Modular energy supply system for load lifting magnets ...

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Modular energy supply system for load lifting magnets

iMAPLA 8, iMAPLA 13, iMAPLA 17, iMAPLA 20, iMAPLA 25, iMAPLA 30

Installation and operating manualEnglish 08/2013

iMAPLA series

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Legend, safety instructions

Legend, safety instructions

This operating manual contains information you must observe for your own personal safety and to prevent material or property damage. The information concerning your own personal safety is emphasised with a warning triangle.Information about material or property damage without personal injury appears without a warning triangle. Depending on the hazard class, the warning information is shown as follows in descending order.

DangerMeans that death or serious bodily injury will occur if the appropriate precautionary measures are not met.

WarningMeans that death or serious bodily injury can occur if the appropriate precautionary measures are not met.

CautionMeans that minor bodily injury can occur if the appropriate precautionary measures are not met.

ImportantMeans that property damage can occur if the appropriate precautionary measures are not met.

NoteMeans that an unexpected event or condition can arise if the appropriate information is not followed.

If more than one hazard class arises, the warning level with the highest level is always the one used. If a warning of injury to personnel in a warning notice with warning triangle appears, an additional warning about material or property damage can be attached to the same warning notice.

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Legend, safety instructionsContents

ContentsLegend, safety instructions 2

1 Important information and notes 61.1 Qualified personnel 61.2 Intended use 61.3 Validity of the manual 71.4 Copyright 81.5 General information 81.6 Manufacturer's address 8

2 Safety instructions 10

3 References to standards and directives 17

4 iMAPLA system description 194.1 Components 194.2 System overview 194.3 Special properties 224.4 Function description 23

4.4.1 Lift load (switch on lifting magnet) 234.4.2 Release load (switch off lifting magnet) 244.4.3 Overload protection iMAPLA 26

4.5 Generator drive types 284.5.1 Drive via belt pulley 284.5.2 Direct drive 284.5.3 Drive via direct flange 284.5.4 Drive via hydraulic motor 28

4.6 MMI control unit (stand-alone version) 294.6.1 General 294.6.2 MMI displays 304.6.3 MMI plug connections (default assignment) 314.6.4 Installation 32

4.7 Generator and controller 334.7.1 Description 354.7.2 Plug connections on the generator and switch box 37

4.8 Dimensions of the systems 424.9 Technical data 51

4.9.1 Construction type “One Unit” 514.9.2 Construction type “External Unit” 52

4.10 GTS type designation and identification 534.10.1 Rating plate, generator 534.10.2 Serial number switch box / controller 554.10.3 Serial number, MMI control unit 57

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5 Installation and commissioning 585.1 General safety instructions 585.2 Delivery scope 635.3 Installation of MMI 645.4 Installation of cables 64

5.4.1 Pre-assembled cables, supplied 655.4.2 Rules for cable installation 665.4.3 Requirements on the connection cables 66

5.5 Generator installation for iMAPLA 8, 13, 17 and 20 695.5.1 Requirements on the installation position 705.5.2 Permissible installation positions 715.5.3 Assembly 715.5.4 Minimum clearances and cooling provisions 725.5.5 Assembly instructions for belt drive 745.5.6 Assembly instructions for flange mount SAE5 765.5.7 Assembly instructions for hydraulic drive 77

5.6 Generator installation for iMAPLA 25 and 30 795.6.1 Requirements on the installation position 805.6.2 Permissible installation position 815.6.3 Assembly (iMAPLA 25 and 30) 825.6.4 Minimum clearances and cooling provisions 825.6.5 Assembly instructions for belt drive 845.6.6 Assembly instructions for flange mount SAE5 865.6.7 Assembly instructions for hydraulic drive 87

5.7 Arrangement of the hydraulic drive 895.7.1 Calculation for hydro-drive for GTS iMAPLA generators 89

5.8 Installation of the switch box, construction type “External Unit” 925.8.1 Requirements on the installation position 925.8.2 Permissible installation site for a switch box 935.8.3 Installing the generator connection cable 93

5.9 Commissioning 94

6 Operation 956.1 Safety instructions for operation 956.2 Operating instructions 986.3 MMI operating- and fault displays 996.4 Establish the system's readiness for use 1066.5 Daily inspection of the insulation monitor 1076.6 Set operating modes, normal mode and jog mode (machine handling and

sorting operation) 1086.6.1 Normal-/machine handling operation [A] (switch on top) 1086.6.2 Jog / Sort mode [B] (switch setting below) 1096.6.3 Other optional modes 109

6.7 Operating in Normal or Material handling mode [A] 1106.7.1 Lift load (switch on the lifting magnet) 1106.7.2 Release load (switch off lifting magnet) 112

6.8 Operation in Jog mode / Sorting mode [B] 1136.8.1 Lift load 1146.8.2 Separating the material 1146.8.3 Releasing load 114

6.9 System restart iMAPLA controller 115

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6.10 Troubleshooting 1166.10.1 Interruption 1186.10.2 Interface fault 1196.10.3 Overload limitation 1206.10.4 System fault 1216.10.5 Underspeed 1226.10.6 Overspeed 1236.10.7 Insulation faults arose 1246.10.8 Overtemperature pre-warning (control electronics) 1266.10.9 Temperature limit exceeded (control electronics) 1276.10.10 Insulation monitor faulty 1286.10.11 Cyclic duration factor greater than or equal to 80 % 1296.10.12 MMI overview display values 1306.10.13 Troubleshooting, system fault blink codes 132

7 Maintenance and care 1347.1 Safety instructions 1357.2 Visual inspection / cleaning work by the user 1387.3 Maintenance work carried out by authorised personnel 140

8 Repairs / repair 141

9 Transport and storage 1449.1 General 1449.2 Ambient conditions for transport and storage 1449.3 Lifting generators and switch boxes 144

10 Decommissioning, storage after disassembly of, disposal 146Disposal instructions 146

11 Options and accessories 14711.1 MMI with radio modem 147

11.1.1 General 14711.1.2 Displays on the MMI 14911.1.3 Plug connections, MMI and radio modem 14911.1.4 Installing the MMI with radio modem 15111.1.5 Installing the radio MMI 15211.1.6 Installing the radio modem 15211.1.7 Configuring the radio channel 15311.1.8 Technical specifications, MMI with radio modem 154

11.2 Customer-specific MMI versions 15411.3 Accessories 154

12 Spare parts 155

13 Commissioning 157

14 EC Declaration of Conformity 158

15 Block circuit diagram 160

17 Index of figures 163

18 Index 164

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Important information and notes

1 Important information and notes

1.1 Qualified personnel

The unit or system may be installed and operated in connection with this manual. Installation, commissioning and operation of a unit or system must only be performed by qualified personnel.Qualified personnel within the meaning of the technical safety information in this manual are persons with the authorisation to put devices, systems and circuits into service, to ground them, and to label them, according to technical safety standards.

1.2 Intended use

The iMAPLA system described in this manual is a modular energy generation system for lifting magnets.The iMAPLA system is designed for use as a permanently installed power generation system in excavators or material folding machine.

y The GTS iMAPLA system is only for use for suitable lifting magnets with suitable rated voltage. Always follow the manufacturer's instructions from the supplier of the lifting magnet and their safety instructions.

y Only use the iMAPLA system according to the voltage and performance data on the rating plate.

y Do not connect the iMAPLA system to other power distribution or generation systems (e.g. domestic installations, power distributors on building sites, other generators or the public electricity supply network).

y Operate the iMAPLA system at the nominal speed. y Only connect an appropriate lifting magnet to the control unit. Before

using ohmic or other loads, consult the manufacturer on their suitability for use. Changes in circuits - parallel or between controller and lifting magnet are not allowed.

y Connecting different iMAPLA systems in parallel or with other systems is not allowed.

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y The GTS iMAPLA system is also available as a single-bearing variant upon request. Normally they are connected directly to combustion engines. When used in this way, the manufacturer must be consulted on the suitability for use and the drive design.

y Use the iMAPLA system exclusively for the uses indicated here and only in accordance with the entries in this uses indicated here and only in accordance with the information in this operating 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 individual components.

1.3 Validity of the manual

This manual applies exclusively for the iMAPLA systems of the following types which are delivered complete with the associated switch boxes and are exclusively for use as permanently installed power generation systems in excavators or material handling machines for lifting magnets. In this manual, the different generator types are distinguished by their type designation and their model.

The manufacturer reserves the right to make technical changes.

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1.4 Copyright

Without the express approval of Generator. Technik. Systeme. GmbH & Co. KG, no part of this operating manual may be distributed, published or transmitted, irrespective of the type and the means by which 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 changes.Version: August 2013

1.6 Manufacturer's address

We are more than happy to provide information, assistance, service and ordering assistance.

Generator. Technik. Systeme. GmbH & Co. KGZiegelfeldstraße 62 + 6573563 Mögglingen (Germany)

Tel +49 (0) 7174 8 98 00-0Fax +49 (0) 7174 8 98 [email protected]

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Dear customer,

Generator. Technik. Systeme. GmbH & Co. KG is a technically leading manufacturer of power generation systems and produces generators from 4 to 40 kVA and electronic control units of its own design. GTS generators are highly durable and of the highest quality. They are maintenance-free, long-lasting, precise and robust.

By purchasing the iMAPLA power generation system, you have opted for a technical high-quality product and a future-proof concept. Only high-quality parts are used in the manufacture of iMAPLA systems which meet the requirements 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 of the iMAPLA system read this operating manual completely and carefully, and follow the instructions herein.

Generator. Technik. Systeme. GmbH & Co. KG cannot take any responsibility for any application contrary to the descriptions in this operating manual nor for damage arising from incorrect operation and management, incorrect installation, failing to use the unit as intended, prohibited technical modifications or due to repairs by unauthorised personnel.

If you have any questions, please get in touch with Generator.Technik.Systeme GmbH & Co. KG. directly.

Best regards

Generator. Technik. Systeme. GmbH & Co. KG

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Safety instructions

2 Safety instructions

The generally valid safety instructions are included in this chapter. Before the installation, commissioning and use of the iMAPLA system read this operating manual completely and carefully, and follow the instructions herein. This safety instructions also appears in the relevant areas of the text in the manual.

Important ►Before the installation, and use of the iMAPLA system read this operating manual completely and carefully, and follow the instructions herein. ►Use the iMAPLA system exclusively for use indicated in the “Intended use” chapters and only according to the information in the operating manuals.

DangerDanger to life through electric shock

y During operation, the iMAPLA system generates potentially fatal electrical voltages.

y All work on the iMAPLA system, visual inspections for maintenance purposes or cleaning work during operation of the system can lead to potentially fatal injury through electric shock. ► Switch off the drive unit before all inspection or

maintenance work on the generator or switch box. Secure the drive unit before being switched on accidentally (e.g. remove the ignition key and keep it in a safe place).

► Never plug in or undo plug connections during operation. ► Touch the iMAPLA system or devices connected to the

system never touch the iMAPLA system with wet hands during operation.

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Safety instructions


y Insulation monitors can mutually influence each other. ► Do not connect any other insulation monitors to the

iMAPLA system.


y With an insulation fault, the “electrical separation” protective measure - which is otherwise provided by the system - is no longer effective. This means that - if another fault arises - potentially fatal contact voltages may arise on metal parts.

y Second faults for sporadic or sudden load releases may also arise and lifted material may drop in an uncontrolled fashion. ► Run the system with an insulation fault.

DangerDanger to life through falling loads!

y Suspended loads which fall mean an accident risk with danger to life. ► Never walk or remain under suspended loads. ► Always observe the regulations of the trade association. ► Never switch on the lifting magnet when it is not needed

for the work. ► The machine must be equipped with an emergency power

supply (e.g. backup battery) with a bridging time of at least 10 minutes in accordance with DIN EN 13155 “Cranes - Non-fixed load lifting attachments”.

► On mobile systems (e.g. material handling machines), observe the manufacturer's specifications. Nobody is allowed to remain in the working area / safety area of the machine during operation.

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Safety instructions


y A loss of drive power always leads to the uncontrolled release of the lifted load from the lifting magnet. ► The machine operator must check that there is sufficient

drive power, and establish the operational reliability of the drive before commissioning.

DangerDanger to life!

y Strong, permanent magnetic 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 safety clearance from the lifting

magnet.

WarningRisk of injury and risk of damage!

y When working on the iMAPLA 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 be carried out by authorised, qualified and specially trained personnel.

► Carry out all connection work according to applicable national regulations (in Germany: these include VDE specifications).

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Safety instructions


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 safely. After the shut-down, hazardous voltages may remain in and on the system for up to a max. 45 seconds.

WarningRisk of injury

y When protective 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 specified.

WarningRisk of explosion

y A discharge of sparks during operation is possible. ► Do not operate the iMAPLA system in potentially explosive

environments.

WarningRisk of accident

y Devices which start up in an uncontrolled fashion can put persons at risk or injury them or cause damage or themselves be damaged. ► Switch off all devices before they are connected to the

iMAPLA system.

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Safety instructions


y An energised lifting magnet suspended in the air can attract unwanted material to it. ► Never switch on the lifting magnet when it is not needed

for the work.

WarningDanger to life caused by electric shock and risk of damage.

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.

CautionBurn hazard

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.

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Safety instructions

Important y The iMAPLA system is not suited for supplying fixed

distribution systems. y The iMAPLA system is designed for a specific output and

speed. The system can be damaged by voltage peaks and overloads. ► The iMAPLA system must not 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. Never connect it with other power generation systems.

► Never connect multiple controllers / systems together.

ImportantThe iMAPLA system must only be operated under the indicated environmental conditions and cooling conditions.

ImportantThe iMAPLA system must only be used for supplying power to suitable lifting magnets. Follow the lifting magnet's manufacturer specifications.

ImportantPay attention to the operating data.

Ö Technical data, page 51.Make sure the load cables connected to the magnet are suitable.

Ö Plug connections on the generator and switch box, page 37.

ImportantWhen carrying out repairs, only use original parts from the manufacturer, or third party parts which have been expressly approved by the manufacturer.

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Safety instructions

ImportantNo modifications may be made to the system or individual components of the system. Any modification, incorrect repair or use of unsuitable third party parts shall cause all warranty claims to lapse and the lapsing of the type approval according to the Equipment Safety Act (GSG) and the certification according to EU-/EEC directives. The manufacturer cannot assume any liability in such a case.

ImportantAs a unit generating electrical power, the iMAPLA system and the machinery materials are to be considered a part of an overall system. The relevant national regulations on accident prevention are applicable (in Germany for instance DIN / VDE 0113-EN60204, DIN / VDE 0701 and DIN / VDE 0702 BGV-A3).Heed the appropriate test deadlines.

ImportantCheck that all the connector plugs have been plugged in/engaged correctly and locked against accidental removal.

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References to standards and directives

3 References to standards and directives

The generator has been manufactured in accordance with the following norms and directives.

y DIN EN 60034 Part 1-9, rotating electrical machines y DIN EN 60204-1; VDE 0113-1:2011-01

Safety of machinery - Electrical equipment of machines: general requirements

y DIN VDE 0100 (VDE 0100) Regulations for the installation of electrical power installations with rated voltages of up to 1,000 V in particular: - DIN VDE 0100-410; VDE 0100-410:2007-06 Low-voltage electrical installations-Part 4-41: protection for safety - Protection against electric shock (IEC 60364-4-41:2005, amended) - DIN VDE 0100-600; VDE 0100-600:2008-06 (previously IEC 60364-6:2006) Low-voltage electrical installations- Part 6: tests (IEC 60364-6:2006, amended) (e.g. Abschaltwerte on IT systems)

y DIN VDE 0701-0702; VDE 0701-0702:2008-06/BGV A3 Inspection after repairs, changes to electrical device repeat checks-General requirements on electrical safety

y GUV2.10DEmpf BR:1981-11-25, UVV Accident prevention regulation “Electrical systems and machinery materials” with implementation instructions

y DIN EN 60529; VDE 0470-1:2,000-09 Protection types through housing (IP code) (IEC 60529:1989 + A1:1999) and also DIN IEC 60529/A1; VDE 0470-1/A1:2010-04 “High-pressure water inspection” (IEC 70/118/CD:2009)

y DIN EN 61557-1; VDE 0413-1:2007-12 Electrical safety in low voltage distribution systems up to 1,000 V a.c. and 1500 V d.c. - Equipment for testing, measuring or monitoring of protective measures- Part 1: general requirements

y DIN EN 61557-8; VDE 0413-8:2007-12 Electrical safety in low voltage distribution systems up to 1,000 V a.c. and 1500 V d.c. - Equipment for testing, measuring or monitoring of protective measures- Part 8: insulation monitor equipment for IT systems

y DIN EN ISO 12100 Safety of machinery - General principles for design - Risk assessment and risk reduction (ISO 12100:2010)

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References to standards and directives

y DIN EN 60204-32; VDE 0113-32:2009-03 Safety of machinery - Electrical equipment of machines-Part 32: requirements for lifting gear (IEC 60204-32:2008)

y DIN EN 13155 Cranes - Safety - Non-fixed load lifting attachments (not for mobile material handling machines)

y DIN EN 60068-2-27; VDE 0468-2-27:2010-02 Environmental testing-Part 2-27: tests - Test Ea and guidance: shock (IEC 60068-2-27:2008)

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 60068-2-64:2008)

y DIN EN 13309 Construction machinery - Electromagnetic compatibility of machines with internal power supply

y ISO 7637-2 Road vehicles -- Electrical disturbances from conduction and coupling-Part 2: electrical transient conduction along supply lines only

y DIN EN 55011; VDE 0875-11:2011-04 Industrial, scientific and medical equipment - Radio-frequency disturbance characteristics - Limits and methods of measurement (IEC / CISPR 11:2009, amended + A1:2010)

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iMAPLA system descriptionComponents

4 iMAPLA system description

4.1 Components

y Generator y Switch box with control electronics y MMI control device (Man-Machine Interface)

4.2 System overview

The iMAPLA system is a modular system for power generation for lifting magnets and is engineered for used in excavators.

Construction type “One Unit”The switch box is attached directly to the generator.

Construction type “External Unit”The switch box and generator are arranged separately.

NoteFollow the installation instructions.

Ö Installation of the switch box, construction type “External Unit”, page 92

MMI control deviceThe MMI control device intelligently controls all system functions and indicates the operating states. The MMI sends the control information to the generator.The MMI is installed inside the cab within the driver's field of vision to allow him / her to monitor the indicated operating states.The MMI control unit is most commonly used as a stand-alone version. Various other options and customer-specific adjustments are possible, e.g. an MMI with a radio modem.

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iMAPLA system descriptionSystem overview

Controller with CAN BusThe controller for the iMAPLA series 2013 offers an additional CAN Bus connection which can be programed according to Standard J1939 specific to the application. It is possible to establish a direct connection to the machine controller without the MMI.Once an external MMI is connected to the MMI interface on the controller, command input via CAN is blocked. Transfer of the status values remains active.

Ö GTS type designation and identification, page 53

GeneratorThe 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 to the generator.

Ö Generator drive types, page 28

Lifting magnetThe lifting magnet is freely selectable as part of the indicated specifications and performance constraints. The system automatically adapts to the connected lifting magnet.

Manual control unitThe system is controlled via a pushbutton which is connected to the MMI.This button is fixed to any part of the manual control unit in the excavator cab. Normally, a button is used in the joystick that is used to control the excavator.The manual control unit is freely selectable as part of the indicated specifications.

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iMAPLA system descriptionSystem overview

Manual control unit with control button (joystick) or footswitch upon request

MMI control devicePossible options:- Stand-Alone version (shown)- Radio modem- Inboard version- Sorting function (MSF)

DrivePossible options:- Belt drive (shown)- Direct drive- Direct flange- Hydraulic motor

Lifting magnet

Generator

Switch box

Fig. 1 iMAPLA system overview (shown: iMAPLA 17 “One Unit” with Stand-Alone-MMI)

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iMAPLA system descriptionSpecial properties

4.3 Special properties

The main distinguishing features of the iMAPLA system are as follows:

y Particularly fast and precise power development on the lifting magnet through quick magnetisation with impulse excitation.

y Extremely quick demagnetisation through automatic demagnetisation with countervoltage and sequence pulsation.

y Simple assembly of and flexible installation in combination with all common drive systems.

y Maintenance-free thanks to brush-less electronically controlled generator and self-protecting electronics system (in the event of disconnections, short circuit and loose connections).

y Controller adapts to different plate sizes automatically (“Plug & Play” installation).

y Visual display of all important functions and operating states on the MMI control unit.

y Integrated insulation monitor with the reporting of insulation faults. y Optional use of analogue measurement outputs and free assignment of

outputs, e.g. for acoustic or visual indicators (for MMI version “Inboard” only).

y Standard MMI programs for materials handling and sorting. Adjustable magnetic force and special programs for extended sorting (MMI Typ INT MSF).

y Backwards-compatible / plug compatible with all earlier iMAPLA systems. MMI control unit or service system tester can continue to be used.

y Overload-enabled / self-protecting from oversized or damaged lifting magnets.

y Optional additional CAN Bus connection which can be programmed application-specifically in accordance with Standard J1939. It is possible to establish a direct connection to the machine controller without the MMI. Contact the particular manufacturer for the specification (Option from iMAPLA series 2013 and later for all performance categories).

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iMAPLA system descriptionFunction description

4.4 Function description

4.4.1 Lift load (switch on lifting magnet)

After pressing the button (Joystick S1) on the MMI manual control unit, the generator sends a voltage out to magnetise the lifting magnet.

When switched on for the first time after a system start, the current that flows through the lifting magnet will increase relatively slowly, exponentially, until the rated current is reached. The rated voltage on the lifting magnet is approx. 230 V. Magnetisation without impulse excitation (up to 280 V).

Ö Fig. 2, Characteristic curve, “lifting”, page 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 of the lifting magnet. The electronic system continuously measures the current in the lifting magnet. The current measured before switch-off is saved and set as the rated current. It will later serve as the reference value for automatic demagnetisation when releasing the load and for the next energisation when lifting the next load.

The next time the lifting magnet is energised, the system uses the quick magnetisation with impulse excitation. Until the saved nominal current value is reached, a significantly higher voltage is generated across the lifting magnet (impulse excitation which can be up to 280 V d.c.).

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Magnetisation is completed a lot earlier and the lifting magnet reaches its maximum tension force much earlier. Once the saved current value has been reached, the voltage is reduced to the rated value. As a result, the current in the lifting magnet remains constant until the load is released.

Ö Fig. 2, Characteristic curve, “lifting”, page 24

Magnetic force (corresponds to the flow 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)

During standard demagnetisation, the magnetic current also falls slowly, like an exponential function. The residual magnetism which persists for a long time means the lifting magnet needs a relatively long time to release the entire load.

Ö Fig. 3, Characteristic curve “release”, page 25

To accelerate the demagnetisation, the iMAPLA system uses an automatic demagnetisation process with countervoltage and sequence pulsation. This method also uses the reference current measured before starting for the first time.

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The iMAPLA system transmits an opposite voltage (negative nominal voltage) after the “release” command until the current in the lifting magnet is zero (“demagnetisation with countervoltage”).

The lifting magnet still has a residual magnetism until the current reaches zero. For this reason, the entire load may not have been released under certain circumstances.

To release the remaining load, 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 carried out a total of 5 times with the current halving each time.

Ö Fig. 3, Characteristic curve “release”, page 25The magnetic field is reduced to zero and the full load that is magnetised by the lifting magnet is released. This is referred to as “sequence pulsation”.

Magnetic force (corresponds to the flow of current)

Automatic demagnetisation with countervoltage and sequence pulsation

Normal demagnetisation

Release

Time

Fig. 3 Characteristic curve “release”

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4.4.3 Overload protection iMAPLA

The intelligent MAPLA system (iMAPLA system) has a sophisticated protection system which provides secure protection to the machine, generator control electronics, load cables and plug connection components against overcurrent caused by faults or excessive magnetic loads.

Magnetic voltage

230 V DC

max. permissible

rated current of MAPLA

Energisation phase

Measurement- and test phase

(teaching phase)

static stateTime t (sec)

The reduced output voltageprotects the generator and the

electronics system from overloading

The iMAPLA system limits the magnetic current

standard overloaded system

Fig. 4 Characteristic curve, overload protection

Thanks to the intelligent measurement procedure in the energisation phase, the characteristic 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 of the machine, the magnetic voltage will be reduced and the magnetic current adjusted to a nominal value. This is usually equivalent to the maximum current configured for the machine. This measurement procedure is repeated continuously during the working process. When the magnet warms up during the cyclic energisation, the electrical resistance of its coils will increase, which leads to a reduced rate of power input. The system intelligently increases the magnetic voltage in order to move the system to the maximum possible range of capacity / maximum current.

This safety function makes it possible to connect precisely adjusted sizes of magnet (lifting magnets corresponding to the rated power of the system). If the magnetic coil is very cold, the operation of an overload is safely controlled. The system is secured against partial short circuits of magnet windings or faults of the load.

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If the overload constraint is active, this is signalled to the machine driver on the MMI control unit.

ÖMMI operating- and fault displays, page 99

Newer MMI versions do not display the overload notification until the overload values are unmistakable (>110 % of the generator's rated power).In the event of a faulty lifting magnet / magnetic load, when the rated load of the machine (>130-140 % of the generator'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.


NoteIf the lifting magnets are very cold, the overload warning may light up on the MMI. However, this is only a warning from the system which always runs in a safe operating state.Once the lifting magnet heats up during cyclical energisation, the warning should go away after a time. Depending on the type of lifting magnet and the way of working, this may take from 5 to 25 minutes.In case of doubt, contact the nearest service contact or manufacturer.

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iMAPLA system descriptionGenerator drive types

4.5 Generator drive types

The iMAPLA generator can be driven in different ways. Installation and required components depend on the drive type

Ö Generator installation for iMAPLA 8, 13, 17 and 20, page 69 Ö Generator installation for iMAPLA 25 and 30, page 79

4.5.1 Drive via belt pulley

The generator is joined to the drive unit via a belt pulley and a belt. The belt drive is an especially simple and cost-effective means of transmission. It also offers the advantage that, by selecting the transmission ratio, it is possible to optimally adjust the speeds of the drive unit and generator to each other.

4.5.2 Direct drive

The shafts of the 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 avoid operating the generator at an under or overspeed which can impair the function of the generator or may even damage it.

4.5.3 Drive via direct flange

The shafts of the generator and drive unit are connected via a flange. 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 avoid operating the generator at an under or overspeed which can impair the function of the generator or may even damage it.

4.5.4 Drive via hydraulic motor

The generator is driven by a hydraulic motor. The hydraulic motor is fed from a hydraulic system. Do not operate the generator at an overspeed. Operating in overspeed can have negative effects on the operation of the generator or may cause damage it.

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iMAPLA system descriptionMMI control unit (stand-alone version)

4.6 MMI control unit (stand-alone version)

NoteThe information in this chapter only applies for the stand-alone version of the standard MMI.

Ö Options and accessories, page 147

4.6.1 General

MMI control device(MMI = Man-Machine-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 the cab within the driver's field of vision to allow him / her to monitor the indicated operating states.

The MMI has a check button for the insulation monitor as well as a switch to set the required operating mode.

Ö Set operating modes, normal mode and jog mode (machine handling and sorting operation), page 108

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4.6.2 MMI displays

The MMI control unit indicates all operating and fault states in the iMALPA system using LEDs.

1

2

3

4

5

6

10

7

8

9

11

Socket for the connection cables to the iMAPLA generator

10

11

9

Fig. 5 MMI control unit (stand-alone) and MMI displaysLED lit flashing

1 Operation indicator, MMI2 Operation indicator, lifting magnet (lift)3 Quick magnetisation running (release)4 Interruption Interface fault5 Overload limitation System fault6 Underspeed Overspeed7 Cyclic duration factor, lifting magnet8 Light sensor for the displays

4+5+6 Temperature warning, control electronicsonly when 100 %-LEDs flash at the same time

Insulation fault

9 Control button (s) connection via M12 4-pole connector10 Check button for insulation monitor

Switch top Switch bottom11 Normal / material handling mode [A] Sorting / Jog mode [B]

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Description of the individual displays ÖMMI operating- and fault displays, page 99

Summary of display values and fault blank codes for error localisation in the event of a system fault

Ö System fault, page 121 Ö Troubleshooting, page 116

4.6.3 MMI plug connections (default assignment)

Plug connection Socket on MMI Connector on the connection cable

RS232 interface to the generator

HARTING 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

63

52

41

1 BK Free

UART data BN 2 2 GY UART data

UART data GN 3 3 BU UART data

GND YE 4 4 GNYE GND

+15 V Input GY 5 5 BN +15 V Input

GND PK 6 6 Shielding GND

Fig. 6 Assignment of the RS232 interface on the MMI STD to the switch box

Socket on MMI type STD Connection cable to the control button

1 A/B switch INPUT 1 brown (not in use)2 Joystick S1 INPUT 2 white (Joystick

S1 Input)3 GND MMI 3 blue (not in use)4 +12 V OUTPUT (S1) 4 black

(Joystick +12 V Output)

Fig. 7 Connection assignment, control button

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4.6.4 Installation

The MMI is installed inside the cab within the driver's field of vision to allow him / her to monitor the indicated operating states.

> Either screw on with 4 screws or secure with the aid of a permanently magnetised plate affixed to the reverse side.

Ö Fig. 8, MMI dimensions and fastening dimensions (stand-alone version), page 32.

DangerRisk of injury and risk of damage!

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 system! ► The iMAPLA system may only be opened by the

manufacturer or a party authorised by it. ► Only carry out the work described in this manual.

Fig. 8 MMI dimensions and fastening dimensions (stand-alone version)

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iMAPLA system descriptionGenerator and controller

4.7 Generator and controller

1

9

8

2

3

4

5

6

7

1 Switch boxes with control electronics (completely cast)2 iMAPLA: generator controller

iMAPLA series 2013: insulation monitor (fully cast)3 Connection for MMI (RS232 interface)4 Connection for lifting magnet5 Cooling element for the switch box6 Cooling air inlet7 Fan wheel cover8 Attachment bracket (both sides)9 Drive shaft

Fig. 9 Generator iMAPLA 17 “One Unit” (example)

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5

1

234

6

117

8

9

10

1 Switch box with control electronics and generator controller2 Connection for generator3 Connection for MMI (RS232 interface)4 Connection for lifting magnet5 Cooling element6 Connection cable for the switch box7 Fan wheel cover with the cooling air inlet8 Drain hole for condensate water9 Attachment bracket (both sides)10 Drive shaft11 Eyebolt for lifting

Fig. 10 Generator iMAPLA 25 “External Unit” (example)

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4.7.1 Description

The generator is a brush-less, electronically controlled synchronous generator which is designed for continuous operation and is very speed-tolerant. As a result, it has a high service life, is maintenance-free and very free of interference. The ball bearings used in the generator are maintenance-free.Usual for the iMAPLA systems: the generator generates a 3-phase a.c. U-V-W (~AC) which becomes d.c. in the switch box for the magnetic voltage.

The generator housing is made from aluminium alloy resistant to see water and protected against splash water according to IP54. The switch box attached to the generator housing with the control electronics and the cables meet protection class IP65 when all of the connection cables have been inserted correctly. The switch box with the control electronics is connected with 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 directly to the foundation to two attachment brackets or is screwed onto rails which allows it to be moved (depends on the type of drive).

The cooling air is drawn in by the fan wheel on the rear side of the generator and across the housing, towards the front side, blown through the cooling profile.

The switch box contains the power electronics for turning the generator voltage into d.c. and for controlling the voltages and currents for the lifting magnet as well as the control electronics for the generator itself. The electronics is highly integrated in the latest C-MOS technology and built in SMD assembly of technology. Where required, the Powerboard can be fully sealed or painted using special coating processes and stuck together. These possible versions have been tried and tested in various shaker and field tests. As a result, the electronic circuits are especially vibration- and shock-proof.

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The task of the generator controller is to control the exciter current at different generator speeds so that the voltage emitted by the generator is constant. The necessary control parameters are firmly programmed ex works in the form of tables, similar to the characteristic diagram. The required / permissible exciter currents are set in these parameter tables for the various speeds (rotational frequencies). The generator controller does not need a separate current supply, as it is supplied by the generator.From iMAPLA series 2013 and later, the generator controller is integrated on the 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 insulation monitor is assembled in the switch box. This equipment monitors the generator windings, controller and the controlled components: load cable and lifting magnet. The system is operated in electrical separation mode. If the isolation value of one of the connected components falls below the permissible response value, the insulation monitor will indicate this, and block the machine from continued operation as a safety measure. Normally, the lifting magnet is automatically checked for isolation faults before operating with the built-in option (an ISO monitor). This function allows the early detection of faults or extensive damage to magnetic coils. An uncontrolled shut-down due to short circuits is thus prevented.

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4.7.2 Plug connections on the generator and switch box

The connector assignment for 132 (BG132) model generators each with a 2-pole assignment from 8 to 20 kW rated power:

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 UC2 C2 2

C3 C3 3

Generator V

C4 C4 4

Generator VC5 C5 5

C6 C6 6

Generator W

B1 B1 7

Generator WB2 B2 8

B3 B3 9

Generator F1+ B4 B4 10 Gen. controller F1+

Generator F2- B5 B5 11 Gen controller F2-

NC B6 B6 NC

Fig. 11 iMAPLA 8 to 17 and 20; plug connection generator switch box

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The connector assignment for 160 (BG160) model generators each with a 4-pole assignment with a rated power >=25 kW:

Generator Socket ongenerator

Cable forSwitch box

Switch box

Housing weight PE PE Housing weight

Generator U1 D1 D1 Generator U1Generator U2 D2 D1 Generator U2

Generator V1 C1 C1 Generator V1Generator V2 C2 C2 Generator V2

Generator W1 B1 B1 Generator W1Generator 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 model generator for >=25 kW has two isolated 3-phase star windings. These are kept in the switch box on two separate converters.For example: first winding, first phase U1/second winding, first phase U2 etc.

RTS data output

BK1 1

6 3

5 2

4 1

63

52

41

1 BK RTS data output

UART data BK2 2 2 GY UART data

UART data BK3 3 3 BU UART data

GND BK4 4 4 GNYE GND

+15 V Input BK5 5 5 BN +15 V Input

GND BK6 6 6 Shielding GND

Fig. 13 Assignment of RS232 interface to MMI on switch box

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The MMI interface is standardised by GTS on all switch boxes and is backwards-compatible. An old MMI and the system tester can be connected to the MAPLA, iMAPLA and the new iMAPLA 2013 series.

WarningRisk of accident if the lifting magnet is connected incorrectly!

y If the 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 the lifting magnet and generator controller is connected to the electricity supply. The reliable detection of external ISO errors in the lifting magnet is only possible when the connection is active.

Load cable (s) to the magnet Lifting magnet

blackGray

brownblue

gn/ge

Fig. 14 Connection assignment at the lifting magnet output, iMAPLA 8 to iMAPLA 20

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Load cable (s) to the magnet Lifting magnet

Gray

brown

black

blue

gn/ge

Fig. 15 Connection assignment at the lifting magnet output iMAPLA 25 and 30

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1 brown CAN-GND (shielding)

2 white CAN Low

3 blue CAN High

4 black MMI-GND Output

5 gray MMI +15 V Output

Fig. 16 Connection assignment CAN socket iMAPLA 2013 series

Information about the CAN connection y From the iMAPLA 2013 series, a CAN Bus connection is also provided

alongside the MMI interface. y The CAN connection has a sealed M12 5-pin socket with A encoding. y The CAN Bus is isolated from the generator potential via a double isolation

barrier. y The CAN GND and MMI GND must be connected separately and must not

be connected together. y By default, the CAN Bus is terminated internally with 120 Ohms. y CAN protocol according to Standard J1939 250Kbit Extended Identifier.

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iMAPLA system descriptionDimensions of the systems

4.8 Dimensions of the systems

Fig. 17 Dimensioned drawing iMAPLA 8 “One Unit”

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Fig. 18 Dimensioned drawing iMAPLA 8 “External Unit”

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178278

306

104

60

ø32k

6

10.5

27

216

12

253

162

132

354

513

M12 (4x)

528.5

ø258

Fig. 24 Dimensioned drawing iMAPLA 20

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Fig. 25 Dimensioned drawing iMAPLA 30 "One Unit

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iMAPLA system descriptionTechnical data

4.9 Technical data

4.9.1 Construction type “One Unit”

iMAPLA8

iMAPLA13

iMAPLA17

iMAPLA20

iMAPLA25/30

Generator principle Brushless electronic controlled synchronised generator (three-phase winding)

Nominal output 8 kW 13 kW 17 kW 20 kW 25/30 kWNominal voltage 230 VSurge voltage 280 VRated current 34.7 A 56.5 A 73.9 A 87 A 108/130 APermissible speed range

2800 to 4500 min-1 2100 to 3600 min-1

Permissible cyclic duration factor

100 % (continuous operation)

Protection class IP54 (Generator)/IP65 (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.

Ö References to standards and directives, page 17

Operating conditions Free cooling air feed, unrestricted cooling air discharge, max. temperature of the sucked cooling air 40 °C; at installation heights <1,000 mean sea level (otherwise, a reduction in output of 1 % per 100 m over 1,000 mean sea level)

Possible drive types Belt drive, direct drive, direct flange, hydraulic motorCaution! Observe the manufacturer's instructions and regulations.

Model 132 160Dimensions in mm with shaft (length x width x height)

447 x 327 x 457

508 x 327 x 457

588 x 327 x 458

698 x 354 x 513

776 x 388 x 565

Weight (mass): 64 kg 75 kg 96 kg 121 kg 196 kg

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iMAPLA system descriptionTechnical data

4.9.2 Construction type “External Unit”

iMAPLA8

iMAPLA13

iMAPLA17

iMAPLA25

Generator principle Brushless electronic controlled synchronised generator (three-phase winding)

Nominal output 8 kW 13 kW 17 kW 25 kWNominal voltage 230 VSurge voltage 280 VRated current 34.7 A 56.5 A 73.9 A 108 APermissible speed range

2800 to 4500 min-1 2100 to 3600 min-1

Permissible cyclic duration factor

100 % (continuous operation)

Protection class IP54 (Generator)/IP65 (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.

Ö References to standards and directives, page 17

Operating conditions Free cooling air feed, unrestricted cooling air discharge, max. temperature of the sucked cooling air 40 °C; at installation heights <1,000 mean sea level (otherwise, a reduction in output of 1 % per 100 m over 1,000 mean sea level) External switch box installed vertically with free convention cooling.

Possible drive types Belt drive, direct drive, direct flange, hydraulic motorCaution! Observe the manufacturer's instructions and regulations.

Model 132 160Dimensions in mm:Generator with shaft (length x width x height)Switch box (width x height x depth)

437 x 327 x 261

213 x 371 x 175

508 x 327 x 261

315 x 371 x 239

588 x 327 x 261

580 x 476 x 239

776 x 334 x 388

800 x 700 x 259

Weight (mass)- Generator- Switch box

48 kg14 kg

61 kg16 kg

80 kg35 kg

155 kg85 kg

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iMAPLA system descriptionGTS type designation and identification

4.10 GTS type designation and identification

The GTS MAPLA and iMAPLA series has a range of possibilities for identifying the existing components and components in use. Normally, information about the generation (iMAPLA or new iMAPLA 2013 series) of the controller (switch box) is needed for analysis or for ordering spare parts.

NoteIf you have technical or service requests, please 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 a rating plate which is securely attached in the vicinity of the plug connection or corrugated pipe connection on the housing profile. A 6-character serial number is also stamped into the profile housing of the generator.

123

456 7

8

91 ID number

2 Generator serial no.

3 Type designation

4 Magnetic voltage

5 Magnetic current

6 Nominal output

7 optimal generator speed

8 Order no.

9 Manufacturer: LOGO

Fig. 26 Example rating plate for a 13 kW iMAPLA generator

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Type designation, generator

DGGM (BL4) 13 - 2 - ZEZE = Twin-bearing versionEE = Single-bearing version

2 = Number of poles, generator (2=2-pole, 4=4-pole)

13 = Rated output in kW(BL4) = brushless exciter machine / exciter unit (BL4 = model 132, BL = model 160)

DGGM

DWGWG

= AC generator for lifting magnet applications (MAPLA & iMAPLA)

= Three-phase generator for mains power replacement applications (not MAPLA)

= Alternator for mains power replacement applications (not MAPLA)

Generator ID number

xxxx stands for the 4-digit generator ID e.g. 7677.xxxx = old MAPLA system, predecessor to the iMAPLA

generationsxxxx-INT13 = iMAPLA system,

position 13 indicates the power class in kW.xxxx-I13G2 = iMAPLA series 2013 (with CAN Bus),

position 13 indicates the power class in kW.

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4.10.2 Serial number switch box / controller

The serial number of the electrical controller / switch box is stamped into the cooling element on the plug side (connection side). This is used for the exact identification of the electronic components and its programmed software.

Serial number, iMAPLA switch box

Ø 1234 INT 13 - 2 ISO

ISO = fitted with optional insulation monitor

2 = number of poles, generator (2=2-pole, 4=4-pole) (if this entry is not present, the following generally applies: 8-20kW=2-pole, 21-30 kW 4-pole)

13 = programmed power class of iMAPLA in kWINT = iMAPLA indicator (INT)

1234 = Serial number of electronic controller (4 digits for iMAPLA)

Ø = hardware ID, switch box (Ø = newer version, not used for iMAPLA series 2013)

Serial number, iMAPLA 2013 series switch box (with CAN Bus)

12345 I13 G2 -2 ISO Uxx

Uxx = programmed CAN report of the controller (switch box)

ISO = fitted with optional insulation monitor

2 = Number of poles, generator 2=2-pole, 4=4-pole (if this entry is not present, the following generally applies: 8-20 kW=2-pole, 21-30 kW 4-pole)

G2 = Identification of the iMAPLA series 2013

I13 = I g iMAPLA Identification 13 g programmed power class of iMAPLA series 2013 in kW

(can also be less than the generator output)12345 = Serial number of electronic controller

(5 characters for iMAPLA series 2013)

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y Using switch boxes with a higher performance class than the generator is not allowed. Risk of permanent / creeping overload / overheating of the generator.

Note2-pole and 4-pole version iMAPLA controllers are only compatible with the connectors on the appropriate generator.

NoteFor test purposes or temporary use, controllers with smaller output classes can also be connected on larger generators (provided the connectors are compatible).The protection functions are always implemented in the connected switch boxes.Make sure that the connected lifting magnet is less than the smallest output figure for the system components (switch box and generator).

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4.10.3 Serial number, MMI control unit

There are a number of specially adapted MMI control units. To provide exact identification, two labels are fixed in the MMI font plate next to the manufacturer logo. The MMI type description is above the logo. The 6- or 8-digit serial number appears underneath the logo.

Possible MMI type descriptions

B13 INT STD

STD = version (here STD = Standard)INT = suitable for the iMAPLA series

(also backwards-compatible to existing MAPLA systems)B13 = MMI with fixed power class in kW

(this entry does not apply with the new MMI which is independent of the power class) B g MMI software version, program variant 13 g programmed power class in kW

NoteThe power class is not used for the new MMI. For this reason, this MMI can be used for any type of generator.The MMI functions are connector- and backwards-compatible with older MAPLA systems. The MMI system adapts automatically to the connected iMAPLA controller.The parameters are automatically read at the system start. Older MMIs can also be used on new controllers, but the scope of functionality may be reduced. The basic functions described in this manual are available, however.

NoteIf a power-specific MMI (e.g. B13) is in use, it will only be able to be used for the one power class of controller, e.g. 13 kW.In this regard, make sure the MMI power class and the power class of the controller match.

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Installation and commissioningGeneral safety instructions

5 Installation and commissioning

This chapter describes the installation and the commissioning of the iMAPLA system. The system may only installed by authorised and appropriately qualified technicians.Minor variations in procedures may arise depending on the MMI version. Reference is made to these deviations in the corresponding chapters of this manual.Variations arise during 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 installing, commissioning and operation of the generator and all of the applicable sections of this chapter and follow the instructions and information therein.

5.1 General safety instructions


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 system! ► The iMAPLA system may only be opened by the


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y Incorrectly installing the iMAPLA system can cause malfunctions or damage, or lead to dangerous situations. ► Before the installation of the iMAPLA system read this

operating manual completely and carefully, and follow the instructions herein.

► Assembly / disassembly of the iMAPLA system, maintenance, service and replacement work may only be carried out by authorised and qualified 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.

DangerDanger to life through modifications to the iMAPLA system

y Any modification, incorrect repair or use of unsuitable third party parts shall cause all warranty claims to lapse and the lapsing of the type approval according to the Equipment Safety Act (GSG) and the certification according to EU-/EEC directives.

y The manufacturer cannot assume any liability in such a case. ► Never make modifications to the iMAPLA system or

individual components. ► Only use third party parts expressly approved by the

manufacturer for the installation.

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y All work on the iMAPLA system, visual inspections for maintenance purposes or cleaning work during operation of the system can lead to potentially fatal injury through electric shock. ► Switch off the drive unit before all inspection or

maintenance work on the generator or switch box. ► Secure the drive unit before being switched on accidentally

(e.g. remove the ignition key and keep it in a safe place). ► During operation, never connect or disconnect plug

connections.




magnet.





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y The use of unauthorised third party parts can lead to malfunctions, damage or danger. ► Only use third party parts expressly approved by the



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 safely. After the shut-down, hazardous voltages may remain in and on the system for up to a max. 45 seconds.


y Always make sure during installation that the PE/PA connection (potential connection, usually green / 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. If this connection is not present, an installed insulation monitor may no longer be able to detect an insulation fault.

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Important

y The iMAPLA system is not suited for supplying fixed distribution systems.

y The iMAPLA system is designed for a specific output and speed. The system can be damaged by voltage peaks and overloads.

► The iMAPLA system must not 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. Never connect it with other power generation systems.

► Never connect multiple controllers / systems together.


ImportantThe iMAPLA system must only be used for supplying power to suitable lifting magnets. Follow the lifting magnet's manufacturer specifications.

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Installation and commissioningDelivery 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 y iMAPLA Generator with attached switch box y MMI y Connection cable, MMI switch box y Connection cable, switch box lifting magnet y Connection cable, MMI to control button

Construction type “One Unit” and MMI with radio modem y iMAPLA Generator with attached switch box y MMI with radio modem y Connection cable, switch box radio modem y Connection cable, switch box lifting magnet y Connection cable MMI to the control button / voltage supply

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Installation and commissioningInstallation of MMI

Construction type “External Unit” and Stand-Alone MMI y iMAPLA Generator y Switch box y MMI y Connection cable, MMI switch box y Connection cable, switch box lifting magnet y Connection cable, MMI to control button

Construction type “External Unit” and MMI with radio modem y iMAPLA Generator y Switch box y MMI with radio modem y Connection cable, switch box radio modem y Connection cable, switch box lifting magnet 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.

ÖMMI plug connections (default assignment), page 31 for stand-alone MMI

ÖMMI with radio modem, page 147

5.4 Installation of cables

Before the installation of cables, carefully read the entire chapter as well as the safety instructions in Chapter 2 and follow the given instructions and regulations.

Ö Safety instructions, page 10

Connection and pin assignment Ö Overview of cables, System overview, page 19. Ö Plug connections on the generator and switch box, page 37 ÖMMI control unit (stand-alone version), page 29 Ö Plug connections, MMI and radio modem, page 149

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Installation and commissioningInstallation of cables

5.4.1 Pre-assembled cables, supplied

Use the pre-assembled cables ex works which are supplied. These cables were specially selected for the requirements in such systems and carefully inspected and, therefore, offer the best-possible guarantee of a fault- and fault-free operation.

If the supplied cables are not used, you must read the chapters “Requirements for supply cables” and “Information for Han modular connectors”.

Ö Requirements on the connection cables, page 66 Ö Information for Han modular connector cables switch box lifting magnet, page 67

The connection cable between MMI and control button is delivered with an open cable end for the connection to the control button and a fully-assembled connector plug for the connection to the MMI.

The connection cable between the switch box and the MMI (for MMIs with radio modem: between the switch box and radio modem) as well as the connection cable for the lifting magnet are completely supplied fully preassembled with plugs.

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5.4.2 Rules for cable installation

Install all the cables according to the mechanical requirements in a way which prevents them from getting damaged!

Secure the cables sufficiently according to the requirements. Where necessary, provide suitable strain relief!

Do not install the cables without taking suitable measures to protect them from damage or 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 With flexible installation: Rmin. = 10 x 0 y With permanent installation: Rmin. = 4 x 0

5.4.3 Requirements on the connection cables

As usual, select all connection cables in accordance with the electrical and mechanical requirements.

Only use the supplied cables which were pre-assembled in the factory, or cable types expressly permitted by GTS.

Minimum requirements for the cables used y UV-resistant, y abrasion resistant, y highly-flexible, y oil-resistant, y resistant to high alternating bending stress.

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Requirements for the connection cables between generator and lifting magnet

Minimum cross sections y iMAPLA 8: 5 x 4 mm² Cu y iMAPLA 13: 5 x 4 mm² Cu y iMAPLA 17: 5 x 6 mm² Cu y iMAPLA 20: 5 x 6 mm² Cu y iMAPLA 25 and 30: 5 x 10 mm² Cu y Maximum line length: 30 m

Information for Han modular connector cables switch box lifting magnet

NoteOnly use the Han axial screw-on module in articulated frames.

Features y 2 contact inserts for power circuits y Contact pin for PE y Pin insert with additional protective collar y Polarisation of the module y Axial screw-on connection system y For larger external cable diameters incl. isolation, max. 10.5 mm Ø

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Specifications

Regulations DIN VDE 0627DIN VDE 0110

Contact insertsNumber of contacts 4 + PERated current max. 40 ARated voltage 1000 VTest voltage Ueff 4 kVContamination level 3 (C)Insulation resistance ≥ 1010 MegaOhmMaterial PolycarbonateTemperature range -40 °C ... +125 °CFlammability to UL 94 V 0Mechanical life (mating cycles) ≥ 500Rated voltage to UL/CSA 600 V

ContactsMaterial Copper alloySurface (hard silver coated) 3 µm AgVolume resistance ≤ 0.5 mΩAxial screw-on connection 2.5-10 mm²AWG 13-7Tightening torque 1 Nm

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Installation and commissioningGenerator installation for iMAPLA 8, 13, 17 and 20

5.5 Generator installation for iMAPLA 8, 13, 17 and 20

y To install the generators, proceed according to the descriptions in this chapter.

y Prior to installation, read the safety instructions attentively and follow the instructions and information therein.

Ö General safety instructions, page 58The generator installation is very much the same for the “One Unit” and “External Unit” construction 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 types vary.

WarningRisk of accident and injury!

y Incorrectly attached lifting gear can cause accidents. ► Follow the instructions in the Lifting generators and switch

boxes chapter. Ö Lifting generators and switch boxes, page 144

► When using lifting gear on the generator, only use the provided attachment points.

► Only use suitable lifting equipment.

Important y Installation of the switch box for “External Unit” systems Ö Installation of the switch box, construction type “External Unit”, page 92

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5.5.1 Requirements on the installation position

iMAPLA Generators “One Unit” construction typewith attached switch box

y Do not assemble the “One Unit” type in the engine compartment.

iMAPLA Generators “External Unit” construction typewith a separate switch box

y Do not expose the External Unit type to the radiation range of heat sources (e.g. exhaust pipes). If no other installation site is available, the generator must be partitioned using suitable insulation- or bulkhead plates against the radiant heat.

y The flow of cooling air in the generator must not be deflected or restricted by the flow of air in the main fan of the engine.

y In each case, the generator switch box must be outside of the engine compartment.

y The iMAPLA generator is protected against spray water according to IP54 and may also be secured to the outside of the vehicle.

y The rotational direction of the generator is not important for its operation. It can be operated in the clockwise- and anti-clockwise direction.

Install the generator safely and securely on a 100 % level surface with a load-bearing capacity adequate for the weight class of the generator. Mount generators with a belt drive on rails or provide other means for adjusting the belt tension.

Important y Install the generator in a way which makes accidental spraying

with high-pressure cleaners impossible. y The installation site must be low-vibration. y Choose an installation location through which it is ensured

that sufficient ventilation is provided at all times, where, if possible, the cooling air temperature does not exceed 40 °C.

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5.5.2 Permissible installation positions

The generator must be monitored on a horizontal surface standing on the attachment brackets as shown.

In the normal installation position, the plug attached to the generator lies on the side of the generator. The generator can also be installed rotated by 90° from the central position.

Note y The generator 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 position Ö Permissible installation positions, page 71

Assemble the two attachment brackets into the appropriate mounting profiles on the generator housing.

Important y Minimum clearances to the cooling unit must be kept. ÖMinimum clearances and cooling provisions, page 72

During assembly, observe the minimum clearances and specifications for cooling in the following chapter.

Ö Dimensions of the systems, page 42 Ö Dimensions of the systems, page 42

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y Secure the generator with at least four mounting screws (minimum M8 or comparable, bolt grade min. 8.8).

y The attachment must be permanent and resistant to shock and vibrations.

y Use suitable means to prevent the screws from coming undone by themselves, e.g. via a tension ring according to DIN 128.

Tightening torque for mounting screwsM = 25 NmPermissible load on the shaftFrmax = 2,000 N for iMAPLA 8 and 13Frmax = 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 13Famax = 380 N for iMAPLA 17 and 20

Important ►Do not attach any third party parts to the mounting profiles on the generator housing.

5.5.4 Minimum clearances and cooling provisions

y The generator needs sufficient ventilation for cooling. The cooling air is drawn through the cooling profiles by the fan wheel on the rear side of the generator and across the housing, towards the front side.

y Ensure adequate air feed and exhaust openings. y Comply with the following minimum clearances and note the regulations

for cooling.

4 Mounting screws

Fr

Fa

max

max

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Minimum clearancesWhen installing, respect the following minimum clearances from fixed parts or walls

Ö adjacent figures

y Both sides and above: a = 100 mm y Front: w = 200 mm y Rear: c = 170 mm

Temperature and pressures of the cooling air

Important y A cooling air feed above 40 °C can lead to power restrictions;

in extreme cases it can cause damage to the generator. ► The temperature of the supplied cooling air should not

exceed 40 °C.

y A maximum underpressure of Pmax. = 4 Pa is allowed in the suction path of the cooling air, otherwise, a sufficient quantity of cooling air cannot be drawn in.

y In the blow-out area of the cooling air on the front side, a maximum overpressure of Pmax. = 7 Pa may arise as otherwise there will not be sufficient circulation of the cooling air.

Important ►Do not impair the circulation of the cooling air with other air flows (e.g. from the front or from the side).

Tmax

c

b

= 7 PaP

= 40˚C

max

= 4 PaPmax

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5.5.5 Assembly instructions for belt drive


y Open drive belts and pulleys are a hazard. ► Never operate the generator without

a protective covering. ► Never reach into a drive belt while it is

running.

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 the belt pulley. > Prevent this screw from being undone

accidentally by placing a suitable locking washer underneath it.

y Threaded hole in the shaft: M10 x 25 mm y Tightening torque: M = 50 Nm y 50 mN bolt grade 8.8

Important ►The axis of the power shaft must run absolutely parallel to the axis of the generator. ►The belt pulleys of both axes must lie flush to each other so that the belt runs absolutely straight.

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Important ►The drive belt must not sag loosely.

When using narrow belt pulleys of type SPA, the clearance between the axes must not exceed 600 mm. For permissible axis clearances for other belts, ask the manufacturer.

Note ►For systems iMAPLA 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 shaftFrmax = 2,000 N for iMAPLA 8 and 13Frmax = 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.

If the belt pulley attachment to the shaft is placed further out, reduce the tension of the belt accordingly in order to balance out the increased leverage effect on the shaft.

F max = 2000 N

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5.5.6 Assembly instructions for flange mount SAE5

Preparatory disassembly Ö Fig. 27, Preparatory disassembly of the flange mount (iMAPLA 8 and 13), page 76

> Unscrew two M8 x 45 screws [2], wrench size 10 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 Ö Assembly of flange mount SAE5 (iMAPLA 8,13,17 and 20), page 77

> Place the flange [2] onto the generator and secure with four screws [4a]. Apply Loctite to the screw thread and place a toothed washer [4b] underneath the screw head.

> Place the collar [2] and clamp securely with two screws. > Mount the coupling plate [5] on the shaft at the generator and prevent it

from twisting on the shaft with a key.

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> Secure the drive side of the coupling [6] to the drive and insert it into the coupling plate. If necessary, while inserting, twist slightly until the gearing locks.

> Secure the flange [1] to the drive unit.

4b

M12x30DIN912DIN128A-12

6 5

4a(4x)

4b

1

2

4a4a M12 x 30 DIN 9124b DIN 128 A-12

Fig. 28 Assembly of flange mount SAE5 (iMAPLA 8,13,17 and 20)

5.5.7 Assembly instructions for hydraulic drive

Preparatory disassembly > Carry out the preparatory disassembly on the generator. Ö Assembly instructions for flange mount SAE5, page 76

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Assembly Ö Fig. 29, Assembly of the flange mount for the hydraulic drive (using iMAPLA 13 as an example), page 78

> Place the flange [2] onto the generator and secure with four screws [4a]. > Place a toothed washer [4b] underneath the screws and secure with

Loctite. > Place the collar [1] and clamp securely with two screws. > Mount the first half of the coupling [5] on the 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 hydraulic motor [8] with washer [6] and the second half of the

coupling on the generator. Where necessary, turn the coupling slightly to ensure the gearing locks.

> Place toothed washers [7b] to eight screws [7a] and secure disk [6] to the flange [2].

> Place the collar [9] onto the coupling unit and tighten firmly with two screws.

4a M12 x 35 DIN 9124b Spring lock washer DIN 128 A-127a M8 x 30 DIN 9127b Spring lock washer DIN 128 A-8

Fig. 29 Assembly of the flange mount for the hydraulic drive (using iMAPLA 13 as an example)

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Installation and commissioningGenerator installation for iMAPLA 25 and 30

5.6 Generator installation for iMAPLA 25 and 30

y To install the generators, proceed according to the descriptions in this chapter.

y Prior to installation, read the safety instructions attentively and follow the instructions and information therein.

Ö General safety instructions, page 58The generator installation is very much the same for the “One Unit” and “External Unit” construction 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 types vary.

WarningRisk of accident and injury!

y Incorrectly attached lifting gear can cause accidents. ► Follow the instructions in the Lifting generators and switch

boxes chapter. Ö Lifting generators and switch boxes, page 144

► When using lifting gear on the generator, only use the provided attachment points.

► Only use suitable lifting equipment.

Important y Installing the switch box for “External Unit” systems Ö Installation of the switch box, construction type “External Unit”, page 92

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iMAPLA Generators “One Unit” construction typewith attached switch box

y Do not assemble the “One Unit” type in the engine compartment.

iMAPLA Generators “External Unit” construction typewith a separate switch box

y Do not expose the External Unit type to the radiation range of heat sources (e.g. exhaust pipes). If no other installation site is available, the generator must be isolated from radiant heat using suitable insulation- or bulkhead plates.

y The flow of cooling air in the generator must not be deflected or restricted by the flow of air in the main fan of the engine.

y The generator switch box must be situated outside the engine compartment.

y The iMAPLA generator is protected against spray water according to IP54 and may also be secured to the outside of the vehicle.

y The rotational direction of the generator is not important for its operation. It can be operated in the clockwise- and anti-clockwise direction.

Install the generator safely and securely on a 100 % level surface with a load-bearing capacity adequate for the weight class of the generator. Mount generators with a belt drive on rails or provide other means for adjusting the belt tension.

Important y Install the generator in a way which makes accidental spraying

with high-pressure cleaners impossible. y The installation site must be low-vibration. y Choose an installation location through which it is ensured

that sufficient ventilation is provided at all times, where, if possible, the cooling air temperature does not exceed 40 °C.

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5.6.2 Permissible installation position

The generator must be monitored on a horizontal 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 switch boxes (controller) can be requested directly from the manufacturer.

All other installation positions are prohibited! Do not install the generator in a rotated position!

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5.6.3 Assembly (iMAPLA 25 and 30)

During assembly, observe the minimum clearances and specifications for cooling in the following chapter.Generator dimensions

ÖMinimum clearances and cooling provisions, page 82

Secure the generator with at least four mounting screws (minimum M12 or comparable, bolt grade min. 8.8). The attachment must be permanent and resistant to shock and vibrations. Use suitable means to prevent the screws from coming undone by themselves, e.g. via a tension ring according to DIN 128.

y Tightening torque for mounting screws: M = 87 Nm

y Permissible load of the shaft: Frmax = 5,000 N (measured in 60 mm axial clearance from the point where the shaft exits the bearing plate) Famax = 500 N

Important ►Do not attach any third party parts to the mounting profiles on the generator housing.

5.6.4 Minimum clearances and cooling provisions

y The generator needs sufficient ventilation for cooling. The cooling air is drawn through the cooling profiles by the fan wheel on the rear side of the generator and across the housing, towards the front side.

y Ensure adequate air feed and exhaust openings. y Comply with the following minimum clearances and note the regulations

for cooling.

4 Mounting screws

Fr

Fa

max

max

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Minimum clearancesWhen installing, respect the following minimum clearances from fixed parts or walls.

Ö Adjacent figures

y Both sides and above: a = 100 mm y Front: w = 300 mm y Rear: c = 200 mm

Temperature and pressures of the cooling air

Important y A cooling air feed above 40 °C can lead to power restrictions;

in extreme cases it can cause damage to the generator. ► The temperature of the supplied cooling air should not

exceed 40 °C.

y A maximum underpressure of Pmax. = 4 Pa is allowed in the suction path of the cooling air, otherwise, a sufficient quantity of cooling air cannot be drawn in.

y In the blow-out area of the cooling air on the front side, a maximum overpressure of Pmax. = 7 Pa may arise as otherwise there will not be sufficient circulation of the cooling air.

Important ►Do not impair the circulation of the cooling air with other air flows (e.g. from the front or from the side).

Tmax

c

b

= 7 PaP

= 40˚C

max

= 4 PaPmax

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5.6.5 Assembly instructions for belt drive


y Open drive belts and pulleys are a hazard. ► Never operate the generator without

a protective covering. ► Never reach into a drive belt while it is

running.

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 the belt pulley. > Prevent this screw from being undone

accidentally by placing a suitable locking washer underneath it.

> Threaded hole in the shaft: M16 x 35 mm. > Tightening torque: M = 200 Nm.

Important ►The axis of the power shaft must run absolutely parallel to the axis of the generator. ►The belt pulleys of both axes must lie flush to each other so that the belt runs absolutely straight.

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Important ►The drive belt must not sag loosely.

When using narrow belt pulleys of type SPA, the clearance between the axes must not exceed 800 mm. For permissible axis clearances for other belts, ask the manufacturer.

Note ►For narrow V belts/V-belts of type XPB, a 2x belt is needed for the iMAPLA 25 and 30 systems.

Maximum tension force (tension) of the drive belt on the shaftFmax = 5,000 N at a max. 60 mm axial clearance from the point where the shaft exits the bearing plate. The belt tension must not exceed a radial force of 5,000 N at a max. axial clearance of 60 mm from the point where the shaft exits the bearing plate. If the belt pulley attachment to the shaft is placed further out, reduce the tension of the belt accordingly in order to balance out the increased leverage effect on the shaft.

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5.6.6 Assembly instructions for flange mount SAE5

Preparatory disassembly Ö Fig. 30, Preparatory disassembly of the flange mount SAE5 (iMAPLA 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 Ö Fig. 31, Assembly of flange mount SAE5 (iMAPLA 25 and 30), page 87

> Place the flange [1] onto the generator and secure with four screws [2a]. > Apply Loctite to the screw thread and place a toothed washer [2b]

underneath the screw head. > Mount the coupling plate [3] on the shaft at the generator and prevent it

from twisting on the shaft with a key.

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> Secure the drive side of the coupling [4] to the drive and insert it into the coupling plate. If necessary, while inserting, twist slightly until the gearing locks.

> Secure the flange [1] to the drive unit.

2a

2b

M12x35DIN912

DIN128A-12

4 3

2a

2b

1

4x

2a M12 x 35 DIN 9122b A-12 DIN 128

Fig. 31 Assembly of flange mount SAE5 (iMAPLA 25 and 30)

5.6.7 Assembly instructions for hydraulic drive

Preparatory disassembly Ö Fig. 30, Preparatory disassembly of the flange mount SAE5 (iMAPLA 25 and 30), page 86

> Carry out the preparatory disassembly on the generator. Ö Assembly instructions for flange mount SAE5, page 86 Ö Fig. 30, Preparatory disassembly of the flange mount SAE5 (iMAPLA 25 and 30), page 86

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Assembly Ö Fig. 32, Assembly of flange mount hydraulic drive (iMAPLA 25 and 30), page 88

> Place the flange [1] onto the generator and secure with four screws [2a]. Place a toothed washer [2b] underneath the screws and secure with Loctite.

> Mount the first half of the coupling [3] on the shaft at the generator and prevent it from twisting on 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

coupling to the generator. Where necessary, turn the coupling slightly to ensure the gearing locks.

> Place toothed washers [5b] to eight screws [5a] and secure disk [4] to the flange [1].

> Place the collar [7] onto the coupling unit and tighten firmly with two screws.

8x

4x

2a

2b

5a

5b

M12x40 DIN912DIN

128 A-12

M8x30 DIN912

DIN128 A-8

76

5a5b 4 3

2a 2b 1

2a M12 x 40 DIN 9122b A-12 DIN 1285a M8 x 30 DIN 9125b A-8 DIN 128

Fig. 32 Assembly of flange mount hydraulic drive (iMAPLA 25 and 30)

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Installation and commissioningArrangement of the hydraulic drive

5.7 Arrangement of the hydraulic drive

5.7.1 Calculation for hydro-drive for GTS iMAPLA generators

These calculation principles are relevant to the use of hydraulic axial piston engines. The feed performance of the hydraulic pump can be found from the central hydraulic systems or other components, such as the hammer piping. Contact the manufacturer of the machine for the connections and characteristic data.

WarningDanger to life through falling loads!

y Power breakdown with a non-prioritised flow rate. 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 nominal current due to an underspeed on the generator. Parts can fall in an uncontrolled fashion! ► To ensure the hydraulic drive runs safely, the flow rate to the

generator drive must be prioritised.

Data required: feed performance of the hydraulic pump in [ l/min ]max. delivery pressure of the pump, max. in [ bar ]max. (peak) power or torque absorption of the generator shaft

flowing flow rate through the motor: in [l/min]

with displacement in [ cm3/revs. ] with speed [ revs./min ]with volumetric efficiency in [ %/100 ] caused by inner and outer leak losses in the engine, etc.

Speed of the motor: in [l/min]

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Installation and commissioningArrangement of the hydraulic drive

applied torque of the motor: in [Nm]

with the pressure difference between the input and output of the hydro-motor calculated in [bar] e.g. via Pump in total - backing-up valve - counter-pressure tank in bar and with the hydraulic / mechanical efficiency of the hydro-motor in [ %/100 ] caused by losses due to friction, etc.

applied output from the motor to the shaft: in [Watt]

with the overall efficiency 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-MotorsGTS offers options in the arrangement of the hydraulic drive through the use of special flow rate control valves. The indicated working pressures and volume flows in the table are to be used using the SunFab axial piston hydraulic motors (optionally also) offered by GTS. Other motor types can also be adapted by a variable assembly of plate and a variety of couplers. Contact GTS special adjustments and special layouts and special layouts.

Ö Overview table for the operation of a GTS iMAPLA on SunFab hydraulic motor generator types: BG132 2-pole and BG160 4-pole., page 91

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G16

0 4p

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net

pow

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kW

mag

net

volta

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t pow

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247

(fram

e si

ze a

nd n

um. o

f pol

es)

need

ed m

engt

h of

oil (

flow

rate

) in

liter

/min

ute

with

a h

ydra

ulic

mot

or d

ispl

acem

ent o

f ccm

/rev.

and

type

of g

ener

ator

need

ed fl

ow p

reas

sure

(diff

eren

ce b

etwe

en in

put/o

utpu

t)di

rect

ly at

the

hydr

aulic

mot

or in

bar

with

a h

ydra

ulic

mot

or d

ispl

acem

ent o

f ccm

/rev.

and

type

of g

ener

ator

with

type

of g

ener

ator

rate

d ge

nera

tor s

peed

for

hydr

aulic

cal

cula

tion

in rp

m

NO

TE:

At fl

ow p

ress

ures

upp

er th

an 2

00 b

ar, t

here

are

spe

cial

hig

h pr

essu

re c

ompo

nent

s re

quire

d. T

he p

ress

ure

valu

es a

re c

alcu

late

d w

ith-

out a

ny lo

sses

of p

ress

ure

in th

e lin

e sy

stem

, tan

k ba

ck p

ress

ure,

oil

cool

er u

nit a

nd a

n op

tiona

l bac

k pr

essu

re v

alve

. In

this

tabl

e on

ly

the

diffe

renc

e pr

essu

re o

f the

hyd

raul

ic m

otor

inpu

t/out

put t

erm

inal

is li

sted

.

Overview table for the operation of a GTS iMAPLA on SunFab hydraulic motor generator types: BG132 2-pole and BG160 4-pole.

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Installation and commissioningInstallation of the switch box, construction type “External Unit”

5.8 Installation of the switch box, construction type “External Unit”

Install the switch box according to the descriptions in this chapter.Prior to installation, read the safety instructions in chapter 2 attentively and follow the instructions and information therein.

Ö Safety instructions, page 10.

WarningRisk of accident and injury

y Incorrectly attached lifting gear can cause accidents. ► When using lifting gear on the generator, only use the

provided attachment points. ► Only use suitable lifting equipment.


y The switch box must not be installed inside the engine compartment. y It must not be mounted in an area of trapped heat nor must air be allowed

to flow through it, e.g. air blown out of the engine compartment. y The switch box must be mounted so that the cooling vanes are vertical

and to ensure unobstructed air convection through the cooling vanes. The cooling vanes must not be covered.

y The switch box must be installed with spray water protection and to make it impossible to spray the switch box with a high-pressure cleaner. When using the covering and rain covers provided by the manufacturer, the switch box is also allowed to be mounted outdoors.

y The switch box must be mounted firmly and securely on a level base with a load-bearing capacity sufficient to support the weight of the switch box.

y The switch box is mounted on a vertical surface for iMAPLA 8 and 13. y For iMAPLA 17 to 20, the supporting frame of the switch box is mounted

on a horizontal surface. y The installation site must be low-vibration. Choose an installation site

for which adequate ventilation is guaranteed at all times where the temperature of the cooling air does not exceed 40 °C.

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Installation and commissioningInstallation of the switch box, construction type “External Unit”

5.8.2 Permissible installation site for a switch box

The switch box must be mounted so that the cooling vanes are vertical and to ensure unobstructed air convection through the cooling vanes.The plug connections on the switch box must face down in the installation position.

Other 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 instructions and regulations.

Ö Installation of cables, page 64.

On the switch boxes for iMAPLA 8, iMAPLA 13, iMAPLA 17, the connection cable is firmly connected to the switch box and has a connector plug for the generator.On the iMAPLA 20 and 25 system, the connection cable is securely connected to the generator and has a connector plug for the switch box.

ok

iMAPLA 8 + 13

ok

iMAPLA17+25iMAPLA 17,

20 and 25

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Installation and commissioningCommissioning

5.9 Commissioning

CAUTIONIn addition to the work given here, checks on the drive system may be necessary as set out in the requirements and regulations of the drive / system manufacturer. This also contains the proper attachment of protective covers. This work must be performed by the person responsible for the machine.

Before commissioning of the iMAPLA system for the first time, carry out the following checks. Remove any defects before commissioning. Before commissioning, read and follow the safety instructions in the General chapter.

Ö General safety instructions, page 58.

> Make sure the performance data of the connected lifting magnet match the data of your iMAPLA system.

> Make sure the generator is mounted correctly and firmly. Ö Generator installation for iMAPLA 8, 13, 17 and 20, page 69 Ö Generator installation for iMAPLA 25 and 30, page 79 ÖMake sure that the protection covers of the generator drive and the drive itself are mounted correctly.

> Make sure that the MMI is mounted correctly and in the driver's field of view.

Ö General, page 29 > Make sure that all connecting cables are correct and are installed correctly

and protected against the mechanical requirements. Ö Installation of cables, page 64.

> Make sure that all connector plugs are plugged in correctly. > Make sure that the connecting cables between MMI and the control

button are properly connected to the control button unit (joystick). > Make sure that the total machine meets the requirements of all the

applicable directives. > Start the system. Ö Establish the system’s readiness for use, page 106.

> Check the correct function of the system by comparing it with the description.

> Acknowledge the first start-up in the commissioning report. Ö Commissioning, page 157

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OperationSafety instructions for operation

6 Operation

This chapter describes the operation of the iMAPLA system. Minor variations in the operating procedures may arise depending on the MMI version. Reference is made to these deviations in the corresponding chapters of this manual.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).Before using the system, read the safety instructions in this chapter and follow the instructions and information therein.

6.1 Safety instructions for operation


y During operation, the power generation system generates voltages that are potentially fatal. ► Work on the electrical installations and equipment must

only be carried out after the system has been switched off and is de-energised.

► Switch off the drive unit before all inspection or maintenance work on the generator or switch box. Secure the drive unit before being switched on accidentally (e.g. remove the ignition key and keep it in a safe place).

► During operation, never connect or disconnect plug connections.



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y A loss of drive power always leads to the uncontrolled release of the lifted load from the lifting magnet. ► The machine operator must check that there is sufficient

drive power, and establish the operational reliability of the drive before commissioning.




magnet.





y An energised lifting magnet suspended in the air can attract unwanted material to it. ► Never switch on the lifting magnet when it is not needed

for the work.

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CautionBurn hazard


touching.

Important y The 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 for repairs.

Ö Daily inspection of the insulation monitor, page 107 Ö Repairs / repair, page 141

CAUTION y Only operate the iMAPLA system under the indicated environment- and

cooling conditions. y Observe the technical data.

Ö Technical data, page 51

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OperationOperating instructions

6.2 Operating instructions

The iMAPLA system offers the highest levels of efficiency in material handling as a result of the quick magnetisation and demagnetisation times. As a result, the time for the full magnetisation of the large lifting magnets can take up to 4 seconds.

For ensuring maximum efficiency when working with the iMAPLA system, do not switch on the lifting magnet after the lifting magnet is placed onto the material to be lifted and not while it is still in the air. In this way, a higher load attachment with impulse excitation is achieved as a result of the quick magnetisation used in the iMAPLA system as the material (induced by a higher acceleration) on the lifting magnet is compacted higher.

Procedures when switching the lifting magnet on and off. Ö Function description, page 23

Follow the operating conditions and only operate the system under these operating conditions.

Ö Operating conditions, from page 46.

NOTE y If a MMI with radio modem is used, a delay of approx. 0.1-0.5 secs may

arise between the pressure on the operator pushbutton and the response of the system due to technical reasons.

y There are MMI versions without a switching option in Jog mode. In this case, the switch on the right-hand side of the MMI is missing. In the MMI description, check whether the “Jog mode” function is available.



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OperationMMI operating- and fault displays

6.3 MMI operating- and fault displays

The MMI control unit indicates all operating and fault states in the iMALPA system using LEDs.

1

2

3

4

5

6

10

7

8

9

11

Fig. 33 MMI displays

LED lit flashing1 Operation indicator, MMI2 Operation indicator, lifting magnet (lift)3 Quick magnetisation running (release)4 Interruption Interface fault5 Overload limitation System fault6 Underspeed Overspeed7 Cyclic duration factor, lifting magnet8 Light sensor for the displays

4+5+6 Temperature warning, control electronicsonly when 100 %-LEDs flash at the same time

Insulation fault

9 Control button (s) connection via M12 4-pole connector10 Check button for insulation monitor

Switch top Switch bottom11 Normal / material handling mode [A] Sorting / Jog mode [B]

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LED 1Green

Operation indicator, MMIThe LED is lit

y Supply voltage present for MMI.The system is switched on and ready for use, the generator is running.Note:The MMI can also be powered by an external power supply.(For example on systems adapted to specific customer needs or with an MMI with radio modem).In this case, the LED only indicates the supply voltage to the MMI, not the functioning of the generator.

LED 2Yellow

Operation indicator lifting magnetThe LED is lit

y The lifting magnet is switched on (lift).The LED lights up when the lifting magnet is switched on.The LED flashes when working in safe mode during magnetisation (slab handling at an initially reduced tension force). The LED will light up continuously once the max. pulling force was requested.NoteIf the LED lights up for approx. 1-2 seconds after lighting up before going on or if LED 4 lights up, this means the connection cable on the lifting magnet is not plugged in or the connection is broken.

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LED 3Yellow

Quick magnetisationThe LED is lit

y Quick magnetisation of the lifting magnet is activated. Ö “Release”

The LED lights up during quick magnetisation.The LED goes out once quick magnetisation has been fully completed.The LED goes out when quick magnetisation is terminated.The LED flashes when the operator requested a slow release (extended sorting) which causes the material to drop very slowly in a controlled fashion.NoteThe lifting magnet can continue to be magnetised for some time - this is because demagnetisation proceeds significantly more slowly.Note:In Jog mode, quick magnetisation is not used and not indicated on the MMI.

LED 4Orange

The LED is lit: interruption 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 whether current is flowing through the lifting magnet. Without a flow of current, the lifting magnet will be switched off again after approx. 1-2 seconds - the LED will light up.The LED goes out when the fault is no longer active after the machine is switched on again.When the magnetic connection monitor is optional, it can be measured as to whether a lifting magnet was connected in advance. The LED interruption already lights up immediately after pressing the button when the switch-on command is issued and goes out automatically once a magnet is connected.The LED is flashing: interface fault

y A fault occurred on the interface between MMI and the controller.

Ö Interruption, page 118

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LED4+5+6

Multi-function / assignment:The LEDs flash at the same time: insulation fault

Ö Insulation faults arose, page 124LED4+5+6

LED 4+5+6 light up and 100 %-LED flashesTemperature warning, control electronics

Ö Temperature for control electronics exceededLED 5Red

Fault indicatorThe LED is lit: overload limitation

y The connected lifting magnet is too big for the iMAPLA system.

The built-in system overload / current limiter is active.The LED continues to light up after being switched back on.The LED will not go out until an overload state is no longer detected after the next 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 that the lifting magnet is suitable for the system.The LED is flashing: system fault

y A critical safety fault occurred.The output to the lifting magnet is switched off immediately.The LED goes out after a system restart.

Ö System restart iMAPLA controller, page 115The plate cannot be switched on before this.Note: On iMAPLA systems, a fault blink code is displayed on the MMI control unit for troubleshooting.More information:

Ö Troubleshooting, page 116

LED4+5+6




Ö Temperature for control electronics exceeded

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LED 6 red

Fault indicatorThe LED is lit: underspeed

y The generator runs at an underspeed and may not be able to provide full power under certain circumstances.

When switching on, it is possible that the lifting magnet is not magnetised with full surge voltage. The efficiency of the system is reduced.The LED goes out once the speed is within the tolerance limits again.The LED is flashing: overspeed

y The generator is operating at an overspeed.After releasing the load, it is not possible to switch the plate back on again.The LED goes out once the speed is within the tolerance limits again.

LED4+5+6




Ö Overtemperature pre-warning (control electronics), page 126

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LED 7 Cyclic duration factor of the lifting magnetMulti-coloured LED display(50 % green, 60 % yellow, 70 % orange, from 80 % red):

y The cyclic duration factor of the lifting magnet is indicated in per cent. Values under 50 % are not shown.

Caution!Switch off the lifting magnet when the cyclic duration factor is less than 80 %. There is an indication but no engagement lock.The cyclic duration factor of the lifting magnet is the ratio between 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). The iMAPLA system is in no way at risk here (100 % suitable, cyclic duration factor S1).ExampleA switch-on time of 1 minute and subsequent switch-off time of 1 Minute is equivalent to a relative connection time of 50 %.

Ö Cyclic duration factor greater than or equal to 80 %, page 129

Sensor Light sensorAutomatic LED brightness adjustment on the MMITo ensure that these indications are easy to follow on the MMI at all times, this sensor is used to adjust the brightness of the LEDs automatically - e.g. so that they are brighter in direct sunlight than when dark.

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Multiple functions when several LEDs light up at the same time

LED4+5+6flashing

Insulation fault indication / ISO fault occurredIf an insulation fault is active, a magnet restart block automatically becomes active, i.e. after putting the load down, the operator is no longer able to switch the magnet back on again.This message will not clear until after a system restart.

Ö System restart iMAPLA controller, page 115WarningWith an insulation fault, the “electrical separation” protective measure - which is otherwise provided by the system - is no longer effective.If another fault occurs, potentially fatal contact voltages on metal parts may arise!

LED4+5+6lit up& 100 % LED flashes

Temperature warning, control electronics Ö Overtemperature pre-warning (control electronics), page 126

y The temperature in the control electronics has exceeded the pre-warning threshold.

The iMAPLA system is secured against being switched back on again until the temperature in the control 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 after approximately 10 minutes, the system is shut down immediately due to the temperature exceeding the threshold.

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OperationEstablish the system's readiness for use

LED4+5+6flashing& 100 % LED flashes

Excess temperature, control electronics Ö Temperature limit exceeded (control electronics), page 127

y The temperature in the control electronics has exceeded the permissible threshold and the system 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 lifting magnet from being switched back on until the temperature of the control electronics drops below the pre-warning temperature again.Note:iMAPLA systems report an excess temperature 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 operating state!If only LED 4+5+6 are flashing (not the 100 % LED), this means an insulation fault is still present.

Ö Insulation faults arose, page 124

6.4 Establish the system's readiness for use

NOTENormally, the MMI is supplied by the iMAPLA generator.On systems adapted to specific customer needs, and when using the MMI with a radio modem, the MMI can also be supplied by an external supply unit (via the on-board power supply).

The MMI is supplied with voltage by the generator > Start the drive unit.

The iMAPLA system is ready for use as soon as the drive unit runs at the required speed and drives the generator.Do not start work if the green LED 1 lights up on the MMI.

> Check the insulation monitor. Ö Daily inspection of the insulation monitor, page 107

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OperationDaily inspection of the insulation monitor

The MMI is not supplied with voltage by the generator(External power supply)

y Switch on the voltage supply for the MMI.The green LED 1 then lights up.

y Start the drive unit. > The iMAPLA system is ready for use as soon as the drive unit runs at the

required speed and drives the generator. > Check the insulation monitor. Ö Daily inspection of the insulation monitor, page 107

6.5 Daily inspection of the insulation monitor

Check the correct function of the insulation monitor every day before starting 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 pressed.

> Release the check button.Clear the LED.Important.If the LEDs do not flash together, this means the insulation monitor is faulty.

> Switch off the iMAPLA system immediately. Ö Insulation monitor faulty, page 128

> Continue with setting the operating mode.


y If there is not a PE/PA connection between controller and magnetic housing, the reliable detection of external ISO faults in the lifting magnet is not assured. ► For this reason, when deploying an insulation monitor,

the electrical potential connection of the magnet to the controller must be assured.

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Operation

NoteThere are systems without the optional insulation monitor. Without an insulation monitor, the LED does not flash during the requested self-test. The serial number on the switch box has the letters “ISO” if an insulation monitor is installed. If “ISO” is not stamped on the switch box this means no insulation monitor is installed.

NotePressing the button switches a test resistor internally. The self-test merely indicates that the insulation monitor is operating correctly. It does not say anything about whether the connection (potential 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 There are MMI versions without a switching option in Jog mode. In this case, the switch on the right-hand side of the MMI is missing. ► In the MMI description, check whether the “Jog mode”

function is available.

> Configure the required operating mode from the switch on the right-hand MMI page.

Ö Fig. 33, MMI displays, page 99

6.6.1 Normal-/machine handling operation [A] (switch on top)

Normal mode is the mode most often used for material handling.In Normal mode, the system works with the functions “quick magnetisation with impulse excitation” and “quick demagnetisation” which accelerate the magnetisation and demagnetisation process considerably.

Ö Function description, page 23

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Operation

6.6.2 Jog / Sort mode [B] (switch setting below)

The Jog mode is particularly good for separating the material. This operating mode is usually not suited for normal material handling.

NoteJog mode is not possible for all MMI variants (switch A/B is not installed).

In Jog mode, the iMAPLA system does not work with the functions “Quick magnetisation” and “Quick demagnetisation”. This means that the processes for full magnetisation and demagnetisation of the lifting magnet last considerably longer than with these functions.

Ö Function description, page 23

Since the full demagnetisation takes some time, the material gradually drops off the lifting magnet corresponding 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 offers a range of different MMI variants adapted to and programmed for specific applications.This can be used with every iMAPLA system and are plug-compatible. Some examples for functions upon demand:

y MMI INT MSF (extended sorting and material handling) Setting magnetic force and release response. Optional second joystick input for optimised sorting.

y MMI with safety mode for slab handling y MMI with interfaces for quick-connect mode y MMI with digital inputs and outputs / analogue outputs for representing

magnetic current and magnetic voltage precisely

The options can also be combined with each other. The basic functions described here are, however, always identical.

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OperationOperating in Normal or Material handling mode [A]

6.7 Operating in Normal or Material handling mode [A]

For Normal mode, the switch on the right-hand side of the MMI must be in the top position [A] = Material handling mode = Normal mode.In Normal mode, the lifting magnet is switched on by pressing the control button briefly and remains switched on until the control button is pressed again briefly.

6.7.1 Lift load (switch on the lifting magnet)

When switching on the lifting magnet for the first time after the system start, quick magnetisation 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 values of the lifting magnet are measured the first time the machine is switched on for safety reasons. In the measurement procedure, it can arise that the magnetic voltage is reduced slightly. This is raised to the rated voltage in the permanent mode if the magnetic load is less than or equal to the max. permissible load on the system.

Ö Lift load (switch on lifting magnet), page 23

> Place the lifting magnet on the load to be raised. > Press the control button briefly.

LED 2 lights up on the MMI. y The lifting magnet is magnetised and remains switched on until the

control button is pressed again. y The load is attracted.

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NoteIf the control button is pressed again after switching on the lifting magnet (while magnetisation is still running), magnetisation is stopped and the automatic quick release / shut-down is started straight away. In this case, the system may require a few magnetisations until the maximum tension force of the lifting magnet becomes available.

NoteThe 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 sensitivity.When the tractive power is reduced, it is possible to increase the switch-on time of the lifting magnet at the same time. The switch-on time indicator is intelligently adjusted to it. This allows the substructure or workplace to be cleaned through very long switch-on times without leading to an overheating of the magnet. To ensure that this application works, contact the manufacturer of the magnet or magnetic system beforehand.

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6.7.2 Release load (switch off lifting magnet)

> Move the lifting magnet with the suspended load into the position for releasing the load.

> Briefly press the control button.LED 2 on the MMI goes out and the LED 3 light is out for the duration of the automatic quick magnetisation.

y The lifting magnet is de-magnetised. y The load drops from the lifting magnet.

NoteIf the control button is pressed again during quick demagnetisation (LED 3 lights up), quick demagnetisation is stopped. The demagnetisation of the lifting magnet is resumed at “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 will activate a stop or whether to switch on the magnet again right away (quick re-activation).


NoteOn a range of MMI variants (e.g. “INT MSF”), the operator can choose whether to allow the material to drop slowly initially by pressing and holding the joystick button. If the button remains pressed for release, LED 3 will light up. From the time of the release, automatic demagnetisation of the lifting magnet is started and LED 3 lights up. The material now drops completely at precisely the specified time. In this way it is possible to position and release the loaded material precisely. The strength of the demagnetisation can be finely adjusted.

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OperationOperation in Jog mode / Sorting mode [B]

6.8 Operation in Jog mode / Sorting mode [B]

Job mode The “switch is down” on the right-hand side of the MMI [B] = Sorting mode = Jog mode.

The Jog mode is particularly good for separating the material. This operating mode is usually not suited 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.

NoteJog mode is not available in all MMI variants.

In Jog mode, the iMAPLA system does not work with the functions “Quick magnetisation” and “Quick demagnetisation”. This means that the processes for full magnetisation and demagnetisation of the lifting magnet last considerably longer than with these functions.

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OperationOperation in Jog mode / Sorting mode [B]

6.8.1 Lift load

> Place the lifting magnet on the load to be raised. > Press the control button and keep it pressed.

LED 2 lights up on the MMI. y The lifting magnet is magnetised and remains switched on until the

control button is held down. y The load is attracted.

6.8.2 Separating the material

> If necessary, move the lifting magnet into the required position for separation while the control button is pressed.

> Release the control button briefly.LED 2 goes out on the MMI.

y The lifting magnet is switched off. 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 release it again as many times as necessary until the

required material separation result is achieved.

6.8.3 Releasing load

> Move the lifting magnet into the required position to release the load with the control button pressed down.

> Release the control button again and wait until all material drops from the lifting magnet.

NoteNormally, in Sorting mode, the magnet is only demagnetised slowly when the control button is released. In various MMI variants (e.g. “INT MSF”), there is the chance to toggle between slow and quick demagnetisation.As a result, the sorting procedure can be terminated quickly and the load can be positioned precisely.

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OperationSystem restart iMAPLA controller

6.9 System restart iMAPLA controller

In processor-controlled systems, faults may arise when processing information during processing programs. In this case, the processor system must be brought into a pre-defined home position. This is achieved via a “restart”.

For certain faults, a system restart of the iMAPLA controller will be necessary.

Carrying out the restartIn the system, the MMI is supplied with voltage by the generator

Ö 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 MMI is fully de-energised and the restart was carried out correctly.

> Switch the drive unit back on.

In the system, the MMI is not supplied with voltage by the generator Ö External supply, Establish the system’s readiness for use, page 106

> Switch off the voltage supply for the MMI. > Wait until all displays on the MMI have gone out. It is only now that it is

assumed that the MMI is fully de-energised and the restart was carried out correctly.

> Switch on the voltage supply for the MMI.

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OperationTroubleshooting

6.10 Troubleshooting

This chapter describes the system fault displays and the required measures for troubleshooting. Carefully read the safety instructions.

Safety instructions for troubleshooting








► Switch off the drive unit before all inspection or maintenance work on the generator or switch box. Prevent the drive unit from being switched back on by accident (e.g. remove the ignition key and keep somewhere safe).

DangerRisk of injury and risk of damage! Danger to life!

► Never plug in or undo plug connections during operation.

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magnet.






y The use of unauthorised third party parts can lead to malfunctions, damage or danger. ► Only use third party parts expressly approved by the


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6.10.1 Interruption

LED 4 The LED is lit: 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 whether current is flowing through the lifting magnet. Without a flow of current, the lifting magnet will be switched off again after approx. 1-2 seconds- the LED will light up.

The LED goes out when the fault is no longer active after the machine is switched on again.When the magnetic connection monitor is optional, it can be measured as to whether a lifting magnet was connected in advance. The LED interruption already 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 secure against being switched on again

(e.g. remove the ignition key and keep it in a safe place). > Check whether the plugs on the connection line to the lifting magnet are

plugged in properly. Plug them in properly where required. > Check the connection line to the lifting magnet for visible damage.

Replace or repair the connection line where necessary. > If the fault persists, please get in touch with the manufacturer or a party

authorised by the manufacturer. > Replacing the load cable between the magnet and controller may help

find the fault directly, just as measuring the resistance of the magnetic coil on the connector plug of the switch box might help. These readings must be performed by an electrician.

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6.10.2 Interface fault

LED 4 The LED is flashing y A fault occurred on the interface between MMI and the

controller.

NoteWhen using an MMI with radio modem, a fault in the radio transmission can also be the cause of the fault.

Troubleshooting measures > Carry out a system restart of the iMAPLA controller. Ö System restart iMAPLA controller, page 115

> If the fault continues after the restart: switch off the drive unit. Check the connection cable between the 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 visible damage. Check whether the plugs on the connection cable are plugged in properly on both sides. Replace or repair the connection line where necessary.

> Carry out a restart again. Ö System restart iMAPLA controller, page 115

> The MMI interface can be checked again using a separate MMI cable using a system tester or a second MMI. This method can be used to rule out an internal fault in the controller.

> If the fault persists, please get in touch with the manufacturer or a party authorised by the manufacturer.

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6.10.3 Overload limitation

LED 5 The LED is lit: y The connected lifting magnet is too big for the iMAPLA system.

The built-in overload / current limiter of the iMAPLA is active.The LED continues to light up after being switched back on.The LED will not go out until an overload state is no longer detected after the next time the lifting magnet is switched off.This fault does not result in an automatic shut-down of the lifting magnet.

NoteOverload limiter active is a warning. On newer iMAPLA systems, this message is not displayed until significant overloads (>110 %) apply. However, you should check that the lifting magnet is suitable for the system.

Ö Overload protection iMAPLA, page 26


(e.g. remove the ignition key and keep it in a safe place). > Check the suitability of the lifting magnet for the generator size. If the

lifting magnet is very cold, it can require an increase in current for the first minutes. This warning message should no longer appear automatically after a few minutes.

> If the warning does not go out, check the magnet itself for faults. Get in touch with the manufacturer or an electrician.

> A smaller or suitable lifting magnet can be connected to the system / machine for test purposes.


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6.10.4 System fault

LED 5 The LED is flashing y A critical safety fault on the iMAPLA controller occurred. (On

old MAPLA systems, this fault message denotes a short circuit on the magnet output.)

The output to the lifting magnet is switched off immediately.The LED goes out after a system restart.

Ö System restart iMAPLA controller, page 115The plate cannot be switched on before this.

NoteOn iMAPLA systems, a fault blink code is displayed on the MMI control unit for troubleshooting.

Ö Troubleshooting, system fault blink codes, page 132

Troubleshooting measures > Read the error blank code on the MMI control unit. Ö Troubleshooting, system fault blink codes, page 132

This is only possible for the iMAPLA systems. On older systems (non-iMAPLA systems), this fault message = short circuit, or no fault blank code is available.

> Switch off the drive unit and secure against being switched on again (e.g. remove the ignition key and keep it in a safe place).

> To respond to the “short circuit” diagnosis, replace or repair the connection lines to the magnet.

> Carry out the system restart. Ö System restart iMAPLA controller, page 115


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6.10.5 Underspeed

LED 6 The LED is lit: y The generator runs at an underspeed and may not be able to

provide full power under certain circumstances.When switching on, it is possible that the lifting magnet is not magnetised with full surge voltage. The efficiency of the system is reduced.The LED goes out once the speed is within the tolerance limits again.This fault does not usually result in an automatic shut-down of the lifting magnet.

Troubleshooting measures > Operate the generator at a speed within the permissible tolerances. Ö Generator drive types, page 28


y In addition, there is also the risk at low speed that the magnet is no longer supplied with enough current and a loaded load can drop in an uncontrolled fashion.


y Underspeed can arise through a drive belt slippage. ► In this case, the machine must be brought to an immediate

standstill and technicians must be contacted to fix the fault.

NoteFor safety reasons, it is no longer possible to switch the magnet on at very low speeds.

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6.10.6 Overspeed

LED 6 The LED is flashing y The generator is operating at an overspeed.

After releasing the load, it is not possible to switch the plate back on again.The LED goes out once the speed is within the tolerance limits again.

Troubleshooting measures > Operate the generator at a speed within the permissible tolerances. Ö Generator drive types, page 28

ImportantMechanical damage

y The generator can sustain mechanical damage caused by excessive speeds. ► Make sure that the machine is permanently operated in the

nominal speed range.

NoteExcessive speeds can also lead to a system fault with the diagnosis: overvoltage fault (fault code: 10).

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6.10.7 Insulation faults arose

LEDs 4+5+6 flash at the same timeIf LEDs 4+5+6 flash at the same time when switching on or operating the machine, the built-in insulation monitor will detect an insulation fault. If this message is active, a magnet restart block is automatically active, i.e. after putting the load down, the operator is no longer able to switch the magnet on again.The insulation monitor (optional) offers additional protection and enables the early detection of hidden faults / magnetic faults. An insulation monitor offers the early detection of a critical fault with the connected load. If these faults remain undetected and a second fault arises 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.

Ö System restart iMAPLA controller, page 115


(e.g. remove the ignition key and keep it in a safe place). > Check the connection line to the magnet for abrasion / open contacts. > Check the plug contacts to the magnet for water or clean and dry the plug

connections. > When using turntable systems with slip rings, check the degree of wear for

dirt and moisture. > Have the lifting magnet tested by an electrician for insulation faults using

an insulation tester with measurement voltage 500 V d.c. > Carry out the system restart. Ö System restart iMAPLA controller, page 115

> Check the system / magnets directly with a new load cable. > If the fault persists, please get in touch with the manufacturer or a party

authorised by the manufacturer.

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y With an insulation fault, the “electrical separation” protective measure - which is otherwise provided by the system - is no longer effective. Potentially fatal contact voltages on metal parts may occur due to these faults. ► Switch off the drive unit and secure against being switched

on again (e.g. remove the ignition key and keep it in a safe place).

► Have the system checked and the insulation fault fixed.

NoteIt is possible that no optional insulation monitor is fitted in the controller on familiar systems. It may happen that an insulation fault is not detected or displayed on older MAPLA controllers.If current systems with ISO monitors are run with faulty magnets, a fault message will arise. The letters “ISO” in the serial number stamped on the switch box / controller indicates whether an insulation monitor has been installed in your system.

Ö GTS type designation and identification, page 53

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6.10.8 Overtemperature pre-warning (control electronics)

LED 4+5+6 light up and 100 %-LED flashesEven though the iMAPLA system is designed for continuous operation, it may become too hot. This risk exists when, under a fill load, the cooling of the generator (for “One Unit”) or the control electronics (for “External Unit”) is impaired, or when the temperature of the cooling air exceeds the maximum permissible value of 40 °C.

Temperature warning, control electronics y The temperature in the control electronics has exceeded the pre-warning

threshold.The iMAPLA system is secured against being switched back on again until the temperature in the control 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 after approximately 10 minutes, the system is shut down immediately due to the temperature exceeding the threshold.

Troubleshooting measuresIf the overtemperature pre-warning occurs once:

> Switch off the lifting magnet and either run the iMAPLA system in idle, or switch off the drive unit until the overtemperature pre-warning disappears again.

If the overtemperature pre-warning occurs again: > Switch off the drive unit and secure against being switched on again

(e.g. remove the ignition key and keep it in a safe place). > Allow the generator (and the switch box for the “External Unit”) to cool off.

CautionBurn hazard


touching.

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y Check whether the cooling air inlet and outlet openings are free and whether the cooling air can flow unimpeded through the cooling profiles of the switch box. Clean the switch box cooling profiles with a damp cloth if required.

y If the fault persists, please get in touch with the manufacturer or a party authorised by the manufacturer.

6.10.9 Temperature limit exceeded (control electronics)

LED 4+5+6 flash and 100 %-LED flashes

Excess temperature, control electronics y The temperature in the control electronics has exceeded the permissible

threshold and the system 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 lifting magnet from being switched back on until the temperature of the control electronics drops below the pre-warning temperature again.

Troubleshooting measures > See Troubleshooting for the previous chapter “Overtemperature

pre-warning control electronics”.


y The control electronics can sustain damage as a result of overheating. At the same time, safe operation of the machine is NOT ensured in this state. Loads may drop in an uncontrolled fashion when the electronics fails. ► Immediately drop the load (switch off the magnet) and have

the system checked by an expert for damage.

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NoteMore recent iMAPLA systems report an excess temperature as a system fault (LED 5 flashes).On newer iMAPLA systems, the control electronics will not switch off the magnet for safety reasons. Nevertheless, this message should ALWAYS be considered as a very critical operating state!

6.10.10 Insulation monitor faulty

When the system is running and after pressing the check button for the insulation monitor, LED 4+5+6 do not flash jointly or the LEDs no longer clear automatically after releasing the test button, this means the insulation monitor is faulty.The insulation monitor is a safety device! When the insulation monitor 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 operator must decide for themselves as to whether they would like to continue working on the machine in spite of a failure to the insulation monitor. However, for safety reasons, we recommend that the iMAPLA system be switched off and repaired right away.


y With an insulation fault, the “electrical separation” protective measure - which is otherwise provided by the system - is no longer effective. Potentially fatal contact voltages on metal parts may occur due to these faults. ► Switch off the drive unit and secure against being switched

on again (e.g. remove the ignition key and keep it in a safe place).

► Have the system inspected and allow the manufacturer fix the fault in the insulation monitor.

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6.10.11 Cyclic duration factor greater than or equal to 80 %

The cyclic duration factor of the lifting magnet is the ratio between the switch-on/switch-off time. A switch-on time of 1 minute and subsequent switch-off time of 1 Minute is equivalent to a relative connection time of 50)%.In normal mode, the cyclic duration factor must lie between 50 % and 70 %.From a cyclic duration factor of 80 % or higher, there is the risk of the lifting magnet overheating. To protect the lifting magnet, reduce the switch-on time of the lifting magnet until the display is back in the normal range 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 protect the lifting magnet, reduce the switch-on time of the lifting

magnet until the display is back in the normal range between 50 % and 70 %.


y 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). The iMAPLA system is in no way at risk here (100 %).

NoteIf the machine has an MMI with option of a configurable tractive force reduction, the switch-on time can be increased by lowering the magnetic force. Keep a regular eye on the switch-on duration indicated on the MMI.

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6.10.12 MMI overview display values

9 Power category in kW(this entry is not required for new MMIs)

10 INT variant:intelligent MAPLA = iMAPLA (these three letters are not used in older versions)

11 Variant of MMI / Typ

Bxx INT xxxx

9

8

7

10

11

6

5

4

3

2

1

1 MAPLA system is ready for useThe voltage supply for the MMI is present.

2 Lifting magnet switched on (“lift”)This LED stays lit while the lifting magnet is switched on.If the 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 up during automatic quick magnetisation (degaussing). The LED goes out once this process has been fully completed. This operating mode is deactivated when (optional) Sorting mode was selected.

4 Disconnection / communication faultLED ON: Disconnection, lifting magnetThis LED lights up when the connection cable of the lifting magnet was not plugged in or has a disconnection.LED is flashing: Internal communication faultThis LED flashes when a fault arose on the MMI controller interface. The data connection has a fault. Check the MMI cable.

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5 Overload / system faultLED on: Overload (current limiter on iMAPLA active)This LED lights up when the connected lifting magnet is too big for the iMAPLA system or a fault arose on the lifting magnet or load cable. The material handling output is reduced accordingly / the magnetic current is restricted to the machine's maximum. This LED can light up in the first few minutes of operation when the lifting magnets are very cold- it should then go out though.LED is flashing: System fault (on old MAPLA systems: short circuit)This LED flashes when a system fault has occurred in the iMAPLA system. A fault blink code is visible from the 100 %-LED and can be used to locate the fault in the iMAPLA MMI. If you do not have an iMAPLA system (older version), this means there is a short circuit. In this case, the load is released immediately and deactivated. The fault must be fixed by an expert. To clear the fault, it will be necessary to restart the machine (Motor-Stop).

6 Underspeed / overspeedLED on: Underspeed, generatorThe generator is being driven at too low a speed. The system is operating at reduced voltage or material handling performance (lifting output).LED is flashing: Overspeed generatorThe generator is operating at an overspeed. It will not be possible to switch the lifting magnet back on until the speed returns to within the tolerance limits.

7 Cyclic duration factor (ED in%) of the lifting magnetThe cyclic duration factor of the lifting magnet is the ratio between the switch-on/switch-off time. To protect the lifting magnet against quick ageing (overtemperature), the switch-on duration must always be less than the lifting magnet manufacturer's specification.

LED 4+5+6 flash: isolation fault triggeredThe insulation monitor has detected an insulation resistance <25 KiloOhm between the lifting magnet housing and active conductor. This is considered a safety risk- call in an electrician. On iMAPLA systems, the system is locked against being switched back on again (clear through a restart).

LED 4+5+6 lit & 100 %-LED flashesTemperature alarm, electronics / generatorThe machine cannot be switched back on again while this fault remains active. The fault is cleared automatically when the temperature has dropped to a safe range. We recommend you allow the generator to cool down in idle for a few minutes while the drive is running. Check the machine for dirt and damage to the fan.

6.10.13 Troubleshooting, system fault blink codes

Blink code table of the iMAPLA (INT) MMIs when a SYSTEM FAULT (= LED No. 5 blinks) is displayed.Valid for MMIs with label: “INT” and suitable iMAPLA controller.

LED No. 5 is flashing= SYSTEM FAULT(Magnet re-engaging lock active)

By pressing the joystick button (for 5 secs.)a fault blink code is indicated on the 100 % ED LED.

Blink code(Number)

Brief descriptioniMAPLA G1/G2

extended error description Class / Category Description / procedure

1 not assigned --- --- not assigned

2Clocking

mechanism / dischargerFault

A clock fault is detected with the degaussing procedure and afterwards an emergency function is switched to active

internal system faultCategory 1

Clocking mechanism / discharger faultNotify after-sales service

3 Limiter OverloadThe permitted limiter limit of >130 % of the rated load of the machine was exceeded. The re-engaging lock is active. Check the load, connect

smaller load where necessary.

external system faultCategory 1

overload too large!Make sure that a suitable lifting magnet was connected. Check the lifting magnet

for winding short circuits and other faults

4 Short circuit type 1 Conductance monitor triggered external system faultCategory 1 Short circuit present at output; check lifting magnet and load cable

5 Short circuit type 2 Limit monitor triggered external system faultCategory 1

high magnetic current lead to the short-circuit disconnection; check the lifting magnet and load cable

6 Short circuit type 3 IGBT desaturation monitor triggered internal system faultCategory 2

critical short circuit present; check the lifting magnet and load cable; if this fault continues, contact customer service

7 Short circuit type 4 Undervoltage monitortriggered


soft (creeping) short circuit or overload >400 % of the rated load at the output; check lifting magnet and load cable

8 G1 Overvoltage type 1 Overvoltage in the intermediate circuit internal system faultCategory 2

Overvoltage controllerNotify after-sales service

8 G2 Overtemperature Overtemperature, electronics internal system faultCategory 2 Overtemperature of the electronics -> critical value, check ventilation

9 G1 Overvoltage Type 2 Overvoltage in the intermediate circuit internal system faultCategory 2


9 G2 Generator fault Generator fault or loose contact on the generator connector internal system faultCategory 2 Phase failure of generator or loose connector contact, contact customer services

10 G1 Overvoltage Type 3 Overvoltage generator in idle internal system faultCategory 2

Overvoltage controller,Notify after-sales service

10 G2 Electronics fault Electronics fault in the controller internal system faultCategory 2 Electronics fault, internal reference voltage, notify customer services

11 System fault Internal system fault internalsystem fault not defined (free)

no blink code

no intelligent MAPLA present the older software version of the MAPLA does not support this function --- Function not available due to older software version of the MAPLA / software

update possible

Example forblink code no. 3:

(LED flashes three times

Count value = Code 3)

LED OFF

LED ON

TimePause LED OFF

Note: On the iMAPLA 2013 series, the description of blink codes 8 to 10 is different. Here the iMAPLA 2013 series is to be indicated as “G2”. All other systems as “G1”.

= 3 x brief ON= 3 x brief ON

Blink code(Number)

Brief descriptioniMAPLA G1/G2

extended error description Class / Category Description / procedure

1 not assigned --- --- not assigned

2Clocking

mechanism / dischargerFault

A clock fault is detected with the degaussing procedure and afterwards an emergency function is switched to active

internal system faultCategory 1

Clocking mechanism / discharger faultNotify after-sales service

3 Limiter OverloadThe permitted limiter limit of >130 % of the rated load of the machine was exceeded. The re-engaging lock is active. Check the load, connect

smaller load where necessary.


overload too large!Make sure that a suitable lifting magnet was connected. Check the lifting magnet

for winding short circuits and other faults

4 Short circuit type 1 Conductance monitor triggered external system faultCategory 1 Short circuit present at output; check lifting magnet and load cable

5 Short circuit type 2 Limit monitor triggered external system faultCategory 1

high magnetic current lead to the short-circuit disconnection; check the lifting magnet and load cable

6 Short circuit type 3 IGBT desaturation monitor triggered internal system faultCategory 2

critical short circuit present; check the lifting magnet and load cable; if this fault continues, contact customer service

7 Short circuit type 4 Undervoltage monitortriggered


soft (creeping) short circuit or overload >400 % of the rated load at the output; check lifting magnet and load cable

8 G1 Overvoltage type 1 Overvoltage in the intermediate circuit internal system faultCategory 2


8 G2 Overtemperature Overtemperature, electronics internal system faultCategory 2 Overtemperature of the electronics -> critical value, check ventilation

9 G1 Overvoltage Type 2 Overvoltage in the intermediate circuit internal system faultCategory 2


9 G2 Generator fault Generator fault or loose contact on the generator connector internal system faultCategory 2 Phase failure of generator or loose connector contact, contact customer services

10 G1 Overvoltage Type 3 Overvoltage generator in idle internal system faultCategory 2

Overvoltage controller,Notify after-sales service

10 G2 Electronics fault Electronics fault in the controller internal system faultCategory 2 Electronics fault, internal reference voltage, notify customer services

11 System fault Internal system fault internalsystem fault not defined (free)

no blink code

no intelligent MAPLA present the older software version of the MAPLA does not support this function --- Function not available due to older software version of the MAPLA / software

update possible

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Maintenance and careTroubleshooting

7 Maintenance and care

All system components are in principal maintenance-free. However, carry out the maintenance activities listed by the user in the maintenance overview in the Visual checks / cleaning work chapter regularly and timely in order to ensure reliable operation of the system.

Ö Visual inspection / cleaning work by the user, page 138

Important y As well as the work described here, inspections of the drive

system may be required according to the requirements and provisions of the drive / system manufacturer. This also includes installed protective coverings. ► Observe the maintenance instructions of the drive or system

manufacturer.

Note ►Have all damage and defects to the iMAPLA system removed right away by authorised and qualified technicians. ►Only specially trained technicians are allowed to perform repairs. ►Do not put the system into operation until the faults have been remedied.

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Maintenance and careSafety instructions

7.1 Safety instructions

This chapter summarises the safety instructions relevant for the maintenance work.








► Switch off the drive unit before all inspection or maintenance work on the generator or switch box. Prevent the drive unit from being switched back on by accident (e.g. remove the ignition key and keep somewhere safe).

DangerRisk of injury and damage! Danger to life!

► Never plug in or undo plug connections during operation.

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y During maintenance, make sure that the PE/PA connection (potential connection, usually green / yellow) between the 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 If this connection is not present, an installed insulation monitor may no longer be able to detect an insulation fault.

CautionBurn hazard


touching.

ImportantAs a unit generating electrical power, the iMAPLA system and the machinery materials are to be considered a part of an overall system. The relevant national regulations on accident prevention are applicable (in Germany for instance DIN / VDE 0113-EN60204, DIN / VDE 0701 and DIN / VDE 0702 BGV-A3).Heed the appropriate test deadlines.


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Maintenance and careVisual inspection / cleaning work by the user

7.2 Visual inspection / cleaning work by the user

Read and follow the safety instructions in the Safety instructions chapter as well as the information given here.

Ö Safety instructions, page 135


y Never carry out visual inspections on the iMAPLA system for maintenance purposes and cleaning during operation. ► Switch off the drive unit and make sure that it cannot be

unintentionally restarted again (e.g. remove the ignition key and keep it in a safe place).

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Maintenance and careVisual inspection / cleaning work by the user

CablesCheck the junction cables and plug connections.

y between generator and switch boxes, y between switch box and the lifting magnet, y between switch box and MMI (for MMI with radio modem: between switch

box and radio modem) and y between MMI and manual control unit (joystick) y for outwardly visible damage and correct fit of the plugs.

MMI y Check the MMI housing for outwardly visible damage, correct fit of the

plugs and dirt. y Clean the MMI housing with a damp cloth if required.

Generator and switch box

CautionBurn hazard


touching.

y Check the generator- and switch box housing for outwardly visible damage, correct fit of the plugs, as well as contamination impairing cooling. Clean the generator and the cooling element of the switch box. Where necessary, use compressed air and a damp cloth.

y Check whether the sign attached to the generator for the safety and warning information and the rating plate is easy to read. Where necessary, clean the signs or replace them.

y Inspect the cooling air openings on the reverse side of the generator for dirt which could impede the flow of cooling air. If necessary, clean with a damp cloth.

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Maintenance and careMaintenance work carried out by authorised personnel

7.3 Maintenance work carried out by authorised personnel





Read and observe the safety instructions in the Safety information chapter as well as the information given here.

Ö Safety instructions, page 135Every 8,000 operating hours, check both ball bearings of the generator and replace them every 20,000 operating hours.





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Repairs / repairMaintenance work carried out by authorised personnel

8 Repairs / repair

The user is not allowed to carry out any repair work on the IMAPLA system. Such work is only to be carried out by authorised and qualified specialists. We strongly recommend you to replace the generator system for this work before sending it to the manufacturer or a party approved by the manufacturer.

CAUTIONWork on the drive system based on the requirements and provisions of the respective drive / system manufacturer. This also includes mounted protective coverings. This work must be performed by the person responsible for the machine.








► Switch off the drive unit before all inspection or maintenance work on the generator or switch box.

► Prevent the drive unit from being switched back on by accident (e.g. remove the ignition key and keep somewhere safe).

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magnet.


y During repairs, make sure that the PE/PA connection (potential connection, usually green / 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 If this connection is not present, an installed insulation monitor may no longer be able to detect an insulation fault.





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Transport and storageGeneral

9 Transport and storage

9.1 General

To protect the generator against damage, the generator of the iMAPLA system is bolted down for transport on a pallet ex works. The MMI and connecting cables are enclosed.Only transport and store the generator.

Note ► Transport and store the iMAPLA system when dry and

protected from water. ► Only transport or store the iMAPLA system in the

as-delivered 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 storage

Permissible temperatures:Transport -25 °C to +60 °CStorage -20 °C to +50 °C

Permissible relative humidity:Transport 95 %, non-condensingStorage 95 %, non-condensing

9.3 Lifting generators and switch boxes

Only use suitable lifting equipment to lift the generators.

iMAPLA 8, 13 and 17, construction type “One Unit”To lift these generators on the front and rear side of the generator, X a load-bearing cable under the attached switch box. Weights: 64 kg for iMAPLA 8, 75 kg for iMAPLA 13, 96 kg for iMAPLA 17.

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Transport and storageLifting generators and switch boxes

iMAPLA 20 and 30, construction type “One Unit”The attached eyebolts may NOT be suitable for lifting the generator!Lift the generators on the front and rear with a load-bearing cable (threaded) under the attached switch box. Weight: 124 kg for iMAPLA 20, 196 kg for iMAPLA 30.

iMAPLA 8 and iMAPLA 13, construction type “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. Weights: 48 kg for iMAPLA 8, 61 kg for iMAPLA 13.No lifting equipment must be used to lift the switch box. Weight: 14 kg for iMAPLA 8, 16 kg for iMAPLA 13.

iMAPLA 17, construction type “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: 80 kg.To lift the switch box on both sides, pull through a load cable between the cooling element and upright base on both sides in a suitable position. Make sure that the housing of the plug connectors and the cable on the switch box is not damaged by the load cable. Weight: 35 kg.

iMAPLA 25, construction type “External Unit”Two eyebolts are attached to the generator to attach the lifting devices. Lifting devices are only allowed to be fixed to the generator using this eyebolt. Weight: 155 kg.To lift the switch box on both sides, pull through a load cable between the cooling element and upright base on both sides in a suitable position. Make sure that the housing of the plug connectors and the cable on the switch box is not damaged by the load cable. Weight: 85 kg.

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Decommissioning, storage after disassembly of, disposalLifting generators and switch boxes

10 Decommissioning, storage after disassembly of, disposal

Removal and decommissioning of the iMAPLA system according to the Installation and commissioning Chapter.

Ö Installation and commissioning, page 58Pack and store still operative systems after the removal based on the Transport and storage Chapter.

Ö Transport and storage, page 144Dispose of systems which are no longer operative according 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 boxHousing / cooling element AluminiumCover for fan wheel Iron / steelFan wheel PolypropeneRotor / shaft Iron / steelWindings CopperImpregnated resin Modified esther-imide (THEIC)Controller circuit board and electronic components

Dispose as electric scrap

MMIHousing PolycarbonateCircuit board and electronic components

Dispose as electric scrap

Connection cable (s)Cover PolypropeneConductor insulation Thermoplastic elastomers

(Halogen-free)Conductor CopperConductor housing Aluminium or zinc cast die

(=Follow the hazardous waste / disposal instructions from the manufacturer)

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Options and accessoriesMMI with radio modem

11 Options and accessories

11.1 MMI with radio modem

CAUTIONDo not use the MMI with radio modem in the following cases:

y In safety-critical machines and when controlled by MMI functions which are important in a safety-related way.

y When faults in the radio transmission by other radio devices or other ambient conditions unfavourable to radio transmission.

NoteIf a MMI with radio modem is used, a delay of approx. 0.1-0.5 secs may arise between the pressure on the operator pushbutton and the response of the system due to technical reasons.

11.1.1 General

The MMI 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 the control button (joystick).

With the MMI with radio modem, the cable connection between the generator control electronics and MMI in the driver's cab is replaced by a radio transmission.

The MMI contains a sender / receiver unit (transceiver) used to communicate with the radio modem mounted in the vicinity of the switch box wirelessly. This radio modem is connected with the control electronics of the generator via a cable. It receives control signals from the MMI wirelessly and forwards this to the generator control electronics. It also sends the signals from the generator control electronics to the MMI in the driver's cab wirelessly.

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NOTEThe radio modem mounted in the vicinity of the switch box gets its voltage supply from the generator.The wireless MMI mounted in the driver's cab needs 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 cab

Display for function- and function and error displays

optional switch for ON/OFF magnet (parallel to the control button)

Socket for the connection cable to the iMAPLA generator

Socket for the connection cable to the control button and for voltage supply;

Fig. 34 MMI with radio modem

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11.1.2 Displays on the MMI

The MMI indicates all operating and fault states of the iMALPA system using LEDs.


11.1.3 Plug connections, MMI and radio modem

Plug connection Socket on MMI or radio modem

Connector on the connection cable

Radio modemRS232 interface to switch box

HARTING STAF 6 STI-S

HARTING HAN 3A-GW-PG11 STAF 6 FE-L

MMIConnection for the control button and voltage supply

Hirschmann ELST 412 PG9, 4-pole

Hirschmann ELWIKA-KV 4412, 4-pole, 5 m cable(Special cable on request for the power supply with a connector for a cigarette lighter)

RTS data input

ws 1

6 3

5 2

4 1

63

52

41

1 sw RTS data input

UART data bn 2 2 gr UART data

UART data gn 3 3 bl UART data

GND ge 4 4 gn/ge GND

+15 V Input gr 5 5 br +15 V Input

GND rs 6 6 Shielding GND

Fig. 35 Assignment, RS232 interface radio modem to switch box

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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 S1 Input)3 blue (Power supply

GND / earth)4 black (Joystick +12 V Output)

Fig. 36 Connection assignment control button

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11.1.4 Installing the MMI with radio modem

To provide a safe radio connection, the clearance between MMI and the radio modem must be at least 1 m. Otherwise, transmission faults may arise.

Ö Fig. 37, Dimensions and fastening dimensions MMI and radio modem, page 153

CAUTIONWhere necessary, the transparent cover can be removed for the attachment and assembly of the wireless MMI.





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11.1.5 Installing the radio MMI

The MMI is installed inside the cab within the driver's field of vision to allow him / her to monitor the indicated operating states. Either screw on with 4 screws or secure with the aid of a permanently magnetised plate affixed to the reverse side.

NoteThe radio MMI installed in the driver's cab needs its own power supply from the on-board power supply which can be switched off and is protected with a fuse. Normally 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 for the control button. Ö Fig. 36, Connection assignment control button, page 150

11.1.6 Installing the radio modem

The radio modem is attached in the vicinity of the switch box in a suitable position. Either screw on with 4 screws or secure with the aid of a permanently magnetised plate affixed to the reverse side.

NoteChoose a suitable installation site for the radio modem to allow the aerial to receive radio waves unimpeded without their separation. A partition can arise e.g. when installing in an engine compartment with very few openings which is fully surrounded by metal.

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t=55 mm(with cover)

Fig. 37 Dimensions and fastening dimensions MMI and radio modem

11.1.7 Configuring the radio channel

Normally, the factory-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 least 5 channels. When operating on a directly adjacent channel, mutual disturbance may arise at a low distance.The radio channel is configured with software. More information is available from the manufacturer.

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Options and accessoriesCustomer-specific MMI versions

11.1.8 Technical specifications, MMI with radio modem

Operating frequency 433.25 MHz to 434.60 MHz28 channels, spacing between channels 50 kHz

Frequency processing Synthesize technologyNeighbouring transmission loss 40 dBTransmission power 10 dBm (10 mW)Capacity max. 400 m in free spaceWorking temperature range -10 °C to +55 °C

11.2 Customer-specific MMI versions

As well as the MMI versions described in this manual, MMI versions adapted to specific customer needs are also available. If the iMAPLA system is equipped with an MMI adapted to specific customer needs, observe the 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 basic functions described in this manual always apply, however.

11.3 Accessories

Documents concerning the available accessories are available from the manufacturer.

The following are available: y Diagnostic tools “System tester” or laptop software (for CAN interface of

iMAPLA series 2013) for displaying all system values and reading statistical values (fault memory data)

y Protective covers and rain covers y Fan covers with intake manifold

(for installing the generator in the engine compartment) y Diverse belts and hydraulic kits y Cable adapters / terminal border adapter for magnetic load line y Safety sockets for magnetic connection at the boom y Universal assembly of plates for generator installation

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Spare partsAccessories

12 Spare parts

Companies authorised for repair- and replacement work must get in touch directly with the manufacturer for the Workshop-/Service manual.

Standard spare parts can be obtained from the manufactureror service contact partners under the following list.

GTS spare parts list iMAPLASPARE PART GTS iMAPLA 8 kW GTS iMAPLA 13 kW GTS iMAPLA 17 kWGenerator (complete) 0/0100-7477-000-001 0/0100-7677-000-001 0/0100-7877-000-001Switch box (8-30 kW) without ISO monitoring

0/0101-5232-008-001 0/0101-5232-013-001 0/0101-5233-017-001

Switch box (8-30 kW) with ISO monitoring

0/0101-5232-113-001 0/0101-5233-117-001 0/0101-5235-117-001

MMI (Man-Machine-Interface) without ISO monitoring

0/0101-9111-408-001 0/0101-9111-413-001 0/0101-9111-417-001

MMI (Man-Machine-Interface) with ISO monitoring

0/0101-9112-408-001 0/0101-9112-413-001 0/0101-9112-417-001

MMI cable; 10 mstraight / angled connector

5/0000-5512-110-001 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 connector

0/0100-5512-110-001 0/0100-5512-110-001 0/0100-5512-110-001

DS3 + DS 6 blue socket 0/0100-5880-003-001 0/0100-5880-003-001 0/0100-5880-003-001DS3 + DS6 and connector 0/0100-5881-003-001 0/0100-5881-003-001 0/0100-5881-003-001MAPLA connector for load cable

2/1210-5502-020-001 2/1210-5502-020-001 2/1210-5502-020-001

MAPLA connector for generator

2/1210-5503-002-001 2/1210-5503-002-001 2/1210-5503-002-001

MAPLA load cable socket 2/1210-5501-013-001 2/1210-5501-013-001 2/1210-5501-013-001Socket on generator 2/1210-7677-013-001 2/1210-7677-013-001 2/1210-7677-013-001end shield A 3/0004-4022-270-001 3/0004-4022-270-001 3/0004-3020-268-001B bearing plate 3/0004-3020-244-001 3/0004-3020-244-001 3/0004-4020-671-001Fan cover 1/0000-5130-211-001 5/0000-5130-210-001 1/0000-5130-211-001Fan blade 1/0000-5110-011-001 1/0000-5110-013-001 1/0000-5110-042-001Controller electronics 1/7477-5410-101-001 1/7677-5410-101-001 1/7877-5410-101-001

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Spare partsAccessories

SPARE PART GTS iMAPLA 20 kW GTS iMAPLA 25 kW GTS iMAPLA 30 kWMAPLA Generator (complete) 0/0100-7879-000-001 0/0100-4023-000-001 0/0101-4023-000-001iMAPLA switch box (8-30 kW) without ISO monitor

0/0101-5235-020-001 0/0101-5235-025-001 0/0101-5235-030-001

iMAPLA switch box (8-30 kW) with ISO monitor

0/0101-5235-120-001 0/0101-5235-125-001 0/0101-5235-130-001

MMI (Man-Machine-Interface) without ISO monitor

0/0101-9111-420-001 0/0101-9111-425-001 0/0101-9111-430-001

MMI (Man-Machine-Interface) with ISO monitor

0/0101-9112-420-001 0/0101-9112-425-001 0/0101-9112-430-001

MMI cable; 10 m with straight / angled connector

5/0000-5512-110-001 5/0000-5512-110-001 5/0000-5512-110-001

MAPLA load cable (8-30 kW & 20+30m) compl. 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 blue socket 0/0100-5880-003-001 0/0100-5880-006-001 0/0100-5880-006-001DS3 + DS6 and connector 0/0100-5881-003-001 0/0100-5881-006-001 0/0100-5881-006-001MAPLA connector for load cable

2/1210-5502-020-001 2/1210-5504-040-001 2/1210-5504-040-001

MAPLA connector for generator

2/1210-5503-020-001 2/1210-5503-030-001 2/1210-5503-030-001

MAPLA load cable socket 2/1210-5501-020-001 2/1210-5501-030-001 2/1210-5501-030-001Socket on generatorend shield A 3/0004-3020-268-001 3/0004-3030-257-001 3/0004-3030-257-001B bearing plate 3/0004-4020-671-001 3/0004-4330-259-001 3/0004-4330-259-001Fan cover 1/0000-5130-055-001 1/0000-5130-153-001 1/0000-5130-153-001Fan blade 1/0000-5110-042-001 1/0000-5110-021-001 1/0000-5130-021-001Controller electronics 1/7879-5450-101-001 1/4023-5450-101-001 1/4023-5450-101-001

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Commissioning

13 Commissioning

The start-up of the system and the inspection of the correct function must be confirmed by the responsible person by filling out this commissioning report in full

Installed system Rated power (8, 13, 17, 20, 25 or 30 kW) kW

Construction type

One Unit External Unit

ID number generatorSerial number of the generator

Assembly SK Serial number switch boxInstalled magnetic plate

ManufacturerTypeRated current A Nominal voltage VPermissible cyclic duration factor

%

MMI version Standard version Stand-Alone

Radio modem

Customer-specific version (description, number)

Voltage supply MMI

System-specific power supply via generator

For external power supply only:Voltage source:Activated by:fuse dataInstallation site of fuse

Customer data Excavator type:Customer / user

Commissioning carried out and check the correct function

Date:Company / Name:

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EC Declaration of Conformity

14 EC Declaration of Conformity

as per the EU Machinery Directive 2006/42/EC from 17 May 2006, Annex II AWe declare herewith that as a result of the manner in which the machine designated below was designed, the construction type and the machines which, as a result, have been brought on to the general market comply with EC Directive 2006/42/EC. This declaration shall become null and void should any alterations be made to the machine without our express approval.

Manufacturer / representative:GTS GmbH & Co. KGGenerator. Technik. Systeme.Ziegelfeldstraße 62 + 6573563 Mögglingen (Germany)Tel.: +49 (0) 71 74/8 98 00-0

Description of system components:

y function: GTS iMAPLA: intelligent lifting magnet lifting system (iMAPLA) with AC-DC generator for magnet applications (DGGM)

y Type / model: DGGM (BL4) or DGGM (BL) 132 and 160 2-pole and 4-pole models

y ID No.: 4023, 4028, 7477, 7677, 7877, 7879, 8208, 8213, 8217 and 8220

y Year of manufacture: from 01/01/2012 and following iMAPLA models y Product description: Lifting magnet lifting system of power classes

6 to 44 kW, generator with iMAPLA control electronics and MMI control unit. All of the data and load lines with associated plug connections recommended / specified by the GTS.

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EC Declaration of Conformity

Compliance with other directives / provisions valid for the product is also declared:

Machinery Directive 2006/42/EC, Appendix II AEMC Directive 2004/108/ECLow Voltage Directive 2006/95/EC

Applied harmonised / national standards where applicable to the product, in particular:

DIN EN 60033-ff Rotating electrical machinesDIN VDE 0100 Regulations for the erection of power installations

(up to 1,000 V)DIN EN 60204-1 Electrical equipment for industrial machinesDIN EN 60529 Protection classes via housing (IP Code)DIN EN 61557 Electrical safety in low voltage distribution systemsDIN EN ISO 12100 Safety of machinery-General principles of design

-risk assessmentDIN EN 60204-32 Safety of machinery-Part 32: requirements for lifting gearDIN EN 13155 Crane safety-Loose load lifting attachments

(not for mobile use)DIN EN 60068 Environmental influencesDIN EN 13309 Construction machinery - EMC of machines with internal

on-board electrical supplyEN 61000-6 Electromagnetic Compatibility (EMC)ISO 7637-2 Road vehicles-Electrical disturbances from conduction

and couplingDIN EN 55011 Industrial limits and methods of measurement of radio

disturbance characteristics

Mögglingen, 28/08/2013

___________________________Managing Director M. Ebbinghaus

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Block circuit diagram

15 Block circuit diagram

Fig. 38 Block circuit diagram 8-17 kW

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Fig. 39 Block circuit diagram 20 kW

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Fig. 40 Block circuit diagram 30 kW

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Index of figures

16 Index of figuresFig. 1. iMAPLA system overview (shown: iMAPLA 17 “One Unit” with Stand‑Alone‑MMI) .......................21Fig. 2. Characteristic curve, “lifting” ...............................................................................................................................24Fig. 3. Characteristic curve “release” ..............................................................................................................................25Fig. 4. Characteristic curve, overload protection ......................................................................................................26Fig. 5. MMI control unit (stand‑alone) and MMI displays .....................................................................................30Fig. 6. Assignment of the RS232 interface on the MMI STD to the switch box ...............................................31Fig. 7. Connection assignment, control button ........................................................................................................31Fig. 8. MMI dimensions and fastening dimensions (stand‑alone version) .....................................................32Fig. 9. Generator iMAPLA 17 “One Unit” (example) .................................................................................................33Fig. 10. Generator iMAPLA 25 “External Unit” (example) .........................................................................................34Fig. 11. iMAPLA 8 to 17 and 20; plug connection generator switch box ............................................................37Fig. 12. iMAPLA 25 and 30; plug connection generator‑switch box ....................................................................38Fig. 13. Assignment of RS232 interface to MMI on switch box ..............................................................................38Fig. 14. Connection assignment at the lifting magnet output, iMAPLA 8 to iMAPLA 20 ............................39Fig. 15. Connection assignment at the lifting magnet output iMAPLA 25 and 30 ........................................40Fig. 16. Connection assignment CAN socket iMAPLA 2013 series ........................................................................41Fig. 17. Dimensioned drawing iMAPLA 8 “One Unit” ................................................................................................42Fig. 18. Dimensioned drawing iMAPLA 8 “External Unit” ........................................................................................43Fig. 19. Dimensioned drawing iMAPLA 13 “One Unit” ..............................................................................................44Fig. 20. Dimensioned drawing iMAPLA 13 “External Unit” ......................................................................................45Fig. 21. Dimensioned drawing iMAPLA 17 “One Unit” ..............................................................................................46Fig. 22. Dimensioned drawing iMAPLA 17 “External Unit” ......................................................................................47Fig. 23. Dimensioned drawing iMAPLA 25 “External Unit” ......................................................................................48Fig. 24. Dimensioned drawing iMAPLA 20 ....................................................................................................................49Fig. 25. Dimensioned drawing iMAPLA 30 "One Unit ................................................................................................50Fig. 26. Example rating plate for a 13 kW iMAPLA generator.................................................................................53Fig. 27. Preparatory disassembly of the flange mount (iMAPLA 8 and 13) .......................................................76Fig. 28. Assembly of flange mount SAE5 (iMAPLA 8,13,17 and 20) ......................................................................77Fig. 29. Assembly of the flange mount for the hydraulic drive (using iMAPLA 13 as an example) ..........78Fig. 30. Preparatory disassembly of the flange mount SAE5 (iMAPLA 25 and 30) .........................................86Fig. 31. Assembly of flange mount SAE5 (iMAPLA 25 and 30) ...............................................................................87Fig. 32. Assembly of flange mount hydraulic drive (iMAPLA 25 and 30) ............................................................88Fig. 33. MMI displays ..............................................................................................................................................................99Fig. 34. MMI with radio modem ..................................................................................................................................... 148Fig. 35. Assignment, RS232 interface radio modem to switch box ................................................................... 149Fig. 36. Connection assignment control button ...................................................................................................... 150Fig. 37. Dimensions and fastening dimensions MMI and radio modem ........................................................ 153Fig. 38. Block circuit diagram 8‑17 kW ......................................................................................................................... 160Fig. 39. Block circuit diagram 20 kW ............................................................................................................................. 161Fig. 40. Block circuit diagram 30 kW ............................................................................................................................. 162

17 Index of figures

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Index

18 Index

AAccessories ..............................................................................................154Ambient conditions for transport and storage ..................... 144Arrangement of the hydraulic drive ..............................................89Assembly ........................................................................71, 76, 78, 86, 88Assembly (iMAPLA 25 and 30) .........................................................82Assembly instructions for belt drive ........................................74, 84Assembly instructions for flange mounting SAE5 ............76, 86Assembly instructions for hydraulic drive ............................ 77, 87

BBlock circuit diagram ........................................................................ 160

CCables .......................................................................................................139Calculation of hydro‑drive for GTS iMAPLA generators .......89Carry out a restart ............................................................................... 115Commissioning .............................................................................94, 157Components ............................................................................................ 19Configuring the radio channel ......................................................153Connection and connector assignments ...................................64Construction type “External Unit” ........................................... 19, 52Construction type “External Unit” and MMI with radio modem .......................................................................................................64Construction type “External Unit” and stand‑alone MMI ..........................................................................64Construction type “One Unit”.................................................... 19, 51Construction type “One Unit” and MMI with radio modem ................................................................................63Construction type “One Unit” and stand‑alone MMI ............63Controller with CAN Bus .....................................................................20Copyright ..................................................................................................... 8Customer‑specific MMI versions ....................................................154

DDaily inspection of the insulation monitor ..............................107Decommissioning, storage after disassembly of, disposal ................................................................... 146Description ...............................................................................................35Description of system components: ............................................158Dimensions of the systems ................................................................42Direct drive ................................................................................................28Displays on the MMI ...........................................................................149Disposal instructions ......................................................................... 146Drive via belt pulley ...............................................................................28Drive via direct flange ..........................................................................28Drive via hydraulic motor ..................................................................28

EEC Declaration of Conformity ........................................................158Establish the system’s readiness for use .................................... 106Excess temperature, control electronics ....................................127

FFunction description ............................................................................23

GGeneral information.............................................................8, 144, 147General safety instructions ................................................................58Generator ..................................................................................................20

Generator and controller ....................................................................33Generator and switch box ...............................................................139Generator drive types ...........................................................................28Generator installation for iMAPLA 8, 13, 17 and 20 ................69Generator installation for iMAPLA 25 and 30 ...........................79GTS spare parts list iMAPLA ............................................................155GTS type designation and identification ....................................53

IiMAPLA 8, 13 and 17, construction type “One Unit” ............ 144iMAPLA 8 and iMAPLA 13, construction type “External Unit” .......................................................................................145iMAPLA 17, construction type “External Unit” .........................145iMAPLA 20 and 30, construction type “One Unit” .................145iMAPLA 25, construction type “External Unit” ........................145iMAPLA generators, construction type “External Unit” ........70iMAPLA generators, construction type “One Unit” ..........70, 80iMAPLA system description ............................................................... 19Important information and notes ................................................... 6Information for Han modular connector cables switch box lifting magnet ..................................................67Installation ................................................................................................32Installation and commissioning .....................................................58Installation of cables ............................................................................64Installing the generator connection cable .................................93Installing the MMI with radio modem .......................................151Installing the radio MMI ....................................................................152Installing the radio modem ............................................................152Installing the switch box, construction type “External Unit” ..............................................................................92Insulation faults arose .......................................................................124Insulation monitor faulty .................................................................128Intended use ............................................................................................... 6Interface fault ........................................................................................119Interruption ............................................................................................118

JJob mode................................................................................................ 108Jog / Sorting mode [B] (switch setting down) ....................... 109

LLifting generators and switch boxes .......................................... 144Lifting magnet ........................................................................................20Lift load ....................................................................................................114Lift load (switch on the lifting magnet) ..............................23, 110

MMaintenance and care ......................................................................134Maintenance work carried out by authorised technicians 140Manual control unit .............................................................................20Manufacturer / representative: ......................................................158Manufacturer’s address ........................................................................ 8Material handling mode ................................................................. 108Maximum tension force (tension) of the drive belt on the shaft .............................................................................................................85Minimum clearances ....................................................................73, 83Minimum clearances and instructions cooling ................72, 82Minimum cross sections .....................................................................67Minimum requirements for the cables used ..............................66MMI ............................................................................................................139MMI control device ......................................................................... 19, 29MMI control device (stand‑alone version) ..................................29MMI displays ............................................................................................30MMI installation .....................................................................................64MMI operating‑ and fault displays ................................................99

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Index

MMI plug connections (default assignment) ............................ 31MMI with radio modem ....................................................................147Multiple functions when several LEDs light up at the same time ................................................................ 105

NNormal drive ......................................................................................... 108Normal‑/machine handling operation [A] (switch on top) ..................................................................................... 108Note when assembling the generator in a rotated position .............................................................................71

OOperating a GTS iMAPLA at SunFab Hydro‑Motors ..............90Operating instructions ........................................................................98Operation ..................................................................................................95Operation in Jog mode / Sorting mode [B].............................. 113Operation in Normal and Material handling mode [A] .....110Options and accessories ...................................................................147Other optional modes (modes) .................................................... 109Overload limitation ............................................................................120Overload protection iMAPLA ...........................................................26Overspeed ...............................................................................................123Overtemperature pre‑warning (control electronics) ...........126Overview table for operating a GTS iMAPLA at SunFab ......91

PPermissible installation site ...............................................................81Permissible installation sites .............................................................71Permissible installation site switch boxes....................................93Plug connections, MMI and wireless modem .........................149Plug connections on generator and switch box ......................37Possible MMI type descriptions ........................................................57Pre‑assembled cables, supplied ......................................................65Preparatory disassembly ............................................... 76, 77, 86, 87

QQualified personnel ................................................................................ 6

RRating plate, generator .......................................................................53References to standards and directives ........................................ 17Release load (switch off lifting magnet) ............................. 24, 112Releasing load .......................................................................................114Repairs ......................................................................................................141Requirements for the connection cables between generator and lifting magnet ......................................67Requirements on the connection cables ....................................66Requirements on the installation site .............................70, 80, 92Rules for cable installation ................................................................66

SSafety instructions ........................................................................10, 135Safety instructions for operation ....................................................95Safety instructions for troubleshooting .....................................116Safety instructions legend ................................................................... 2Scope of supply .......................................................................................63Separate the material ........................................................................114Serial number, iMAPLA 2013 series switch box (with CAN Bus) .................................................................55Serial number, iMAPLA switch box ................................................55Serial number, MMI control unit .....................................................57Serial number switch box / controller ..........................................55Sorting mode ...............................................................................108, 109Spare parts ..............................................................................................155Special properties ..................................................................................22Specifications ..........................................................................................68System fault ............................................................................................121System overview ..................................................................................... 19System restart iMAPLA controller ................................................. 115

TTechnical data .........................................................................................51Technical data MMI with radio modem ....................................154Temperature and pressures of the cooling air ...................73, 83Temperature limit exceeded (control electronics) .................127Temperature warning, control electronics ...............................126The MMI is not supplied with voltage from the generator ..............................................................................107Transport and storage ...................................................................... 144Troubleshooting ...................................................................................116Troubleshooting measures ......118, 120, 121, 122, 123, 124, 126, .............................................................................................................127, 129Type designation, generator .............................................................54

UUnderspeed ............................................................................................122

VValidity of the manual ........................................................................... 7Visual inspection / cleaning work by the user .........................138

WWhen the MMI is supplied with voltage from the generator ................................................. 106

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Ziegelfeldstraße 62 + 65 // D-73563 Mögglingen //T. +49(0) 71 74 8 98 00-0 // F. +49 (0) 71 74 8 98 00-25 //E. [email protected] // W. www.gts-generator.com

Modular energy supply system for load lifting magnets ...

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