KWG GEMA Manual

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GEMA system

Operating instructions

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Page 1 Generators. Powerful. Innovative. GEMA system Operating instructions...
Page 2: Manufacturer Address
Gema Operating instructions Imprint Document type: Operating instructions Document name: KWG_GEMA_Operating-Manual_V3-1_EN Version: Language: Number of pages: 64 Pages Created by: T. Kurz Created on: 06.02.2024 Modified by: T. Kurz Modified on: 18.05.2024 Copyright Copyright © 2019 KW-Generator GmbH All rights reserved.
Page 3: List Of Changes
Gema Operating instructions List of changes Index Modified by Stand Amendment T. Kurz 05/2024 New layout; adaptation of texts Version: 3.1 Doc.name: KWG_GEMA_Operating-Manual_V3-1_EN page 3 from 64...
Page 4 Gema Operating instructions 1 - Table of contents ABLE OF CONTENTS ABLE OF CONTENTS IST OF ILLUSTRATIONS IST OF TABLES OREWORD AND GENERAL INFORMATION BOUT THESE OPERATING INSTRUCTIONS RESENTATION OF WARNINGS RESENTATION CONVENTIONS 2.3.1 XTENDED SYMBOLISM GEMA NTENDED USE OF THE...
Page 5 Gema Operating instructions 1 - Table of contents 4.5.5 ONNECTION FOR GENERATOR YPE DESIGNATIONS AND SERIAL NUMBERS 4.6.1 GEMA YPE PLATE ON THE GENERATOR 4.6.2 GEMA YPE PLATE ON THE CONTROLLER BOX 4.6.3 AMEPLATE ON THE CONTROL UNIT ECHNICAL DATA...
Page 6 Gema Operating instructions 1 - Table of contents 7.6.2 HORT CIRCUIT IN MAGNETIC PLATE LOAD CABLE 7.6.3 NTERRUPTION IN MAGNETIC PLATE LOAD CABLE 7.6.4 VERTEMPERATURE 7.6.5 ARTH FAULT INSULATION FAULT 7.6.6 ULTIPLE FAULTS IN THE LOAD CIRCUIT GEMA ESTARTING RESETTING...
Page 7 Figure 6: Connection for magnetic plate ..................30 Figure 7: Connection for generator ....................31 Figure 8: Example of a rating plate for a GEMA 9 generator ............32 Figure 9: Example of a type plate on the GEMA controller box ............33 Figure 10: Example of a type plate on the HMI operating device ..........33 Figure 11: Dimensions GEMA system ....................34...
Page 8 Table 2: Components of the HMI control unit ................22 Table 3: Operating and display elements on the HMI control unit ..........24 Table 4: CAN bus and supply; connection to GEMA-Controllerbox_V1 ........25 Table 5: CAN bus and supply; connection to GEMA-Controllerbox_V2 ........25 Table 6: CAN bus and supply;...
Page 9 It also ensures a high level of reliability and a long service life for the GEMA system. Keep the instructions for the GEMA system accessible to personnel at all times at the place of use until the product is disposed of.
Page 10 Gema Operating instructions 2 - Foreword and general information 2.2 Display of warnings For better differentiation, hazardous risks are identified in the instructions by the following warning signs and signal words. DANGER Disregarding such warnings can lead to serious injury or even death.
Page 11 Gema Operating instructions 2 - Foreword and general information 2.3 Presentation conventions The following presentation conventions are used: Name Representation Function Instruction for action 1), 2) etc. Prompts an action. 1st level Instruction for action a), b) etc. Designates a section in a sequence of 2nd level actions.
Page 12: Warranty
Intended use of the GEMA system The GEMA system is a modular generator system for magnetic disks. It is intended for permanent installation in excavators or in conjunction with power or hydraulic units and may only be used for the purpose of generating power for magnetic disk systems in accordance with the specifications in these operating instructions.
Page 13: Safety Instructions
These specific warnings are indicated at the relevant points in the manual and highlighted accordingly. 3.1 Qualification of staff Installation, maintenance and repair work on the GEMA system may only be carried out by authorized and electrically trained personnel. 3.2 General safety instructions and symbols attached to the system The meaning of the warning symbols on the GEMA system is explained below.
Page 14 ➢ Before working on the appliance, it must be disconnected from the power supply! ➢ Wearers of pacemakers must not carry out any work on the GEMA system and must always ensure a sufficient safety distance from the magnetic plate and the HMI control unit when operating the system.
Page 15 The following safety instructions must be observed when installing and carrying out work on the GEMA system. 3.4.1 Safety rules for working on electrical systems Always follow the five safety rules for working on electrical systems when working on the GEMA system: ➢ Unlock.
Page 16 ➢ Before carrying out any work on the appliance, switch it off completely and secure it against unintentional restarting. ➢ Work on electrical installations and the GEMA system may only be carried out by trained specialist personnel and in accordance with the applicable national regulations.
Page 17: Personal Protective Equipment
➢ Before working on the appliance, it must be disconnected from the power supply! ➢ Work on electrical systems and the GEMA system may only be carried out when the system is switched off and de-energized. Switched-off drive units must be secured against unintentional restarting (e.g.
Page 18 Gema Operating instructions 3 - Safety instructions Commandment Meaning Explanation sign Use hand Safety gloves must be used wherever injuries caused by protection M009 stabs, cuts, burns or hypothermia as well as other harmful effects, such as substances that can permanently damage the skin and above all severely damage the hands.
Page 19: System Overview
Magnetic disk system (third-party manufacturer). Table 1Components of the GEMA system The GEMA system is a modular generator system for magnetic plates and can be used, for example, in excavators or in conjunction with power or hydraulic units. The splash-proof and maintenance-free IP54 system consists of a generator with attached control electronics and an HMI (Human Machine Interface) control unit.
Page 20 • Magnetic force can be adjusted by simply pressing a button on the HMI control unit. • Wide speed range for the drive speed, as all GEMA systems are available in both 2-pole and 4-pole versions. • Extremely quiet generator operation thanks to special housing design.
Page 21 Gema Operating instructions 4 - Description 4.3 Normal mode and jog mode The preset programs of the GEMA system are divided into the operating modes "Normal mode" and "Inching mode". What is the difference? The operating mode affects the behavior of the system when the Mag. button on the HMI control unit or the corresponding button on the joystick is pressed.
Page 22 Gema Operating instructions 4 - Description 4.4 Advantages of the system 4.4.1 Overview of HMI operating device Illustration 3HMI operating device No. Designation Function Type plate Type plate with serial number and software version. Touch display with Display for showing system/operating data and error messages, with operating buttons integrated control buttons for operating the system.
Page 23 Current insulation resistance between the phases and the housing. For applications in which the GEMA system is fed by an energy grid instead of a generator is supplied by an energy grid instead of a generator, the torque is not displayed, but the grid frequency is displayed here in [Hz].
Page 24 Information on the other pages of the HMI software interface can be found in the document "KWG-3HMI User Manual".
Page 25 Black 5 +15 V Gray 5 +15 V Gray Table 5CAN bus and power supply; connection to GEMA-Controllerbox_V2 Available variant 3 Socket on the HMI Plug on the connection cable 8-pin M12 round plug connector, 8-pin M12 round plug connector,...
Page 26 Gema Operating instructions 4 - Description Available variant 1 (standard) Socket on the HMI Plug on the Pin assignment connection cable Pin Function Color Wiring 4-pole M12 4-pole M12 round Brown Circular connector, connector, White Pin contacts Socket contacts SACC-E-MS-4CON- Blue M16/0.5 SCO...
Page 27 Gema Operating instructions 4 - Description 4.5 Advantages of the system 4.5.1 Overview of generator with control electronics Illustration 5Generator with control electronics (schematic diagram) No. Designation Connection for magnetic plate. Connection for HMI operating device (symbolic). Connection for generator cable (plugged in in the illustration).
Page 28 The electronic control unit can be integrated into existing engine management systems via a CAN interface. The control electronics do not require a separate power supply; they are supplied by the generator. 4.5.3 Connections on the GEMA controller box Available variant 1 Socket on the GEMA controller box...
Page 29 Gema Operating instructions 4 - Description Available variant 2 Socket on the GEMA controller box Plug on the connection cable 5-pin M12 round plug connector, 5-pin M12 round plug connector, Socket contacts Pin contacts Type: SACC-E-FS-5CON-M16/0.5 SCO 1 Shield_GND Brown...
Page 30 Death or serious injury due to electric shock ➢ Before working on the appliance, it must be disconnected from the power supply! ➢ Work on electrical systems and the GEMA system may only be carried out when the system is switched off and de-energized.
Page 31 Death or serious injury due to electric shock ➢ Before working on the appliance, it must be disconnected from the power supply! ➢ Work on electrical systems and the GEMA system may only be carried out when the system is switched off and de-energized.
Page 32 4.6.1 Type plate on the GEMA generator Each GEMA generator has a unique type designation and an individual serial number. Both numbers can be found on the type plate of the generator.
Page 33 4 - Description 4.6.2 Type plate on the GEMA controller box The type plate on the GEMA controller box contains the name and serial number of the controller box as well as information on the software version of the control electronics.
Page 34: Technical Data
Gema Operating instructions 4 - Description 4.7 Technical data The following table provides an overview of the available GEMA systems and their technical data. GEMA 9 GEMA 15 GEMA 20 GEMA 25 / GEMA 30 Number of poles 2-pole 4-pole...
Page 35: Transportation And Storage
Only use lifting slings with sufficient load-bearing capacity to lift and move the generator. Ensure that all devices and aids used for lifting the GEMA system are designed to withstand the weight of the GEMA system and that all safety precautions have been taken for transportation.
Page 36: Installation And Commissioning
Before installing and commissioning the GEMA system, carefully read the chapter 3 "Safety instructions". 6.1 Standard scope of delivery The components included in the standard scope of delivery of the GEMA system are listed below. Please check that the delivery is complete before installing the system. NOTE Please note that various options are available for the GEMA system, which may result in different order scopes.
Page 37 Gema Operating instructions 6 - Installation and commissioning The HMI control unit is mounted in the operator's field of vision. This allows an optimum view of all system data and quick operation of the control functions on the touch display.
Page 38 Gema Operating instructions 6 - Installation and commissioning 6.3.1 Mounting with metal plate (screw fastening) Proceed as follows to install the HMI with the metal plate: 1. Mount the metal plate to the wall with four screws. 2. Attach the HMI control unit to the metal plate using the magnets on the back of the HMI.
Page 39: Installing The Cabling
The connection cables HMI <-> joystick and HMI <-> GEMA generator (generator cable) as well as the connection cable for the magnetic plate (load cable) are supplied pre-assembled with connection plugs.
Page 40: Requirements For The Installation Location
The GEMA generator can be mounted at any suitable location, e.g. in the engine compartment of the excavator or on a generator set. The GEMA generator is protected against splash water in accordance with IP54 and can therefore also be mounted on the outside of vehicles.
Page 41 Gema Operating instructions 6 - Installation and commissioning 6.6.2 Installation position and mounting The GEMA generator must be mounted on a horizontal surface on the generator feet, as shown opposite. In the normal installation position, the switch box attached to the generator is located on the top of the generator. At the customer's request, the switch box can also be mounted on the generator rotated by 90°.
Page 42 4.7 "Technical data". 6.6.3 Minimum distances and cooling The GEMA generator requires sufficient ventilation for cooling. The cooling air is drawn in at the rear of the generator through the fan wheel and blown along the front of the housing through the cooling profiles.
Page 43 • The belt pulley must be pushed onto the drive shaft as far as possible. • The axis of the driving shaft must be absolutely parallel to the axis of the GEMA generator. • The pulleys of both axles must be flush with each other so that the belt runs absolutely straight.
Page 44 Gema Operating instructions 6 - Installation and commissioning type of drive. It also offers the advantage that the speeds of the drive machine and generator can be optimally matched by selecting the transmission ratio. The flange for the V-belt drive is fitted to the alternator as standard.
Page 45 Gema Operating instructions 6 - Installation and commissioning Hydraulic drive / Europe With the hydraulic drive, the generator is driven by a hydraulic motor that is fed from the vehicle's hydraulic system. Illustration 17Flange for hydraulic and gear drives ATTENTION Damage to the generator due to water ingress possible.
Page 46 Gema Operating instructions 6 - Installation and commissioning Drive via direct flange connection / hydraulic drive USA With the direct flange connection, the shafts of the generator and drive machine are connected via a connection bell. As with the direct drive, the prime mover must also have a suitable speed here, as otherwise the generator will be operated at underspeed or overspeed, which can restrict the function of the system.
Page 47 7. Check whether the safety precautions for starting the drive machine (e.g. excavator, power unit, hydraulic unit) are complied with in accordance with the applicable guidelines. 8. Start the drive unit and bring it up to the speed that is intended for operating the GEMA generator.
Page 48: Operation
The rapid magnetization with shock excitation used in the GEMA system allows you to achieve a faster load pick-up.
Page 49: Switching On The System
7.1 Switching on the system To switch on the GEMA system, proceed as follows: 1. Start the drive unit and bring it up to the speed that is intended for operating the GEMA generator. 2. You can start working as soon as the "CAN active" information is displayed on the HMI control unit (...
Page 50 Gema Operating instructions 7 - Operation 7.2 Self-test of the insulation monitoring (option) The insulation monitoring self-test is used to check whether the integrated insulation monitoring is working properly. Prerequisite: The generator must be powered. NOTE During the insulation monitoring self-test, operation of the HMI control unit is only possible to a limited extent.
Page 51 Gema Operating instructions 7 - Operation 7.3 Programs and their function This chapter provides an overview of the preset programs and their functions. The programs have been created and optimized by KW-Generator GmbH and can be used, for example, for automatic sorting and for working quickly and cleanly with different materials.
Page 52: Selecting A Program
130 V to 230 V during operation. Press the + plus button to increase the solenoid voltage and the - minus button to decrease the voltage. NOTE After restarting the GEMA control unit, the default value for the solenoid voltage is automatically active again. page 52 from 64 Doc.name: KWG_GEMA_Operating-Manual_V3-1_EN...
Page 53 In addition to the main page displayed during normal operation, the software interface of the HMI control unit has additional pages with further information, such as the history of the GEMA controller, the built-in DVR generator controller or the parameterizations. Further information on these pages of the software interface can be found in the document...
Page 54 7.6.2 Short circuit in magnetic plate/load cable In the event of a short circuit, the GEMA generator is switched off immediately. The HMI control unit then displays the message "Error: external SC" in red. This status remains until the GEMA system is restarted (...
Page 55 Gema Operating instructions 7 - Operation If an interruption in the load line is detected after the solenoid is switched on, the GEMA system switches off automatically. The HMI control unit then displays the message "Warn. magnet plate open" in yellow.
Page 56 7.7 Restarting (resetting) the GEMA control unit In certain cases, it may be necessary to restart (reset) the GEMA control unit (e.g. in the event of a short circuit in the load cable). Proceed as follows to restart the system: 1.
Page 57: Maintenance
This also includes installed protective covers. The person responsible for the system is responsible for carrying out this work. Damage and defects in the GEMA system must be rectified immediately. The system may not be put into operation until the defects have been rectified.
Page 58: Maintenance Schedule
ATTENTION Damage to components due to water ingress possible. ➢ Never expose the components of the GEMA system to the jet of a high-pressure cleaner. 8.1 Maintenance schedule The following maintenance work must be carried out in good time by the relevant persons.
Page 59: Troubleshooting
Gema Operating instructions 9 - Troubleshooting ROUBLESHOOTING Malfunction Possible cause Remedy Generator makes Foreign object in the fan cowl. Remove foreign bodies. noise. Ball bearing is defective. Have the ball bearing checked by a specialist. The drive unit is not working correctly.
Page 60 Gema Operating instructions 9 - Troubleshooting Malfunction Possible cause Remedy System is Drive speed not within the valid range (most Check the drive unit. working, but has common cause). too little power. Setting for solenoid voltage, power or torque Check the setpoint settings and The solenoid too low.
Page 61 The user is not permitted to carry out any repair or maintenance work on the components of the GEMA system. This type of work may only be carried out by authorized and qualified specialist personnel. We strongly recommend that the GEMA system is removed for this work and sent to KW-Generator GmbH.
Page 62 Carry out the decommissioning and uninstallation of the GEMA system according to the descriptions in chapter 6.6 "Installation of the GEMA generator". A GEMA system that is still functional must be uninstalled according to the descriptions in chapter 5 "Transportation and storage" must be packed and stored.
Page 63: Spare Parts
Gema Operating instructions 12 - Spare parts PARE PARTS Please contact KW-Generator GmbH directly for spare parts due to the possible wide range of variants. Version: 3.1 Doc.name: KWG_GEMA_Operating-Manual_V3-1_EN Page 63 from 64...
Page 64 13 - Installation and acceptance protocol NSTALLATION AND ACCEPTANCE PROTOCOL The installation and testing of the correct function of the GEMA system must be confirmed by the person responsible. The following installation and acceptance protocol must be completed in full for this purpose.