GTS iMAPLA series User manual

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

Issue 08/2013Page 2
MAPLA- Modular energy supply system for load lifting magnets
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.
Danger
Means that death or serious bodily injury will occur if the
appropriate precautionary measures are not met.
Warning
Means that death or serious bodily injury can occur if the
appropriate precautionary measures are not met.
Caution
Means that minor bodily injury can occur if the appropriate
precautionary measures are not met.
Important
Means that property damage can occur if the appropriate
precautionary measures are not met.
Note
Means 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.

Page 3Issue 08/2013
Legend, safety instructionsContents
Contents
Legend, safety instructions 2
1 Important information and notes 6
1.1 Qualied personnel 6
1.2 Intended use 6
1.3 Validity of the manual 7
1.4 Copyright 8
1.5 General information 8
1.6 Manufacturer's address 8
2 Safety instructions 10
3 References to standards and directives 17
4 iMAPLA system description 19
4.1 Components 19
4.2 System overview 19
4.3 Special properties 22
4.4 Function description 23
4.4.1 Lift load (switch on lifting magnet) 23
4.4.2 Release load (switch o lifting magnet) 24
4.4.3 Overload protection iMAPLA 26
4.5 Generator drive types 28
4.5.1 Drive via belt pulley 28
4.5.2 Direct drive 28
4.5.3 Drive via direct ange 28
4.5.4 Drive via hydraulic motor 28
4.6 MMI control unit (stand-alone version) 29
4.6.1 General 29
4.6.2 MMI displays 30
4.6.3 MMI plug connections (default assignment) 31
4.6.4 Installation 32
4.7 Generator and controller 33
4.7.1 Description 35
4.7.2 Plug connections on the generator and switch box 37
4.8 Dimensions of the systems 42
4.9 Technical data 51
4.9.1 Construction type “One Unit” 51
4.9.2 Construction type “External Unit” 52
4.10 GTS type designation and identication 53
4.10.1 Rating plate, generator 53
4.10.2 Serial number switch box/controller 55
4.10.3 Serial number, MMI control unit 57

Issue 08/2013Page 4
MAPLA- Modular energy supply system for load lifting magnets
Legend, safety instructionsContents
5 Installation and commissioning 58
5.1 General safety instructions 58
5.2 Delivery scope 63
5.3 Installation of MMI 64
5.4 Installation of cables 64
5.4.1 Pre-assembled cables, supplied 65
5.4.2 Rules for cable installation 66
5.4.3 Requirements on the connection cables 66
5.5 Generator installation for iMAPLA 8, 13, 17and 20 69
5.5.1 Requirements on the installation position 70
5.5.2 Permissible installation positions 71
5.5.3 Assembly 71
5.5.4 Minimum clearances and cooling provisions 72
5.5.5 Assembly instructions for belt drive 74
5.5.6 Assembly instructions for ange mount SAE5 76
5.5.7 Assembly instructions for hydraulic drive 77
5.6 Generator installation for iMAPLA 25and 30 79
5.6.1 Requirements on the installation position 80
5.6.2 Permissible installation position 81
5.6.3 Assembly (iMAPLA 25and 30) 82
5.6.4 Minimum clearances and cooling provisions 82
5.6.5 Assembly instructions for belt drive 84
5.6.6 Assembly instructions for ange mount SAE5 86
5.6.7 Assembly instructions for hydraulic drive 87
5.7 Arrangement of the hydraulic drive 89
5.7.1 Calculation for hydro-drive for GTS iMAPLA generators 89
5.8 Installation of the switch box, constructiontype“ExternalUnit” 92
5.8.1 Requirements on the installation position 92
5.8.2 Permissible installation site for aswitch box 93
5.8.3 Installing the generator connection cable 93
5.9 Commissioning 94
6 Operation 95
6.1 Safety instructions for operation 95
6.2 Operating instructions 98
6.3 MMI operating- and fault displays 99
6.4 Establish the system's readiness for use 106
6.5 Daily inspection of the insulation monitor 107
6.6 Set operating modes, normal mode and jog mode (machine handling and
sorting operation) 108
6.6.1 Normal-/machine handling operation[A] (switch on top) 108
6.6.2 Jog/Sort mode[B] (switch setting below) 109
6.6.3 Other optional modes 109
6.7 Operating in Normal or Material handling mode[A] 110
6.7.1 Lift load (switch on the lifting magnet) 110
6.7.2 Release load (switch o lifting magnet) 112
6.8 Operation in Jog mode/Sorting mode[B] 113
6.8.1 Lift load 114
6.8.2 Separating the material 114
6.8.3 Releasing load 114
6.9 System restart iMAPLA controller 115

Page 5Issue 08/2013
Legend, safety instructionsContents
6.10 Troubleshooting 116
6.10.1 Interruption 118
6.10.2 Interface fault 119
6.10.3 Overload limitation 120
6.10.4 System fault 121
6.10.5 Underspeed 122
6.10.6 Overspeed 123
6.10.7 Insulation faults arose 124
6.10.8 Overtemperature pre-warning (control electronics) 126
6.10.9 Temperature limit exceeded (control electronics) 127
6.10.10 Insulation monitor faulty 128
6.10.11 Cyclic duration factor greater than or equal to 80% 129
6.10.12 MMI overview display values 130
6.10.13 Troubleshooting, system fault blink codes 132
7 Maintenance and care 134
7.1 Safety instructions 135
7.2 Visual inspection/cleaning work by the user 138
7.3 Maintenance work carried out by authorised personnel 140
8 Repairs/repair 141
9 Transport and storage 144
9.1 General 144
9.2 Ambient conditions for transport and storage 144
9.3 Lifting generators and switch boxes 144
10 Decommissioning, storage after disassembly of, disposal 146
Disposal instructions 146
11 Options and accessories 147
11.1 MMI with radio modem 147
11.1.1 General 147
11.1.2 Displays on the MMI 149
11.1.3 Plug connections, MMI and radio modem 149
11.1.4 Installing the MMI with radio modem 151
11.1.5 Installing the radio MMI 152
11.1.6 Installing the radio modem 152
11.1.7 Conguring the radio channel 153
11.1.8 Technical specications, MMI with radio modem 154
11.2 Customer-specic MMI versions 154
11.3 Accessories 154
12 Spare parts 155
13 Commissioning 157
14 EC Declaration of Conformity 158
15 Block circuit diagram 160
17 Index of gures 163
18 Index 164

Issue 08/2013Page 6
MAPLA- Modular energy supply system for load lifting magnets
Important information and notes
1 Important information and notes
1.1 Qualied 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 qualied personnel.
Qualied 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.
yThe 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.
yOnly use the iMAPLA system according to the voltage and performance
data on the rating plate.
yDo 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).
yOperate the iMAPLA system at the nominal speed.
yOnly 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.
yConnecting dierent iMAPLA systems in parallel or with other systems is
not allowed.

Page 7Issue 08/2013
Important information and notes
yThe 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.
yUse 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 dierent generator types are distinguished by their type designation and
their model.
The manufacturer reserves the right to make technical changes.

Issue 08/2013Page 8
MAPLA- Modular energy supply system for load lifting magnets
Important information and notes
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. KG
Ziegelfeldstraße 62 + 65
73563Mögglingen (Germany)
Tel [phone]
Fax [phone]
www.gts-generator.com
[e-mail]

Page 9Issue 08/2013
Important information and notes
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
veried 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
modications 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

Issue 08/2013Page 10
MAPLA- Modular energy supply system for load lifting magnets
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.
Danger
Danger to life through electric shock
yDuring operation, the iMAPLA system generates potentially
fatal electrical voltages.
yAll 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 o 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.

Page 11Issue 08/2013
Safety instructions
Danger
Danger to life through electric shock
yInsulation monitors can mutually inuence each other.
►Do not connect any other insulation monitors to the
iMAPLA system.
Danger
Danger to life through electric shock
yWith an insulation fault, the “electrical separation” protective
measure - which is otherwise provided by the system - is no
longer eective. This means that - if another fault arises -
potentially fatal contact voltages may arise on metal parts.
ySecond 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.
Danger
Danger to life through falling loads!
ySuspended 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-xed load lifting attachments”.
►On mobile systems (e.g.material handling machines),
observe the manufacturer's specications. Nobody is
allowed to remain in the working area/safety area of the
machine during operation.

Issue 08/2013Page 12
MAPLA- Modular energy supply system for load lifting magnets
Safety instructions
Danger
Danger to life through falling loads!
yA 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 sucient
drive power, and establish the operational reliability of the
drive before commissioning.
Danger
Danger to life!
yStrong, permanent magnetic elds 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sucient safety clearance from the lifting
magnet.
Warning
Risk of injury and risk of damage!
yWhen working on the iMAPLA system, insuciently qualied
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, qualied and specially trained
personnel.
►Carry out all connection work according to applicable
national regulations (in Germany: these include VDE
specications).

Page 13Issue 08/2013
Safety instructions
Warning
Risk of injury and risk of damage!
yShutting o the drive motor counts as ageneral EMERGENCY
STOP function.
►In the event of an emergency, shutting down the drive
machine can switch o the system safely. After the
shut-down, hazardous voltages may remain in and on the
system for up to amax. 45seconds.
Warning
Risk of injury
yWhen 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 tted for the drive as specied.
Warning
Risk of explosion
yA discharge of sparks during operation is possible.
►Do not operate the iMAPLA system in potentially explosive
environments.
Warning
Risk of accident
yDevices which start up in an uncontrolled fashion can put
persons at risk or injury them or cause damage or themselves
be damaged.
►Switch o all devices before they are connected to the
iMAPLA system.

Issue 08/2013Page 14
MAPLA- Modular energy supply system for load lifting magnets
Safety instructions
Warning
Risk of accident
yAn 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.
Warning
Danger to life caused by electric shock and risk of damage.
yWater 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.
Caution
Burn hazard
yParts of the iMAPLA system can get very hot during and after
operation.
►Allow the iMAPLA-System and parts to cool down before
touching.

Page 15Issue 08/2013
Safety instructions
Important
yThe iMAPLA system is not suited for supplying xed
distribution systems.
yThe iMAPLA system is designed for aspecic 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 xed 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.
Important
The iMAPLA system must only be operated under the indicated
environmental conditions and cooling conditions.
Important
The iMAPLA system must only be used for supplying power
to suitable lifting magnets. Follow the lifting magnet's
manufacturer specications.
Important
Pay attention to the operating data.
ÖTechnical data, page51.
Make sure the load cables connected to the magnet are suitable.
ÖPlug connections on the generator and switch box,
page37.
Important
When carrying out repairs, only use original parts from the
manufacturer, or third party parts which have been expressly
approved by the manufacturer.

Issue 08/2013Page 16
MAPLA- Modular energy supply system for load lifting magnets
Safety instructions
Important
No modications may be made to the system or individual
components of the system. Any modication, 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 certication according to
EU-/EEC directives. The manufacturer cannot assume any liability
in such acase.
Important
As aunit generating electrical power, the iMAPLA system and
the 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.
Important
Check that all the connector plugs have been plugged in/
engaged correctly and locked against accidental removal.

Page 17Issue 08/2013
References to standards and directives
3 References to standards and directives
The generator has been manufactured in accordance with the following
norms and directives.
yDIN EN 60034Part 1-9, rotating electrical machines
yDIN EN 60204-1; VDE 0113-1:2011-01
Safety of machinery - Electrical equipment of machines:
generalrequirements
yDIN 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)
yDIN VDE 0701-0702; VDE 0701-0702:2008-06/BGV A3
Inspection after repairs, changes to electrical device repeat
checks-General requirements on electrical safety
yGUV2.10DEmpf BR:1981-11-25, UVV Accident prevention regulation
“Electrical systems and machinery materials” with implementation
instructions
yDIN 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)
yDIN 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
yDIN 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
yDIN EN ISO 12100
Safety of machinery - General principles for design - Risk assessment and
risk reduction (ISO 12100:2010)

Issue 08/2013Page 18
MAPLA- Modular energy supply system for load lifting magnets
References to standards and directives
yDIN 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)
yDIN EN 13155
Cranes - Safety - Non-xed load lifting attachments (not for mobile
material handling machines)
yDIN 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)
yDIN 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)
yDIN EN 13309
Construction machinery - Electromagnetic compatibility of machines with
internal power supply
yISO 7637-2
Road vehicles -- Electrical disturbances from conduction and
coupling-Part2: electrical transient conduction along supply lines only
yDIN EN 55011; VDE 0875-11:2011-04
Industrial, scientic and medical equipment - Radio-frequency disturbance
characteristics - Limits and methods of measurement (IEC/CISPR 11:2009,
amended + A1:2010)

Page 19Issue 08/2013
iMAPLA system description
Components
4 iMAPLA system description
4.1 Components
yGenerator
ySwitch box with control electronics
yMMI 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.
Note
Follow the installation instructions.
ÖInstallation of the switch box,
constructiontype“ExternalUnit”, page92
MMI control device
The 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 eld 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-specic adjustments are possible, e.g.an
MMI with aradio modem.

Issue 08/2013Page 20
MAPLA- Modular energy supply system for load lifting magnets
iMAPLA system description
System overview
Controller with CAN Bus
The controller for the iMAPLA series 2013oers an additional CAN Bus
connection which can be programed according to Standard J1939specic 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.
ÖGTS type designation and identication, page53
Generator
The generator provides the electrical voltage/current needed for an action
to the connected lifting magnet.
There are arange of options for providing drive power to the generator.
ÖGenerator drive types, page28
Lifting magnet
The lifting magnet is freely selectable as part of the indicated specications
and performance constraints. The system automatically adapts to the
connected lifting magnet.
Manual control unit
The system is controlled via apushbutton which is connected to the MMI.
This button is xed 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
specications.