MOZELT CoolGen 4 User manual

Technical Manual
CoolGen 4
Please observe the following safety
information and recommendations
before start-up !

MOZELT GmbH & Co. KG
Load liing magnet devices
Technical manual: CoolGen 4
Copyright: MOZELT GmbH & Co. KG, D-47269 Duisburg Edition: August 2014 Rev.: 00
Page 2
English
2. Usage to the Intended Purpose
Synchronous generators with integrated electronics are
components for installaon in machines which are used
in industrial plants.
Start-up of the power generators is not allowed before
it has been veried that the machine in which the
generators are installed conforms to the Machinery
Direcve.
The generators conform to the protecon goals of the
low-voltage direcve.
Operaon is only allowed when the EMC Direcve is
adhered to.
The technical data and informaon about connecon
condions are given in the nameplate and documentaon
and shall be adhered to by all means.
3. Transport, Storage
The instrucons for transport, storage and proper
handling are to be observed.
Defects detected aer delivery shall be reported
immediately to the carrier. Before start-up, the supplier is
to be noed, if necessary.
4. Installation
The installaon and cooling of the devices must be
carried out according to the provisions of the respecve
documentaon.
The generators are to be protected against inadmissible
loads. They are only to be touched in such a way that no
components are bent and/or insulaon clearances are
changed. Avoid touching the electronic elements and
contacts.
1. General
During use the generator may have live, bare, if
applicable, also hot surfaces. In the case of inadmissible
removal of the required cover, inappropriate use, wrong
installaon or operaon, there is the risk of death or
severe injury or material damage.
All work concerning the transport, installaon and start-
up as well as maintenance are to be carried out by
qualied technical personnel (IEC 364 and/or CENELEC
HD 384 or DIN VDE 0100 and IEC Report 664 or DIN VDE
0110 and naonal regulaon for accident prevenon or
VGB 4 are to be observed).
Qualied technical personnel according to these basic
safety references are persons who are familiar with the
installaon, assembly, start-up and operaon of the
product and possess corresponding qualicaons for
their acvity (dened in IEC 364 or DIN
VDE 0105).
For reasons of safety and the preservaon of
documented system data and funcons, repairs to the
generator or its components may only be undertaken by
the manufacturer.
Technical data, as well as data concerning connecon
condions, are to be taken from the rang plate and the
documentaon and are to be strictly observed.
Safety information / General information
All passages provided with the „warning“ sign in the manual contain informaon
important for avoiding danger!
WARNING
All passages provided with the „cauon“ sign in the manual contain informaon
necessary for avoiding damage to the power supply or accessories!
CAUTION
It is absolutely necessary to observe the
following warnings.
If these warnings are not observed,
serious personal injuries with fatal result,
severe injuries to health or considerable
damage to property cannot be ruled out!
WARNING

MOZELT GmbH & Co. KG
Load liing magnet devices
Technical manual: CoolGen 4
Copyright: MOZELT GmbH & Co. KG, D-47269 Duisburg Edition: August 2014 Rev.: 00
Page 3
English
5. Electrical Connection
When working on energized power generators, the
applicable naonal accident prevenon regulaons shall
be observed.
The electrical installaon is to be carried out in
accordance with the relevant regulaons (e.g. line cross
secons, provision of safety arrangements). Further
instrucons are given in the documentaon.
The manufacturer of the system is responsible for
adherence to the EMC legislature. Instrucons for
installaon in accordance with the EMC Direcve are
given in the documentaon of the power generators.
6. Operation
Installaons into which the generators are built must be
equipped, if necessary, with addional monitoring and
protecon devices.
The manufacturer’s documentaon is to be observed.
Aer separang the generators from the drive unit, live
components and line connecons must not be touched
when the generator spindle is running, due to the
voltage.
All covers are to be kept closed during operaon.
In the electronics, there are intermediate
circuit capacitors.
Their discharge may take longer than 10
minutes!
Before start of work, verify isolaon from
power supply!
If this is not observed, serious personal
injuries with fatal result, severe injuries
to health or considerable damage to
property cannot be ruled out!
WARNING
7. Applicable Documents
A prerequisite for the use of a power
generator is that these operang
instrucons have been read and
understood. In parcular, the safety
notes contained there are to be
observed.
If these notes are not observed,
serious personal injuries with fatal
result, severe injuries to health or
considerable damage to property
cannot be ruled out!
WARNING

MOZELT GmbH & Co. KG
Load liing magnet devices
Technical manual: CoolGen 4
Copyright: MOZELT GmbH & Co. KG, D-47269 Duisburg Edition: August 2014 Rev.: 00
Page 4
English
Table of contents
1. Technical descripon 5
1.1 General informaon 5
1.2 Range of Applicaon 5
1.3 Descripon 5
1.4 Funcon mode 5
1.5 Protecon Concept, Behaviour in the Case of Faults 6
1.6 Safety regulaons magnet operaon 6
2. Technical Data 7
2.1 Performance Data 7
2.2 Accessories 7
2.2.1 MFD display 7
2.3 Generator Drives 8
2.3.1 Belt Drives 8
2.3.2 Hydraulic Drives 8
3. Assembling 9
3.1 Assembling instrucons 9
3.2 Installaon of „BELL CLUTCH“ Coupling 9
3.3 EMC Notes Electromagnec Compability 10
3.3.1 Interference Immunity 10
3.3.2 Interference Radiaon 10
3.4 Magnet Connecon 10
3.5 LED Funcons 10
3.6 Control cable 11
3.7 Terminal Box 11
3.8 Terminal Block 12
3.8.1 Start command via switch line on the MFD display 12
3.8.2 Start Command via Terminal Block 12
3.9 USB Connecon 12
3.10 Cable Allocaon 230 Volt 13
3.11 Dimensional Drawings Power Generator 14
4. Commissioning 15
4.1 Safety Notes 15
4.2 Operang instrucons 16
4.3 Operaonal indicators MFD 17
4.4 Fault indicators MFD 19
4.5 Assembly Plan Power Generator 22
4.6 Mechanical Speed Measurement 23
5. Shutdown 23

MOZELT GmbH & Co. KG
Load liing magnet devices
Technical manual: CoolGen 4
Copyright: MOZELT GmbH & Co. KG, D-47269 Duisburg Edition: August 2014 Rev.: 00
Page 5
English English
1.2 Range of Applicaon
The MOZELT power supply system with synchronous
generator is designed to supply and acvate load liing
magnets on mobile excavators.
At present it is available with the output sizes 13, 20 and
30 kW.
Due to the duty rang of 100% (ED), the generators are
the opmal soluon for loading and handling in the
industrial scrap metal industry.
The maintenance-free and compactly designed generator
system is powered by the diesel engine of the excavator
or the hydraulic system.
1.3 Descripon
* rpm = revoluons per minute
1. Technical descripon
1.1 General informaon
MOZELT does not take any liability for the consequences
resulng from inappropriate, negligent or incorrect
installaon or operaon of the synchronous generator
with integrated electronics.
The condions of guarantee of MOZELT in the valid
version at the me of purchase shall apply for the
equipment.
The content of the present manual is considered correct
at the me of prinng for the indicated generator
version. MOZELT reserves the right to make changes
which represent a technical advantage.
Any change to the generators which is not performed by
us, including the installaon of addional devices, can
lead to a change of the technical specicaon and the
content of the documentaon and manual and therefore
leads to an exclusion of our liability, also from the
guarantee.
CAUTION
CAUTION
CAUTION
CAUTION
The rated speed of a generator of the
CG 4-series is around 3000 rpm*.
In this connecon, the range from
2700 rpm to 3400 rpm is to be
regarded as the tolerance range.
It is parcularly important that the
rotaonal speed remains constant
and no uctuaons occur!
The most important operang and switching states
are indicated in a mul-funcon display (MFD) in the
operator‘s cab.
1.4 Funcon mode
The transformaon of brushless three-phase voltage into
DC voltage in the generator and its contactless delivery
aer acvang the generator provides the operator with
comfort and the highest safety.
The generator CG 4 is praccally maintenance-free. The
abolion of contactors or relay circuits in the external
electrical plant area, as well as the absence of adjustment
buons or potenometers, protects this installaon
system against faulty operaon.
Important!
The electronic modules are equipped
with electrostacally sensive CMOS
and MOS components.
It is absolutely necessary to observe the following
instrucons since otherwise these switching circuits
can be destroyed.
• For servicing work, rst equipotenal bonding (stac
charging) is to be ensured between electronic modules,
tools, measuring devices and personnel.
• Grasp electronic modules by the edges only, do not
touch components and their connecons.

MOZELT GmbH & Co. KG
Load liing magnet devices
Technical manual: CoolGen 4
Copyright: MOZELT GmbH & Co. KG, D-47269 Duisburg Edition: August 2014 Rev.: 00
Page 6
English
The generator CG 4 is independent of the on-board
electrical system, and produces its own supply voltage for
internal control and monitoring. The machine is overload
and short-circuit proof.
The correct supply voltage is regulated automacally for
the magnet aached to the generator and the necessary
release me is opmized and implemented for every
kind of material to be loaded.
The operator can read o important operang condions
from the funcon display (MFD) in the operator‘s cab.
The display of the relave duty rang in % (ED) is to be
observed for the range 50% to 100% of the aached
load liing magnet. If this exceeds the value 80% ED, the
danger of the magnet overheang is signalized by a red
LED.
It is then recommended to change the work mode or to
take a break to allow the magnet to cool down.
The localizaon of work related errors in the 230 V cable
system is directly possible. Cable damage and
shortcircuits in the 230 V cable system lead to immediate
disconnecon of the supply voltage (passive protecon
for individuals).
1.5 Protecon Concept, Behaviour in the Case of
Faults
The intrinsic safety of the power generator is enhanced
by an extension of the monitoring funcons, Installed
monitors ensure a high operaonal reliability of the
system.
In case of fault, the electronics is immediately blocked. At
the same me, a fault is indicated and the LED „Ready for
operaon“ exnguishes.
The following monitoring funcons are integrated:
• Overload protecon
• Insulaon monitoring
• Overtemperature protecon
• Overspeed protecon
• Open magnec circuit
• Short circuit
1.6 Safety regulaons magnet operaon
The operaon of a load liing magnet on a mobile
excavator represents a special mode of operaon and
an increased safety risk. In contrast to working with
a hydraulic grabber, the magnet picks up all available
ferromagnec material immediately aer it is switched
on.
This may even be more than the load-carrying capacity of
the mobile excavator allows.
Similarly, the magnet suddenly releases the lied
material aer it is switched o, if there is cable damage
or a short-circuit in the magnet feed cable. This can
lead to dangerous situaons in the working vicinity, for
example, if falling material causes other objects to be
hurled up by lever force. Furthermore, it is not excluded
that pieces of scrap iron may separate from the magnet
during a swiveling procedure, if these are located at the
lower end of the lied material cluster.
For these reasons, it is parcularly important to observe
the following principle:
WARNING
WARNING
The magnet can oscillate strongly aer load release!
For this reason, the mechanically safe aachment of
the magnet in the form of a special magnet suspension
at the end of the arm on the mobile excavator is highly
recommended!
Do not swivel the working equipment
or change the locaon of the
excavator with the magnets
switched on without a
payload - unintenonally
lied materials can lead to
human injury by lever force!
While working with the load
liing magnet it is forbidden to
stand within the extended reach of
the excavator

MOZELT GmbH & Co. KG
Load liing magnet devices
Technical manual: CoolGen 4
Copyright: MOZELT GmbH & Co. KG, D-47269 Duisburg Edition: August 2014 Rev.: 00
Page 7
English English
2. Technical Data
2.1 Performance Data
Model CoolGen 4 13 kW 20 kW 30 kW
Rated voltage 230 V 230 V 230 V
Max. output current 57 A DC 87 A DC 130 A DC
Operang speed range * 2700....3400 U/min **
Venlaon Internal venlator
Weight 58 kg 87 kg 135 kg
Protecon class IP 55
Permied ambient
temperature
-25° C…..+50° C non-condensing
Installaon height < 1000 m NN, above 1000 m output reducon of 1% per 100 m
2.2 Accessories
2.2.1 MFD display
The data indicated on the nameplate
are of signicance!
CAUTION
When the power generator is installed
in a casing or under a cover the
temperature of the air used for cooling
should not be more than 50 °C max.
(maximum internal temperature of the
casing / cover!)
CAUTION
1
2
3
4
5
Fig.: 1 | General view CG4 Display
The dierent operang condions of the generator are
indicated in the funcon display (MFD) via LEDs.
An addional 6 LEDs indicate the working loading
ulizaon of the magnet (On/O rao) within the range
50…100%.
The release switch to turn the magnet on/o is also
aached to this display unit.
6
7
9
8
The most important operang states can be immediately
read o:
15Funcon and fault indicaon
6Relave duty factor of the magnec disks in %
Cover USB connecon (servicing purposes)7
Screw terminal for switch line / pushbuon
8
Connecon for control line
9
* guaranteed performance data at 100 % duty factor
** in the range of 2350 rpm to 2700 rpm, limited operaon at
reduced output voltage is possible.

MOZELT GmbH & Co. KG
Load liing magnet devices
Technical manual: CoolGen 4
Copyright: MOZELT GmbH & Co. KG, D-47269 Duisburg Edition: August 2014 Rev.: 00
Page 8
English
2.3 Generator Drives
Depending on the type of mobile excavator, the power generator is mechanically or hydraulically driven.
Both variants are designed so that the necessary operang speed of the power generator is ensured as soon as the
diesel engine has reached its full speed.
2.3.1 Belt Drives
To ensure that the belt runs straight both axes must be ush with each other. The sha axes shall be parallel with the
axis of the generator.
It is recommended to use a Laser alignment device for aligning the belt pulleys.
For adjustment of the pretension, we recommend the use of belt measuring devices. During and aer installaon, the
belt is to be revolved several mes. This causes uniform seling of the pulley.
The rst check of the run-in belt pulley is carried out aer 0.5 to 4 hours.
The belt tension should be checked every 6 to 12 months and, if necessary, corrected.
2.3.2 Hydraulic Drives
Hydraulic generator drives are always to be supplied with a priority ow of hydraulic oil.
This means the supply ow should not be adversely aected by motor uctuaons, liing, travelling or other
movements. Depending on the manufacturer of the construcon machine, this is implemented in various technical
designs. Please ask the respecve manufacturer for informaon on this maer or contact us for the alternave
soluon of the „HydraBrain“ system.
With some hydraulic drives, opmum operaon is also possible at low speed of the diesel engine. For this, please
check the manual of the mobile excavator manufacturer.
Never reach into the running belt
drive!
WARNING
Never operate the power generator
without belt guard!
WARNING
Fig.: 2 | Belt drive
Fig.: 3 | Hydraulic drive with „BELL CLUTCH“ coupling
For hydraulic motor drives, speed peaks up to 4000 rpm are allowed at the moment of shutdown
of the magnet, if they do not last longer than 0.5 seconds. At speeds above 3400 rpm and below
2700 rpm, magnet operaon is not, or only to a limited extent, possible.
CAUTION
CAUTION
It is parcularly important that the speed
remains constant and does not show any
uctuaons!
CAUTION
Speeds above 3400 rpm can destroy the
power generator!
CAUTION
The speed should be measured not only
during no-load operaon, but also during
the starng and shutdown phase!

MOZELT GmbH & Co. KG
Load liing magnet devices
Technical manual: CoolGen 4
Copyright: MOZELT GmbH & Co. KG, D-47269 Duisburg Edition: August 2014 Rev.: 00
Page 9
English English
3. Assembling
3.1 Assembling instrucons
3.2 Installaon of „BELL CLUTCH“ Coupling
Table of distances coupling halves
1
2356
78
5
8
4
Generator type Hydraulic motor Distance A Distance B
T4002 / CG4 13 kW Bosch-Rexroth 16 ccm / Sunfab 17 ccm 0 mm 0 mm
T4002 / CG4 13 kW Bosch-Rexroth 23 ccm / Sunfab 25 ccm 12 mm 12 mm
T4002 / CG4 20 kW Bosch-Rexroth 23 ccm / Sunfab 25 ccm 11 mm 0 mm
1
2
3
4
Hydraulic motor
Adaptor ring for 16/17 ccm hydraulic motors
Clutch bell
Cover for speed measurement
6
7
8
9
Clamping bushing on the hydraulic motor
Coupling spider
Clamping bushing on the power generator
Sha / end shield on the power generator
5Coupling half
Fig.: 4 | Explosion drawing „BELL CLUTCH“ coupling
Fig.: 5 | Distance drawing coupling halves
1
CAUTION
The environmental atmosphere must be free of aggressive dust, corrosive vapours, gases and
liquids. The generator is to be protected against moisture according to IP 55.
Synchronous generators with integrated electronics may not be operated in areas classied as
dangerous, unless they are installed and cered in an approved housing.
The generators are designed for foot assembly
Make sure that the heat produced by the generator can be dissipated. The venlator screen must always be kept
free, in order to ensure an adequate supply of fresh air. All heat sources must be considered when determining
the ambient temperature, so that the temperature does not rise above the permissible maximum value for the
generator.

MOZELT GmbH & Co. KG
Load liing magnet devices
Technical manual: CoolGen 4
Copyright: MOZELT GmbH & Co. KG, D-47269 Duisburg Edition: August 2014 Rev.: 00
Page 10
English
3.3 EMC Notes Electromagnec Compability
As all electrical equipment, synchronous generators with integral electronics can emit electromagnec energy and
be inuenced by it.
Electromagnec compability requires on the one hand that equipment is insuscepble to interference as regards
electromagnec radiaon, i.e. that they cannot be inuenced, and on the other hand does not exceed a certain
level of interference radiaon, and as a consequence does not interfere with other equipment.
These levels depend on the environment in which the equipment is operated. Here a disncon is made between
industrial and residenal environments including business and commercial as well as light-industrial environments.
This chapter is to serve as a guideline for installaon of the drives to avoid EMC problems and realize an EMC-
compliant wiring in accordance with the EMC Direcve.
3.3.1 Interference Immunity
CG4 ... are extremely suscepble to interference as regards electromagnec radiaon.
Interference immunity is achieved for the equipment without addional aids. In addion, all inducon components,
such as relay and contactor coils, electromagnec brakes, etc. are to be interference-suppressed using suitable
components (e.g. RC elements).
3.3.2 Interference Radiation
To avoid unallowable interference radiaon it is absolutely necessary to observe the given wiring instrucons.
Non-line-related interference radiaon is directly emied by the integrated electronics and wiring within a
frequency range of 30 MHz to 1 GHz. It is mainly generated by the fast logic circuits and has very low energy.
Problems with other electronic equipment due to this are not be expected.
Line-related interference radiaon in the frequency range of 150 kHz to 30 MHz is mainly caused by switching of
the power semiconductors. Because of the independent network, no problems with other equipment will occur.
3.4 Magnet Connecon
The electrical line connecons and plug-in connecon (plug / coupling) are matched to the corresponding output of
the power generators. In the process, the highest requirements are made on funconality and safety.
Please only use original MOZELT spare parts as required.
3.5 LED Funcons
Fig.: 6 | LED funcons on the control card
Various operang states are in addion indicated on the control card
of the power generator via LED. The following operang states can be
read o via the LED:
1Ext. pushbuon input LED Status external pushbuon input via terminal block
2
3
4
5
Signal output LED Selecon signal output
Status LED Status „On“
Supply voltage LED Internal electronics supply voltage available
Fault LED LED signals a fault
6Stand-by LED Stand-by LED
2 4 6
35
1

MOZELT GmbH & Co. KG
Load liing magnet devices
Technical manual: CoolGen 4
Copyright: MOZELT GmbH & Co. KG, D-47269 Duisburg Edition: August 2014 Rev.: 00
Page 11
English English
3.6 Control cable
Cable for control signals must be shielded. The cable shield must be connected to the connector shell.
The signal ground must not be grounded.
If necessary, please use only original spare parts.
3.7 Terminal Box
Before isolaon of power generator and electronics, the following warning should be observed:
The discharge me begins aer nal shutdown of the power generator!
Fig.: 8 | Connecon control line on the power generator
5
1Magnet connecon 230 V DC
2
3
4
5
Protecve earth conductor connecon
Terminal block
USB connecon
Screw terminal control line
Fig.: 7 | Terminal box
Steuerelektronik
1
4
2
3
5
6
6Control card
WARNING
In the electronics, there are intermediate circuit capacitors.
Their discharge may take longer than 10 minutes!
Before start of work, verify isolaon from power supply!
If this is not observed, serious personal injuries with fatal result, severe
injuries to health or considerable damage to property cannot be ruled out!
Fig.: 9 | Terminal block
3

MOZELT GmbH & Co. KG
Load liing magnet devices
Technical manual: CoolGen 4
Copyright: MOZELT GmbH & Co. KG, D-47269 Duisburg Edition: August 2014 Rev.: 00
Page 12
English
3.8 Terminal Block
Wiring of the hydraulic and temperature sensor terminals is always arranged in the same way. Due to the various
switch wirings there are the following possibilies:
3.8.1 Start command via switch line on the MFD display
During run-up of the power generator, the electronics detects a signal at terminal 7.
Thus, the display pushbuon on the MFD is acvated and the pushbuon input at terminals 5 & 9 is deacvated.
3.8.2 Start Command via Terminal Block
During run-up of the power generator, the electronics detects the missing signal at terminal 7.
Thus, the display pushbuon is deacvated and the pushbuon input on terminals 5 & 9 acvated.
12 3 4 5678910 11
Hydraulic control
HydraBrain
Pushbuon wiring Temperature sensor
generator
Bridge Internal
Temperature
sensor
MFD Display
Keying signal
Keying signal
on the display
deacvated
3.9 USB Connecon
On the control card and MFD, there is an USB port. Both USB connecons are idencal and allow the following
funcons via the DriveSo service soware (see Annex DriveSo):
• Changing of the output voltage
• Changing of the ramps of the liing and detachment behaviour of the magnet
• Adjustments for sorng operaon
• Fault analysis
• Operang states (speed, temperature, operang hours, output voltage, etc.)
• Oscilloscope funcon
• Firmware updates
12 3 4 5678910 11
Hydraulic control
HydraBrain
Pushbuon wiring Temperature sensor
generator
See Annex
„HydraBrain“ Unit
Bridge Internal
Temperature
sensor
MFD Display
Switch line
Keying signal
Fig.: 10 | Terminal allocaon on the terminal block (pushbuon on MFD acvated)
Fig.: 11 | Terminal allocaon on terminal block (pushbuon on terminal block acvated)
Fig.: 12 | USB connecon on
the control card
See Annex
„HydraBrain“ Unit

MOZELT GmbH & Co. KG
Load liing magnet devices
Technical manual: CoolGen 4
Copyright: MOZELT GmbH & Co. KG, D-47269 Duisburg Edition: August 2014 Rev.: 00
Page 13
English English
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BK
BN
GY
BU
GNYE
1 2 3
N
1 2 3
N
P1 P2
P1 P2
BK BN GY BU GNYE P1 P2
Black Brown Grey Blue Green - Yellow Protecve earth cond. Pole 1 Pole 2 Adherent sleeves Ring cable lugs
Legend
Plug-in connecon on the strut
Magnet connecon line | beam line
Oponal addional plug-in connecon on the beam Terminal box on the generator
Terminal box at the magnet
P1 P2
P1 P2
Fig.: 13 | Cable allocaon magnet system wiring system 230 V
3.10 Cable Allocaon 230 Volt

MOZELT GmbH & Co. KG
Load liing magnet devices
Technical manual: CoolGen 4
Copyright: MOZELT GmbH & Co. KG, D-47269 Duisburg Edition: August 2014 Rev.: 00
Page 14
English
3.11 Dimensional Drawings Power Generator
Fig.: 14 | Power generator CG4 30 kW
Zahnwelle: W 30x2x30x14x9g DIN 5480
Spline Shaft: W 30x2x30x14x9g DIN 5480
Fig.: 15 | Power generator CG4 20 kW
Fig.: 16 | Power generator CG4 13 kW

MOZELT GmbH & Co. KG
Load liing magnet devices
Technical manual: CoolGen 4
Copyright: MOZELT GmbH & Co. KG, D-47269 Duisburg Edition: August 2014 Rev.: 00
Page 15
English English
4. Commissioning
The generator‘s internal electronic unit has been completely balanced at the works and does not require any
further adjustments and checks. Only the „MFD“ display is to be connected with the generator system via a 9-pole
cable, double-ended plug connecon.
To this display unit the release pushbuon is connected via the 3-pole plug. The magnet is connected via two
clamping bolts. Operaon is possible in both direcons of rotaon without rewiring.
4.1 Safety Notes
It is required that the user has familiarized himself with the operang instrucons before commissioning of the
power generator.
It is absolutely necessary to observe the following warning notes:
WARNING
During operaon of this power generator, dangerous voltage may occur which can cause death
or severe bodily injuries! Utmost care is advised during work on the power generator.
WARNING
• Only qualied maintenance and repair personnel are permied to examine and repair
the unit or parts of it.
• Never leave open or open terminal connecon spaces, covers and 230-volt plug-and-
socket devices on the power generator and magnet with the drive motor in operaon!
• Stand on an isolang mat (suitable for electrostacally sensive devices) and make
sure that this mat is not earthed before performing commissioning work on
the switch-on unit.
WARNING
Before start of work, verify isolaon from power supply. Make sure that no voltage is applied to
the magnet connecon. If this note is not observed, severe or even fatal bodily injuries may be
caused!
WARNING
• When working on the connected machine or supply leads to the machine, the power
generator should be shut down and locked out in O posion.
• According to VDE 1060, safety isolaon by locking the release pushbuon is not allowed.
• A safety isolaon blocks the power modules in the case of faults. However, with this
funcon it cannot be ensured that there is no residual voltage at the output terminals
and inside the power generator. Aer opening of the power generator, the
remaining residual voltage should be measured at the usually live parts. Before touching
electrical contacts make sure that no voltage is applied to voltage-carrying parts.
• Do not use any measuring equipment of which you know that it is in damaged or
defecve condion.
WARNING
Important!
In case of fault, modules potenal-free during operaon may carry voltage. Before start of work
on the equipment, make sure by measurement aer safety isolaon that the equipment is
deenergized. If this note is not observed severe or even fatal injuries may be caused.

MOZELT GmbH & Co. KG
Load liing magnet devices
Technical manual: CoolGen 4
Copyright: MOZELT GmbH & Co. KG, D-47269 Duisburg Edition: August 2014 Rev.: 00
Page 16
English
The V-belt tension with belt drives is to be examined and,
if necessary, the belts are to be reghtened according to
regulaon.
Unless otherwise expressly stated, the diesel engine
of the mobile excavator is to be brought up to full
revoluons. The generator then runs within its operang
range. The yellow LED „Ready“ automacally appears on
the mul-funcon display MFD in the operator‘s cab.
Switching the power supply and/or the load liing
magnet on and o is usually accomplished with a switch
located in the handle. Depending on the type of device,
this must be energized with a separate switch in the
control console of the mobile excavator. For this purpose
also see the notes in the manual for the mobile excavator.
If the switching-on command is given, then the generator
CG 4 connects the voltage contactless through to the load
liing magnet. If the command is given to switch o, then
the generator automacally leads to its demagnezaon.
During the process of demagnezing, whereby the
magnet releases its load (approx. 1 sec), no renewed
switching-on command can be given.
Switching-on of the installaon is only possible, if a load
liing magnet is aached to the system.
Switching on the magnet:
Operate the buon in the control lever 1 x.
In addion to the yellow LED „Ready“, the green LED
„Power on“ lights up in the mul-funcon display.
Switching o the magnet:
Operate the same buon in the control lever again only
1 x. The already illuminated green LED „Power on“ now
goes out and a red LED with „Power o“ lights up.
Aer the load has been dropped, this goes out
automacally. The permanently illuminated LED „Ready“
during the shiing processes indicates that a renewed
procedure is now possible and that the power can be
switched on. Breakdowns are indicated by illuminated
red LEDs.
The meaning and eliminaon of such disturbances are
explained using gurave illustraons and texts under -
Breakdown indicators on the MFD -.
Make sure that ...
• the person supervising the trial run is qualied
and competent to carry out, and supervise,
the mechanical and electrical installaon.
• the nominal values of the power generator
correspond to the operang condions.
• the power generator is securely xed.
• the power generator is adequately venlated.
Safety measures shall be properly adhered to!
4.2 Operang instrucons
When working with the load liing magnet, the pernent
industrial safety and accident prevenon regulaons are
to be observed.
In addion, liing magnet operaon may only be started,
if the operator knows the „Safety Regulaons Magnet
Operaon“ (see Table of Contents).
Before start-up of the power supply CG 4, the operator
should ensure that the 230V cable system is in an
opcally perfect condion. Plugs and plug connectors are
to be examined for ghtness of t, the anchoring device
of the magnet connecng cable is to be examined for
perfect funcon.
WARNING
Before start-up, subject the complete
system to a visual inspecon!
WARNING
Before start-up, check correct seang
of the V-belts!
WARNING
Connect only liing magnets to the
system! For other electrical consumers,
operaon is not allowed!
WARNING
Before start of all work on the enre
system, shut down the drive motor!

MOZELT GmbH & Co. KG
Load liing magnet devices
Technical manual: CoolGen 4
Copyright: MOZELT GmbH & Co. KG, D-47269 Duisburg Edition: August 2014 Rev.: 00
Page 17
English English
4.3 Operaonal indicators MFD
Indicaon: - LED 1 (yellow), „Ready“
Note: Generator is waing for switching-on command.
1
Generator running in the working range
Fig.: 17 | MFD signals Ready for operaon
Indicaon: - LED 1 (yellow), „Ready“
- LED 2 (green), „Power on“
Note: Magnet liing material.
1
Aer switching-on command given via operang switch, the magnet lis
Fig.: 18 | MFD signals an acvated magnet
2
Indicaon: - LED 1 (yellow), „Ready“
- LED 3 (red), „Power o“
Note: Magnet releases the material.
1
Aer switching-o command given via operang switch, magnet releases
load
Fig.: 19 | MFD signals throwing-o of
the material
3

MOZELT GmbH & Co. KG
Load liing magnet devices
Technical manual: CoolGen 4
Copyright: MOZELT GmbH & Co. KG, D-47269 Duisburg Edition: August 2014 Rev.: 00
Page 18
English
Indicaon: - LED 1 (yellow) „Ready“,
- LED 2 (green, ashing) „Power on“.
Note: - Magnet lis material. The power generator operates in the
sorng mode .
1
Aer the start command has been given via the operang pushbuon, the
magnet lis
Fig.: 20 | MFD signals an acvated
magnet in the sorng mode
2

MOZELT GmbH & Co. KG
Load liing magnet devices
Technical manual: CoolGen 4
Copyright: MOZELT GmbH & Co. KG, D-47269 Duisburg Edition: August 2014 Rev.: 00
Page 19
English English
4.4 Fault indicators MFD
Faults are oen indicated by red LED.
Indicaon: LED 1 (yellow), „Ready“.
Possible cause : - Interrupon in switch cable
- Operang switch defecve
- Control cable defecve
Aer switching-on command given via operang switch, no funcon
1
Fig.: 21 | Starng command does not respond
Aer giving the start command via the operang pushbuon, „line interrupt“
is displayed
4
Fig.: 22 | MFD signals „Line interrupt“
Indicaon: LED 4 (red), „Line interrupt“.
Possible cause: - Line interrupon in the 230V circuit
- Magnet not, or incorrectly, connected
- Magnet, line or plug-and-socket device defecve
Note: The power generator is to be immediately shut
down unl the fault has been corrected.
The fault indicaon can only be cancelled by
shutdown of the power generator.
Aer giving the shutdown command via the operang pushbuon LEDs 1 to 5
are ashing
Fig.: 23 | MFD signals short circuit
Indicaon: LED 1 -5 (ashing).
Possible cause: - Short circuit in the 230V wiring system
- Full earth fault of the magnet
- Magnet too much power for the power supply
Note: The power generator is to be immediately shut
down unl the fault has been corrected.
The fault indicaon can only be cancelled by
shutdown of the power generator
1
2
3
4
5

MOZELT GmbH & Co. KG
Load liing magnet devices
Technical manual: CoolGen 4
Copyright: MOZELT GmbH & Co. KG, D-47269 Duisburg Edition: August 2014 Rev.: 00
Page 20
English
No LED indicator recognizable, possibly also
all LED lights up.
- Cable damage / power breakdown in the
control cable.
Generator runs within its working range, however, no funcon is
recognizable or all LED light up
Fig.: 24 | MFD has no funcon / all LED
light up
Indicaon:
Possible cause:
LED 1 (yellow), „Ready“,
LED 5 (red, ashing), „R.P.M not o.k.“.
The display „R.P.M not o.k.“ ashes and the indicaon „Ready“ is on
5
Fig.: 25 | MFD signals „R.P.M not o.k.“
Indicaon:
Possible cause: The power generator runs at overspeed.
Shut down motor immediately and have the
speed checked to prevent damage to the power
generator!
WARNING
The display „R.P.M not o.k.“ lights up
Fig.: 26 |MFD signals underspeed
Indicaon:
Possible cause:
Note:
only LED 5 (red), „R.P.M not o.k.“, possibly
also ashing.
The power generator runs at underspeed.
Have the speed checked!
LED 5 (steady light), speed of 1650 - 2000 rpm
LED 5 (ashing), speed of 2000 - 2350 rpm
5
1