Maurer DN150 User manual

Translation from German manual
Power modules
DN150
DN750
DN1100
DN1850

Revisions
Power Module DN Version 09.2019 Page 2/43
Revisions
Version
Description
12.2008
First Version
09.2010
English Translation
05.2014
Description of the external enabling function
Maximum load adapted for interfaces
Warranty conditions adapted to current warranty sheet
Chapter 5.5 supplemented (Customer-specific configuration)
Additions to the analogue output 0 …1DC 0V
Additions to the process monitoring level 1 / Chapter 6.5.3
05.2014
New interface module
08.2015
General revision manual
Safety Instructions, Intended use, Installation and Commissioning, Operation, Demagnetization, Maintenance,
Troubleshooting, Specifications
10.2015
Troubleshooting with Fault
03.2016
Fault at Overtemperature
05.2016
Prefusing, RCCB, ELCB, leakage compensation
08.2017
Junction Box incl. lamp
09.2017
Description STO
07.2018
Additions Residual risk and decommissioning
08.2018
Revision
09.2019
Fieldbus coupler
08.2021
Fieldbus coupler adjustments

General Information
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General Information
•This manual contains information for safe operation of the machine/machine
components
•Read manual of all machine components
•Respect accident prevention regulations
•Respect local regulations
•This manual is a translation of the German original
•In case of questions regarding Installation, commissioning, operation or intended use
contact Maurer Magnetic. Contact information on the last page
Liability
Liability is restricted to the intended use. Any other liability is explicitly excluded.
Improper installation, operation, maintenance or use of the machine can lead to body injury
and property damage. Maurer Magnetic AG cannot be held liable for losses, consequential
damages or cost resulting from or linked with improper installation, operation, maintenance or
use.
© September 2019, Maurer Magnetic AG, Industriestrasse 8, CH-8627 Grüningen
Information, drawings and images in this manual serve exclusively the explanation of the
operation and handling of the designated machine. This manual is subject to change without
notice.

General Information
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Table of contents
1Safety instructions ....................................................................................................................6
1.1 Symbols...................................................................................................................................................6
1.2 Information on restrictive risks.................................................................................................................6
1.3 Notes on restrictive risks..........................................................................................................................7
1.4 Safety electromagnetic fields...................................................................................................................8
2Intended use...............................................................................................................................9
2.1 Compatibility MM coil modules................................................................................................................9
3Device characteristics............................................................................................................ 10
3.1 Scope of delivery...................................................................................................................................10
3.2 MM DN150 ............................................................................................................................................11
3.2.1 Controls ............................................................................................................................................. 11
3.2.2 Connectors ........................................................................................................................................ 11
3.3 MM DN750…DN1850............................................................................................................................12
3.3.1 Controls ............................................................................................................................................. 12
3.3.2 Connectors ........................................................................................................................................ 12
4Installation............................................................................................................................... 13
4.1 Transport...............................................................................................................................................13
4.2 Installation process................................................................................................................................13
4.3 Mounting................................................................................................................................................14
4.1 Connection to grid .................................................................................................................................14
4.1.1 DN150................................................................................................................................................ 14
4.1.2 Power cable (DN150)......................................................................................................................... 14
4.1.3 DN DN750…1850.............................................................................................................................. 15
4.2 Prefuse..................................................................................................................................................15
4.2.1 Operator Protection ........................................................................................................................... 15
4.3 Coil module connector HAN 3/HAN 10 B...............................................................................................15
4.4 Fan connector........................................................................................................................................16
4.4.1 Fan connector DN150 (optional)........................................................................................................ 16
4.4.2 Fan connector DN750-1850............................................................................................................... 16
4.5 Control signals.......................................................................................................................................16
4.5.1 Coil module monitoring M8................................................................................................................ 16
4.5.2 Sensor connector M12....................................................................................................................... 16
4.5.3 D-Sub15 Control Interface................................................................................................................. 16
4.5.4 D-Sub9 power setting interface (DN750…1850, optional) ................................................................. 16
4.6 Modification ...........................................................................................................................................17
5Commissioning....................................................................................................................... 18
5.1 Power on ...............................................................................................................................................18
5.2 Trigger demagnetization pulse ..............................................................................................................18
5.3 Demagnetisation test with intended object ............................................................................................18
5.4 Control via interface (if applicable) ........................................................................................................18
6Operation................................................................................................................................. 19
6.1 Operation mode.....................................................................................................................................19
6.1.1 Manual operation............................................................................................................................... 19
6.1.2 Integration in production line.............................................................................................................. 20
6.2 Controls.................................................................................................................................................20
6.2.1 Main switch........................................................................................................................................ 20
6.2.2 Start/Pulse button .............................................................................................................................. 20
6.3 Indicators...............................................................................................................................................20
6.3.1 Operation lamp .................................................................................................................................. 20
6.3.2 Ready lamp........................................................................................................................................ 20
6.3.3 Fault lamp.......................................................................................................................................... 20
6.3.4 Active lamp........................................................................................................................................ 20
6.3.5 Process OK lamp (Process Monitoring Step 1, optional)................................................................... 21
6.4 Sensor connection M12.........................................................................................................................21
6.5 D-Sub15 Control Interface (isolated) .....................................................................................................21
6.5.1 Configuration D-Sub15 connector...................................................................................................... 21
6.5.2 PIN2 Start.......................................................................................................................................... 21
6.5.3 PIN3 Ready ....................................................................................................................................... 21

Gener al Informat i on
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6.5.4 PIN4 Fault.......................................................................................................................................... 21
6.5.5 PIN5 Active........................................................................................................................................ 21
6.5.6 PIN7 Process OK (Process Monitoring Step 1, Optional).................................................................. 22
6.5.7 PIN10 External enable signal............................................................................................................. 22
6.5.8 PIN11 Module Ready......................................................................................................................... 22
6.5.9 PIN14/15 Analogue out (Field strength proportional signal)............................................................... 22
6.5.10 Interface board D-Sub15.................................................................................................................... 23
6.5.11 Status LED P1… P12 description ...................................................................................................... 23
6.5.12 Interface module fieldbus coupler...................................................................................................... 24
6.6 Power setting (MM DN750…1850, optional) .........................................................................................26
6.6.1 Power setting via selector switch....................................................................................................... 26
6.6.2 D-SUB9 power setting interface......................................................................................................... 26
6.6.3 Configuration D-Sub9 connector........................................................................................................ 26
6.7 Continuous demagnetization.................................................................................................................26
6.8 Safety control.........................................................................................................................................27
6.8.1 Safe Torque Off (STO), Optional....................................................................................................... 27
7Demagnetization..................................................................................................................... 28
8Maintenance............................................................................................................................ 29
8.1 Daily maintenance interval.....................................................................................................................29
8.1.1 Visual check....................................................................................................................................... 29
8.2 Monthly maintenance interval................................................................................................................29
8.2.1 Visual check....................................................................................................................................... 29
8.2.2 Functional check................................................................................................................................ 29
8.2.3 Maintenance...................................................................................................................................... 29
8.3 Yearly maintenance interval ..................................................................................................................29
8.3.1 Functional check................................................................................................................................ 29
8.4 Spare and wear parts ............................................................................................................................30
8.4.1 Fuse protection.................................................................................................................................. 30
8.4.2 Inverter replacement.......................................................................................................................... 30
8.5 Decommissioning ..................................................................................................................................31
8.5.1 Disassemble...................................................................................................................................... 31
8.5.2 Disposal............................................................................................................................................. 31
9Troubleshooting ..................................................................................................................... 32
9.1 Ready lamp dark / no Ready signal:......................................................................................................32
9.2 Active lamp flashing / Active Signal flashing (5 Hz)...............................................................................32
9.3 Fault lamp flashing / Fault Signal flashing (5 Hz)...................................................................................32
9.4 Fault lamp indicates / +24VDC on Fault signal:.....................................................................................32
9.5 Process OK lamp dark / no Process OK signal: ....................................................................................32
9.6 False triggering of the RCCB, ELCB......................................................................................................33
9.7Insufficient demagnetization..................................................................................................................33
9.8 Demagnetization pulse check................................................................................................................34
9.9 Malfunction external coil fan at Fan connector ......................................................................................34
9.10 Error analysis LED interface board........................................................................................................35
10 Specifications ......................................................................................................................... 36
10.1 General..................................................................................................................................................36
10.1.1 Minimal cycle times............................................................................................................................ 36
10.2 Power supply.........................................................................................................................................36
10.3 Output....................................................................................................................................................37
10.3.1 Fan connector.................................................................................................................................... 37
10.4 Control signals.......................................................................................................................................38
10.4.1 Sensor connector M12....................................................................................................................... 38
10.4.2 D-Sub15 control interface.................................................................................................................. 39
10.4.3 D-Sub9 power setting interface (optional, DN750-1850).................................................................... 40
10.5 Ambient conditions ................................................................................................................................41
10.5.1 Operation........................................................................................................................................... 41
10.5.2 Storage.............................................................................................................................................. 41
11 Standard Warranty.................................................................................................................. 42

Safety instructions
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1 Safety instructions
1.1 Symbols
Indicates situations with risk for body injury and property damage by
electromagnetic radiation.
Indicates situations with risks by high electric voltages.
Indicates situations with risk of burns.
Indicates situations that demand special attention.
Indicates danger for persons with a cardiac pacemaker.
1.2 Information on restrictive risks
Persons with cardiac pacemaker must not use the device.
Operate device only in premises with limited access!
Modification, repairs and opening of the device only by skilled personell.
•Wait 10 minutes for capacitor discharge before opening
The supply line to the power module up to the main switch always carries voltage.
High voltages can lead to lethal electric shock and burns.
Opening of the device only by skilled personell.
•No physical contact to energized parts
Modification of the machine leads to loss of waranty.
•Modification can lead to body injury and property damage
•Modification of the parametrisation can lead to overheating and shutdown
•Approval of modification only by Maurer Magnetic AG in writing

Safety instructions
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1.3 Notes on restrictive risks
Endangerment
Result or protection target
Measures
Life phase
Endangerment
Causes
1. 1. Transport, Assembly, Installation
1.1
Transporting /
Lifting the
machine
Squeezing/Pushing
Gravity
During pick-up / transport, the centre
of gravity of the machine could be
ignored, so that the machine falls
over / down. There is a risk of
crushing body parts when setting
down.
Specify weight; the load capacity of
the conveyor vehicle must be able to
lift the weight of the system,
Secure the system on the conveyor
vehicle against slipping,
wear safety shoes
1.2
Installation
and orientate
Squeezing/Pushing
Gravity
Ensure that the ground is stable,
otherwise tipping is possible.
Specify weight and dimensions
1.3
Up-, and
unload with
the conveyor
vehicles
Squeezing/Pushing
Movable Elements
Prevent moving elements (e.g.
doors) on the machine from
damaging persons
Secure movable elements against
unintentional swivelling or slipping
2. Commissioning
2.1
Connecting
the electrical
system
Electric shock
Contact with voltage charged
parts
Incorrect connection could cause
machine parts to carry voltage
Only qualified personnel may connect
the machine
3. Operation
3.1
Persons in the
coil area
Electromagnetic
radiation
Illegal exposure to
electromagnetic radiation
If a person stays in the exposure
area it may cause damage to health
Applying warning glue,
Perform and include exposure
measurement,
A shielding chamber is
recommended to reduce the
exposure radius,
The operator of the system is
recommended to install a protective
housing
3.2
Demagnetizin
g of
components
Moving parts
Attraction of components by
the magnetic field of the coil
Components must not be held in the
coil by hand,
Do not place ferromagnetic
parts/tools in the area of the coil
Notes in the manual
3.3
Heating of
components
Incineration
Heating
If a ferromagnetic component is
exposed to the magnetic field for a
long time, the component heats up.
Demagnetization of components
using the pulse method
4. Fault diagnostics, Troubleshooting
4.1
Trouble-
shooting
Electric shock
Contact with voltage charged
parts
Incorrect fault diagnostic or
measurement may result in contact
with voltage charged parts
Only qualified personnel may inspect
the machine
5. Maintenance
5.1
All
maintenance
work
Squeezing
Moving parts
Prevent uncontrolled movement
Switch off the main switch before
carrying out any work on the
machine,
Lock main switch and attach warning
sign
6. Decommissioning, Disassemble, disposal
6.1
Disassemble
See section 1.1

Safety instructions
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1.4 Safety electromagnetic fields
See manual coil module

Intended use
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2 Intended use
The demagnetization power modules MM DN150…1850 are products developed and sold by
Maurer Magnetic AG. They are intended to be used in combination with compatible
demagnetization coil modules such as the MM CT-U, MM SE, MM RE, MM KE, MM VE series
or custom-built coil modules.
MM DN modules feature the following functionality:
•A/C source for demagnetization coils
•User interface
•Monitoring of demagnetization coil modules
•External control interface (24VDC)
2.1 Compatibility MM coil modules
Type coil modules
DN150
DN750-1850
MM CT-U
x
x
MM KE
x
-
MM SE
-
x
MM RE
-
x
MM VE-2/4
-
x
custom-built coil
x
x
Table 1: compatible coil modules

Devi ce characteristics
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3 Device characteristics
The power modules MM DN are separated into two classes. Housing, interface and available
options differ between the classes but are identical within the respective class.
•MM DN150
•MM DN750…1850
Following devices are available. The addition „-xx“ indicates the installed capacity.
•MM DN150-xx
•MM DN750-xx
•MM DN1100-xx
•MM DN1850-xx
DN type power modules features:
•CFT –Constant Field Technology
•FMT –Field Multiplicator Technology
3.1 Scope of delivery
•Power module
•Key for enclosure
•Documentation (printed and digital)
•Fixed base (optional)
•Power cable (only DN150)
•Additional options according to order scope

Devi ce characteristics
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3.2 MM DN150
3.2.1 Controls
Figure 1: Controls DN150
3.2.2 Connectors
Figure 2: Connectors DN150
Power cable
Fan connector (optional)
Coil module connector
s
Sensor connector M12
s
Coil module monitoring M8
Control interface D-Sub15
Operation Lamp
Ready Lamp
Fault Lamp
Active Lamp
Process OK lamp (optional)
Main switch
Cam Lock
Start button

Devi ce characteristics
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3.3 MM DN750…DN1850
3.3.1 Controls
Figure 3: Controls DN750-1850
3.3.2 Connectors
Figure 4: Connectors DN750-1850
Coil module connector
s
Power cable
Fan connector
Sensor connector M12
s
Main switch
Cam Lock (2x)
Operation Lamp
Ready Lamp
Fault Lamp
Active Lamp
Pulse button
Power selector
(optional)
Coil module monitoring M8
Control Interface D-Sub15
Power selector interface
D-Sub9
Process OK lamp (optional)

Instal lat ion
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4 Installation
Mount device on and flat ground, stable and flat surface.
•Ensure safe operation of device at all times
•Operate power module only upright. Do not operate in horizontal position.
Connection and disconnection of the coil module only with main switch off.
Installation and commissioning of the device only by skilled personell.
•Connect only to power source with correctly installed protection conductor
•Connect with regard to local regulations
Improper connection can damage the machine.
•Installation with off-state power source
•Installation with main switch off
Interface signals maximal current load 100mA
D-Sub15 PIN14/15: 0...10 VDC Output maximal current load 1 mA
Do not connect D-Sub interface with computer interface verbinden. Pc and power
module may be damaged.
4.1 Transport
Do not lift components of more than 25 kg by hand.
Do not lift coils mounted in shielding chambers on the shielding chamber.
•Lift with support from below
Power module can be lifted and transported by two persons.
4.2 Installation process
•Mounting of coil
•Mounting of power module
•Check fastening torque of power connections
•Connection power supply power module
•Connection Coil module connector and Coil module monitoring M8
•Connection Fan connector (if applicable; MM VE)
•Optional: Connection D-Sub15 Control Interface
•Optional: Connection Power selection interface D-Sub9 (DN750-1850)
•Optional: Connection photo sensor on Sensor connector M12

Instal lat ion
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4.3 Mounting
Power module cabinet mounting:
•Placing on fixed base (optional)
•Wall-mount using 4 available mounting eyes
Figure 5: DN with base and wall-mounted
4.1 Connection to grid
4.1.1 DN150
Voltage, current and frequency ranges according to technical specification!
Phase-neutral connection:
For connection phase (L1) and neutral (N) and protective conductor (PE) are required
(1P/N/PE).
Phase-phase connection (US) (optional)
For connection two phases (L1/L2) and protective conductor (PE) are required (2P/PE).
Colour code supply connector DN150:
Labelling 1P/N/PE
Colours 1P/N/PE
Labelling 2P/PE
Colours 2P/PE
L1 (phase)
brown
L1 (phase)
black
N (neutral)
blue
L2 (phase)
black
PE (protective conductor)
green/yellow
PE (protective conductor)
green/yellow
Table 2: Colour code supply connector DN150
4.1.2 Power cable (DN150)
The DN150 can be connected to the grid with the provided power cable. If required, replace
cable to comply with local regulation.
Delivery worldwide: cable type (16A/250VAC) with safety plug (type E/F, CEE 7/7).
Delivery Switzerland: cable type (13A/250VAC) with safety plug (type J, SEV 1011).

Instal lation
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4.1.3 DN DN750…1850
The DN750…1850 is connected as TN-S Network. Three phases (L1, L2, L3) and the
protective conductor (PE) are required. Neutral and protective conductor laid separately. A
terminal connector for the neutral conductor is available but connection is not necessary.
Voltage, current and frequency ranges, according to 10.2!
Figure 6: TN-S connection DN750-1850
Colour code supply connector DN750…1850:
Conductor
Colour
L1 (phase)
brown or black
L2 (phase)
black
L3 (phase)
grey or black
N (neutral)
blue
PE (protective conductor)
green-yellow
Table 3: Colour code supply connector DN750…1850
4.2 Prefuse
For maximal and minimal prefuse see electric circuit diagram.
4.2.1 Operator Protection
If a RCCB or ELCB is used it needs to be a universal current sensitive RCCBs B
type, suitable for protecting frequency inverters.
In case of false triggering of the RCCB, we recommend installation of a leakage compensation
(See chapter troubleshooting).
4.3 Coil module connector HAN 3/HAN 10 B
The coil module is connected with a HAN 3 (DN150) or HAN 10 B (DN750-1850) to the power
module and latched.
•Voltage range see appendix
•Connector configuration and pin assignment according to circuit diagram

Instal lat ion
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4.4 Fan connector
•Voltage range see appendix
•Connector configuration and pin assignment according to circuit diagram
4.4.1 Fan connector DN150 (optional)
For 230 VAC cooling fan
4.4.2 Fan connector DN750-1850
For 24 VDC cooling fan
4.5 Control signals
Interface signals maximal current load 100mA
D-Sub15 PIN14/15: 0...10 VDC Output maximal current load 1mA.
Do not connect D-Sub interface to a PC verbinden. PC and power module may be
damaged.
4.5.1 Coil module monitoring M8
Connection of Coil module monitoring M8 is required for operation.
The M8 monitoring cable is connected to the Coil module monitoring M8. It controls the coil
warning lightand monitors the coil temperature.Connection isrequired to operate themachine.
•Connector configuration and pin assignment according to circuit diagram
4.5.2 Sensor connector M12
The Sensor connector M12 allows the connection of an external pulse trigger (light barrier,
capacitive sensor, ...). A suitable light barrier is available at Maurer Magnetic AG.
•Voltage range see appendix
•Connector configuration and pin assignment according to circuit diagram
4.5.3 D-Sub15 Control Interface
The 15 pin D-Sub15 Control Interface allows control and monitoring of themachine via 24 VDC
signals. Further information
•More information in chapter Operation
•Voltage range see appendix
•Connector configuration and pin assignment according to circuit diagram
4.5.4 D-Sub9 power setting interface (DN750…1850, optional)
The 9 pin D-Sub9 power setting interface allows setting power of the power level of the
machine via 24 VDC signals.
•More information in chapter Operation
•Voltage range see appendix
•Connector configuration and pin assignment according to circuit diagram

Instal lat ion
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4.6 Modification
Modification of the machine leads to loss of waranty.
•Modification can lead to body injury and property damage
•Modification of the parametrisation can lead to overheating and shutdown
•Agreement of modification only by Maurer Magnetic AG in writing
DN power modules can be automated and integrated in many ways without modification. In
case of questions regarding automation and integration contact Maurer Magnetic AG.

Commi ssi o ni ng
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5 Commissioning
Indicates danger for persons with a cardiac pacemaker.
Installation and commissioning of the device only by skilled personell.
•Connect only to power source with correctly installed protection conductor
•Connect with regard to local regulations
Mount device on and flat ground, stable and flat surface.
•Ensure safe operation of device at all times
•Operate power module only upright. Do not operate in horizontal position
Connection and disconnection of the coil module only with main switch off.
5.1 Power on
•After correct installation turn main switch on
•White lamp Operation lamp is lit
•Green lamp Ready lamp is lit
5.2 Trigger demagnetization pulse
•Trigger pulse by pushing Start button
•Machine carries out demagnetisation automatically
•Yellow lamp Active lamp is lit during demagnetization pulse
•Lamp at the coil is lit Yellow
•After the pulse the Active lamp goes out
•Check fan (if available)
•Pulse duration: ~4…13 second (according to electric circuit diagram)
5.3 Demagnetisation test with intended object
•Measure residual magnetism according to measurement process definitions
•Place object in coil
•Trigger demagnetization pulse
•Remove object after completion (Active lamp goes out) of demagnetization pulse
•Measure residual magnetism according to measurement process definitions
5.4 Control via interface (if applicable)
•Readout Module OK signal
•Readout Module Ready signal
•Trigger pulse
•Readout Active Ready signal
•Readout Analog Signal
•Readout Process OK signal (if applicable)

Operat ion
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6 Operation
Indicates danger for persons with a cardiac pacemaker.
Operate device only in enclosed premises accessible only by authorised personell.
Connection and disconnection of the coil module only with main switch off.
•High current flow during demagnetization pulse
•Physical contact to energised parts can be lethal
•Disconnection during pulse results in damaging of the connector
•Wait 10 minutes for capacitor discharge before opening
Interruption of power supply during demagnetization pulse leads to immediate pulse
disruption.
•Parts in the vicinity of the coil are magnetised and need to be demagnetised
once more
•Frequent interruption accelerates electric wear
Cycle times below specification may lead to overheating of the coil. Pulse triggering
is blocked („Ready“ indicator dark, no „Ready“ signal). After cooldown pulse
triggering is enabled again.
Danger of burns at power connectors. Poor coupling of conductors can lead to
heating of connectors and conductors. Physical contact can lead to burns.
6.1 Operation mode
The machine can be operated manually or automated.
•Manual operation via control panel
•Automated operation via D-Sub15 Control Interface
6.1.1 Manual operation
•Place object in coil
•Trigger demagnetization pulse by pushing Start button
•Remove object after completion of demagnetization pulse (Active lamp goes out) and
measure residual magnetism regard to measurement process definitions

Operat ion
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6.1.2 Integration in production line
Cycle times below specification may lead to overheating of the coil. Pulse triggering
is blocked („Ready indicator dark/ no „Ready“ signal, Alarm lamp red / Alarm signal).
After cooldown pulse triggering is enabled again.
•Transport of object into coil (conveyor belt, robot, …)
•Object stops inside the coil and does not move during demagnetisation pulse
1
•Trigger demagnetization pulse via D-Sub15 Control Interface
•Further transport of object after completion of demagnetization pulse (Active Signal
low)
6.2 Controls
6.2.1 Main switch
Only switch off machine during demagnetization pulse in case of an emergency.
The machine is turned on/off with the main switch.
6.2.2 Start/Pulse button
The white button Start/Pulse triggers a demagnetization pulse.
6.3 Indicators
Troubleshooting and analysis in chapter troubleshooting.
6.3.1 Operation lamp
The Operation lamp indicates an active 24VDC power supply.
6.3.2 Ready lamp
The Ready lamp indicates readiness of the power module to trigger a pulse.
6.3.3 Fault lamp
Occurance of a fault during a demagnetization pulse results in immediate pulse
disruption. Parts in the vicinity of the coil are magnetised and need to be
demagnetised once more.
The Fault lamp indicates an error of the inverter.
A flashing Fault lamp indicates over temperature of the coil. Operation is no longer possible.
After cool-down, pulse triggering is enabled again.
Further Information in Chapter Troubleshooting.
6.3.4 Active lamp
The Active lamp is lit during a demagnetisation pulse.
A flashing Active lamp warns of high coil temperature. Demagnetisation pulse is possible.
1
The maximum speed of a moving object is 0.1 m/s.