MOZELT T4002 User manual

MOZELT GmbH & Co. KG
Load lifting magnet devices
Technical Manual
Electrical Power Supply System T4002
Please observe the following safety
information and recommendations
before start-up !
Copyright: MOZELT GmbH & Co. KG, D-47269 Duisburg Edition: Mai 2012
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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.
2. 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.
3. Electrical connection
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..
4. 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.
General information
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.
Safety information / General information
Englisch
MOZELT GmbH & Co. KG
Load liing magnet devices
Technical Manual: Electrical Power Supply T4002 www.mozelt.com
Copyright: MOZELT GmbH & Co. KG, D-47269 Duisburg Edition: May 2012 -2-
Englisch
MOZELT GmbH & Co. KG
Load liing magnet devices
Technical Manual: Electrical Power Supply T4002

Table of Contents
1. Technical descripon 4
1.1 Range of applicaons 4
1.2 Descripon 4
1.3 Funcon mode 4
2. Technical data 5
2.1 Performance data 5
2.2 Accessories 5
2.2.1 Mul-funcon display MFA 5
2.2.2 Electrical cable connecons 5
2.2.3 Generator drives 5
3. Assembly, drawings 6
3.1 Assembling instrucons 6
3.2 Connecons 6
3.3 Dimensional drawings of generator 7
4. Start-up 8
4.1 Safety informaon 8
4.2 Safety regulaons magnet operaon 8
4.3 Operang instrucons 9
4.4 Overview mul-funcon display MFA 10
4.5 Structural design of current supply 10
4.6 Operaonal indicators MFA 11
4.7 Fault indicators MFA 12
All passages in the manual which are marked with the symbol „Warning“ contain
informaon which is important to avoid danger!
WARNING
All passages in the manual which are marked with the symbol „Cauon“ contain
informaon which is necessary to avoid damage to the current supply or to accessory
equipment!
CAUTION
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Englisch
MOZELT GmbH & Co. KG
Load liing magnet devices
Technical Manual: Electrical Power Supply T4002
Copyright: MOZELT GmbH & Co. KG, D-47269 Duisburg Edition: May 2012 -3-

1.3 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 T 4002 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 and
sabotage.
The generator T 4002 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 (MFA) 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 220 V cable
system is directly possible. Cable damage and short-
circuits in the 220 V cable system lead to immediate
disconnecon of the supply voltage (passive protecon
for individuals).
1. Technical descripon
1.1 Range of applicaons
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.
1.2 Descripon
The rated speed of a generator of the
T 4002-series is around 3000 rpm*.
In this connecon, the range from
2600 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!
With hydro-motor drives, maximum
speeds of up to 4000 rpm are
permied in the tripping torque of
the magnet, as long as they do not last
longer than 0.5 seconds. With rotaonal speeds above
3400 rpm and below 2600 rpm, magnet operaon is not
possible and/or is only limited.
The most important operang and switching states
are indicated in a mul-funcon display (MFA) in the
operator‘s cab.
The following displays are available for direct reading:
• Ready for use (ready)
• Magnet is liing
• Magnet is releasing
• Line interrupt
• R.P.M not ok
• Relave duty rang of 50 to 100% ED
• Short-circuit
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CAUTION
CAUTION
CAUTION
CAUTION
* rpm = revoluons per minute
Englisch
MOZELT GmbH & Co. KG
Load liing magnet devices
Technical Manual: Electrical Power Supply T4002
Copyright: MOZELT GmbH & Co. KG, D-47269 Duisburg Edition: May 2012 -4-

2. Technical data
2.1 Performance data
Model T 4002 13 kW 20 kW 30 kW
Rated voltage 230 V 230 V 230 V
Max. output current 56,5 A DC 87 A DC 130,5 A DC
Operang speed range * 2600....3400 rpm
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 Multi-function display MFA
The dierent operang condions of the generator
are indicated in the funcon display (MFA) 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.
2.2.2 Electrical cable connections
The electrical cable connecons as well as the plug
connecons (plugs / coupler) are matched for the
respecve loads of the generators. The highest demands
are placed on funconality and safety.
If necessary, please use only original spare parts.
2.2.3 Generator drives
Depending on the version of the mobile excavator, the
generator is powered mechanically or hydraulically.
Both variants are designed in such a way that the
required rotaonal speed of the generator is ensured,
as soon as the diesel engine reaches its full speed.
With some hydraulic drives, opmal working is also
possible at low diesel speeds. In this respect, please check
the manual of the mobile excavator manufacturer.
Fig. 1 | Mul-funcon display MFA
Fig. 2 | Hydraulically powered 13 kW power supply
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Englisch
MOZELT GmbH & Co. KG
Load liing magnet devices
Technical Manual: Electrical Power Supply T4002
Copyright: MOZELT GmbH & Co. KG, D-47269 Duisburg Edition: May 2012 -5-

3. Assembly, drawings
3.1 Assembling instrucons
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.
3.2 Connecons
1
Protecve conductor connecon
Magnet connecon
Connecon for control cable to the MFA
1
2
3
Fig. 3 | Connecon box T4002 13 kW and 20 kW
Control electronics
2
1
3
Fig. 4 | Connecon box T4002 30 kW
1
2
3
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CAUTION
Englisch
MOZELT GmbH & Co. KG
Load liing magnet devices
Technical Manual: Electrical Power Supply T4002
Copyright: MOZELT GmbH & Co. KG, D-47269 Duisburg Edition: May 2012 -6-

3.3 Dimensional drawings of generator
Fig. 7 | Generator 13 kW DPE-0715
Fig. 6 | Generator 20 kW DPE-0815
Fig. 5 | Generator 30 kW DPE-0920
Spline sha
W 30 x 2 x 30 x 14 x 9g
DIN 5480
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Englisch
MOZELT GmbH & Co. KG
Load liing magnet devices
Technical Manual: Electrical Power Supply T4002
Copyright: MOZELT GmbH & Co. KG, D-47269 Duisburg Edition: May 2012 -7-

4. Start-up
4.1 Safety informaon
Read the operang instrucons before
start-up of the magnet device!
A visual check is to be made before start-
up of the complete system!
Ensure that the generator is ghtened
rmly before start-up!
Check the correct t of the drive belts
before start-up!
Only aach load liing magnets to the
system! Operaon for other electrical
users is not permied!
Before beginning work on the enre
system disengage the drive motor!
Never open the terminal connecon box
and the 220 V connector on the generator
and the magnet while the motor is
running!
Fig. 8 | Load liing magnets with various aachments
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4.2 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:
While working with the load
liing magnet it is forbidden to
stand within the extended reach of
the excavator
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!
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!
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
WARNING
Englisch
MOZELT GmbH & Co. KG
Load liing magnet devices
Technical Manual: Electrical Power Supply T4002
Copyright: MOZELT GmbH & Co. KG, D-47269 Duisburg Edition: May 2012 -8-

4.3 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 T 4002, the operator
should ensure that the 220V 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.
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 MFA I 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
T 4002 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 MFA - (see 4.7 page
12/13).
Operaon with load liing magnet:
First place the magnet on the
material and then switch it on.
Swivel the magnet back in a
switched-o state.
Fig. 9 | Touch down of the switched-o magnet on the material
First ‘touch down’
of the magnet, then
switch it on !
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CAUTION
Englisch
MOZELT GmbH & Co. KG
Load liing magnet devices
Technical Manual: Electrical Power Supply T4002
Copyright: MOZELT GmbH & Co. KG, D-47269 Duisburg Edition: May 2012 -9-

1
2
3
4
5
6
Fig. 10 | Overview of the mul-funcon display MFA/MFD I
4.4 Overview mul-funcon display MFA
4.5 Structural design of current supply
The most important operang condions can be read
immediately:
Fig. 11 | Overview of structure power supply system T4002
8
7
9
6
123
54
1
2
3
4
5
6
7
8
9
Generator T4002
Mul-funcon display MFA/MFD I
Operang switch on the control lever
Switch cable
Control cable
Magnet cable 220 V
Connector
Magnet connecng cable
Load liing magnet
The essenal components are:
15
6
Funcon and breakdown indicators
(see 4.6 and 4.7 page 11-13)
Relave on-me of the magnec plate in %
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Englisch
MOZELT GmbH & Co. KG
Load liing magnet devices
Technical Manual: Electrical Power Supply T4002
Copyright: MOZELT GmbH & Co. KG, D-47269 Duisburg Edition: May 2012 -10-

4.6 Operaonal indicators MFA
Display: LED 1 (yellow), „Ready“
Note: Generator is waing for switching-on command.
1
Generator running in the working range
Fig. 12 | MFA indicates ready for
operaon
Display: 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. 13 | MFA indicates an acvated
magnet
2
Display 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. 14 | MFA indicates the release of the
material
3
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Englisch
MOZELT GmbH & Co. KG
Load liing magnet devices
Technical Manual: Electrical Power Supply T4002
Copyright: MOZELT GmbH & Co. KG, D-47269 Duisburg Edition: May 2012 -11-

4.7 Fault indicators MFA
LED 1 (yellow), „Ready“
- 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. 15 | Switching-on command does
not react
LED 4 (red), „Line interrupt“
Aer switching-on command given via operang switch, „Line interrupt“
appears
4
Fig. 16 |MFA indicates „Line interrupt“
Aer switching-o command given via operang switch, LEDs ash
1
Fig. 17 | MFA indicates short-circuit
Display:
Possible cause:
Display:
Possible cause: - Cable break in the 220 V circuit
- Magnet aached wrongly or not aached
- Cable or connector defecve
- Magnet defecve
Display:
Posible cause:
LED 1 -5 (ashing),
- Short-circuit in the cable system 220 V
- Full earth fault of the magnet
- Magnet too much power for electrical supply
2
3
4
5
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Englisch
MOZELT GmbH & Co. KG
Load liing magnet devices
Technical Manual: Electrical Power Supply T4002
Copyright: MOZELT GmbH & Co. KG, D-47269 Duisburg Edition: May 2012 -12-

No LED indicator recognizable
- Cable damage / power breakdown in the
control cable
Generator runs within its working range, however, no funcon is
recognizable
Fig. 18 | MFA does not funcon
Only LED 5 (red), „R.P.M not o.k.“
The indicators „R.P.M not ok“ is lit up and the indicator „Ready“ is o
5
Fig. 19 | MFA indicates „R.M.P not ok“
The indicators „ R.P.M not ok „ and „Ready“ are lit up
1
Fig. 20 | MFA indicates a low speed
Display:
Possible cause:
Display:
Possible cause: - The generator is running too fast
Display:
Possible cause:
Note:
Turn o the engine immediately and have the
speed checked in order to prevent damage to the
generator !
LED 1 (yellow) „Ready“
LED 5 (red), „R.P.M not o.k”, possibly
also ashing
The generator is running too slow
Normal magnet operaon is only possible to a
limited extent; lower performance is to be expected
LED 5 (permanent), speed 2200 - 2400 rpm
LED 5 (ashing), speed 2400 - 2700 rpm
5
-
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CAUTION
Englisch
MOZELT GmbH & Co. KG
Load liing magnet devices
Technical Manual: Electrical Power Supply T4002
Copyright: MOZELT GmbH & Co. KG, D-47269 Duisburg Edition: May 2012 -13-