sub15 Control ...

Страница 17: ...n can lead to body injury and property damage Modification of the parametrisation can lead to overheating and shutdown Agreement of modification only by Maurer Magnetic AG in writing DN power modules can be automated and integrated in many ways without modification In case of questions regarding automation and integration contact Maurer Magnetic AG ...

Страница 18: ...p Ready lamp is lit 5 2 Trigger demagnetization pulse Trigger pulse by pushing Start button Machine carries out demagnetisation automatically Yellow lamp Active lamp is lit during demagnetization pulse Lamp at the coil is lit Yellow After the pulse the Active lamp goes out Check fan if available Pulse duration 4 13 second according to electric circuit diagram 5 3 Demagnetisation test with intended...

Страница 19: ...e magnetised and need to be demagnetised once more Frequent interruption accelerates electric wear Cycle times below specification may lead to overheating of the coil Pulse triggering is blocked Ready indicator dark no Ready signal After cooldown pulse triggering is enabled again Danger of burns at power connectors Poor coupling of conductors can lead to heating of connectors and conductors Physic...

Страница 20: ...lse button The white button Start Pulse triggers a demagnetization pulse 6 3 Indicators Troubleshooting and analysis in chapter troubleshooting 6 3 1 Operation lamp The Operation lamp indicates an active 24VDC power supply 6 3 2 Ready lamp The Ready lamp indicates readiness of the power module to trigger a pulse 6 3 3 Fault lamp Occurance of a fault during a demagnetization pulse results in immedi...

Страница 21: ...C verbinden PC and power module may be damaged The machine can be fully controlled and monitored via D Sub15 Control Interface The interface except PIN14 15 is electrically isolated and requires external power supply 6 5 1 Configuration D Sub15 connector See appendix for the configuration of the D Sub15 connector 6 5 2 PIN2 Start 24VDC at PIN2 for at least 100 ms starts the demagnetization For con...

Страница 22: ... module connector is correctly connected and the coil temperature is ok 6 5 9 PIN14 15 Analogue out Field strength proportional signal PIN14 15 are not electrically isolated We recommend using an isolating amplifier e g Phoenix Contact MINI MCR LS UI UI NC especially with connection length 5m PIN14 0 10 VDC Scale 0 100 of maximum specified field strength PIN15 Reference to PIN14 0 10 VDC at PIN14 ...

Страница 23: ...process monitoring internal ok white 6 Process ok ext process monitoring external ok white 7 Fault general fault red 8 Module ready Coil module connecter connected coil temperature ok white 9 External enabling External enabling signal ok D SUB15 interface white 10 External start External start D SUB15 interface white 11 Pulse start Pulse Start button or external start D SUB15 or Sensor connector M...

Страница 24: ...wer Module DN Version 09 2019 Page 24 43 6 5 12 Interface module fieldbus coupler Figure 1 Fieldbus coupler for example 750 375 8 channel digital input output 750 1502 End module 750 600 Fieldbus coupler PROFI NET 750 375 ...

Страница 25: ...ault DI 0 5 Coil module ready Plug and configuration ok 6 1A1 X7 6 1 Ready DI 0 6 Coil overtemperature 7 1A1 X7 7 1 over Temp DI 0 7 Fault fuse 24V BUS Blower 8 1A1 X7 8 1 Fault DI 0 8 External Enabling 1 1A1 X7 9 1 Enabling DO 0 1 Reset 2 1A1 X7 10 1 Reset DO 0 2 Start Pulse 3 1A1 X7 11 1 Start Pulse DO 0 3 Reserve 4 1A1 X7 12 DO 0 4 Reserve 5 1A1 X7 13 DO 0 5 Power selection Step 1 6 1A1 X7 14 1...

Страница 26: ...den PC and power module may be damaged Power settings can be controlled via D SUB9 power setting interface The interface is electrically isolated and requires external power supply 6 6 3 Configuration D Sub9 connector Find the configuration and voltage range of the D Sub9 connector in the appendix To select a power setting supply 24VDC to PIN1 PIN2 or PIN3 If no PIN is supplied the maximal field s...

Страница 27: ...upply is immediately terminated Safe stop 0 Interruption of the External enable signal see chapter D Sub15 Control Interface makes triggering a demagnetization pulse impossible An already running pulse is completed The energy supply is not terminated 6 8 1 Safe Torque Off STO Optional For integration in a centralized safety control the DN power module can be equipped with an interface Applications...

Страница 28: ...D e m a g n e t i z a t i o n Power Module DN Version 09 2019 Page 28 43 7 Demagnetization See manual coil module ...

Страница 29: ...or connection cable incl cable relief 8 2 Monthly maintenance interval 8 2 1 Visual check Housing damage Contamination can lead to short circuits and failure of the device Breakaway torque check of electric connectors Poor contacts can lead to heating and fire 8 2 2 Functional check Control elements and indicators Emergency stop Demagnetization check Measurement of residual magnetism at demagnetiz...

Страница 30: ...if present 1 week Interface module 1 week Inverter replacement 1 2 weeks Mains filter 1 2 weeks Table 6 Spare and wear parts 8 4 1 Fuse protection DN150 DN750 1850 1A1 F1 1A1 F2 Interface module 20x5mm slow blow 315mA 2x 1FT1 Secondary fuse 24VDC power supply 20x5mm slow blow 1A 1FT2 Fan connector fuse 20x5mm slow blow 4A Blown fuses 1FT1 and 1FT2 are indicated by an LED on fuse carrier 8 4 2 Inve...

Страница 31: ...nstalled that require disposal in hazardous waste Dispose of the machine at a scrapping off plant or an approved collection point Before the machine is disposed of the following materials must be removed and handed over separately to the various disposal points in compliance with the legal requirements for environmental hygiene Electrical and electronic components Remove electrical components in t...

Страница 32: ...in o Ready lamp dark signal LOW Connection box lamp red flashing o Cool down coil and possibly decrease cycle time 9 4 Fault lamp indicates 24VDC on Fault signal Switch off wait 30 seconds switch back on Check power supply inverter In DN750 1850 check motor circuit breaker If Fault still indicates open DN record error message contact Maurer Magnetic AG 9 5 Process OK lamp dark no Process OK signal...

Страница 33: ...e demagnetized changed Material treatment magnetization supplier Material changes within supplier tolerances are not communicated but can affect demagnetization Has the amount of objects changed Has the container changed Ferromagnetic containers have a shielding effect Machine inspection Attention maximum coil current and maximum field strength flow only during 0 1 0 7s Inspection of contact pins ...

Страница 34: ...ble a Coil module connector Trigger pulse and record current over entire pulse length Maximal current RMS corresponds to the value in the inspection protocol Take a picture of the pulse example see below and send incl setup current clamp mV A to Maurer Magnetic AG for analysis Figure 9 Measurement demagnetization pulse 9 9 Malfunction external coil fan at Fan connector Inspect fuse 1FT2 Fuse Fan c...

Страница 35: ...ocess monitoring external ok End process monitoring external Process failed Check P5 Process ok intern white P7 Fault General fault No fault Switch off wait 30s switch on Check circuit breaker inverter Error code inverter send to MMAG red P8 Module ready Coil module connector connected Coil temperature ok Coil module connector connected Coil temperature ok Check Coil module connector Check Coil mo...

Страница 36: ...ocked Ready indicator dark no Ready signal After cooldown pulse triggering is enabled again Coil module DN150 DN750 1850 CT U 1 Pulse 10 s 1 Pulse 10 s KE 1 Pulse 40 s SE 1 Pulse 40 s VE 2 4 According manual coil module Others According manual coil module Table 9 Minimal cycle times 10 2Power supply DN150 DN750 DN1100 DN1850 Supply voltage4 1 phasig 200 240 VAC 3 phasig 380 480 VAC Frequency range...

Страница 37: ...0 240VAC 50 60Hz 9 0 24 VDC Fuse protection 10A 4A Connector Phoenix Contact SACC E MINFS 3CON PG13 0 5 Phoenix Contact SACC E MINFS 5CON PG13 0 5 Table 12 Fan connector Figure 10 Configuration Fan connector DN150 left DN750 1850 right Configuration PIN DN150 DN750 1850 1 PE not connected 2 L 0V 3 N PE 4 not available 24V 5 not available not connected Table 13 PIN configuration 5 Output voltage su...

Страница 38: ...50 1850 Coil module monitoring M8 0 24 VDC 100mA Sensor connector M12 0 24 VDC 200mA 0 24 VDC 100mA D Sub15 Control Interface 0 24 VDC 100mA PIN14 15 0 10 VDC 1 mA D Sub09 power setting interface 0 24 VDC 100mA Table 14 Control Signals 10 4 1 Sensor connector M12 DN150 DN750 1850 Voltage range 0 24 VDC Maximum current 100mA Connector Device socket M12 4 pin Pole no 4 Configuration PIN Type Colour ...

Страница 39: ... voltage LOW 10VDC Gate current at UN 7mA Input impedance 20 C 3 2 kΩ Output current max 20 C 100mA 1mA Table 15 D Sub15 Interface Configuration PIN Type Voltage Role 1 Input Customer power supply 0VDC reference potential 2 Input 24VDC Start 3 Output 24VDC Ready 4 Output 24VDC Fault 5 Output 24VDC Active 6 Output 24VDC Operation lamp 7 Output 24VDC Process OK Process monitoring Optional 8 9 10 Inp...

Страница 40: ...HIGH 24VDC Range HIGH 19 2 28 8VDC Nominal voltage LOW 0VDC Release voltage LOW 10VDC Gate current at UN 7mA Table 17 D Sub09 power setting interface Configuration The signals are potentially separated PIN Type Voltage Role 1 Input 24VDC Select setting 1 2 Input 24VDC Select setting 2 3 Input 24VDC Select setting 3 4 5 6 7 8 9 0V 24VDC Power supply 0VDC reference potential Table 18 Configuration D...

Страница 41: ...or use only no aggressive gases no oil dust dust dirt free assembly Altitude Up to 1000m above sea level Above derate 3 for every 500m up to 2500m Vibration resistance Max 5 9 m s2 Table 19 Ambient conditions Operation 10 5 2 Storage DN150 DN750 DN1100 DN1850 Temperature range ambient air 20 C to 65 C Relative humidity Max 90 no condensate formation Vibration resistance Max 5 9 m s2 Table 20 Ambie...

Страница 42: ...e of equipment damage through inappropriate combination of components Maurer Magnetic AG components coil modules demagnetization cables power units are commissioned combined internally and parameterised accordingly They must be used exclusively in combination expressly provided for Maurer Magnetic AG cannot be held liable for direct or indirect damage as well as consequential damage resulting from...

Страница 43: ...ology residual magnetism Measurement devices Zero Gauss Chambers MaurerClassic Hand held demagnetizer Loop demagnetizer MaurerClassic Yoke demagnetizer Maurer Degaussing Technology FMT Technology CFT Technology Shielding chambers Address Maurer Magnetic AG Industriestrasse 8 10 CH 8627 Grüningen Tel 41 0 44 936 60 40 Fax 41 0 44 936 60 49 Internet www maurerdegaussing com E Mail info maurermagneti...

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