ELECON EPC PROJECTS LIMITED

Post Box No. 28, Vithal Udyognagar - 388 121, Vallabh Vidyanagar, Gujarat , India. Phone : + 91 - 2692 - 231070,231170, 232118, 236468 Fax : +91 - 2692 - 236559

Website : www.eleconepcprojects.com: Factory Address :

24, Manjusar G.I.D.C., Savli, Vadodara, Gujarat, India. 391 775

INSTALLATION, OPERATION AND MAINTENANCE

OVERBAND MAGNETIC SEPARATORS/SUSPENDED MAGNETS

I N D E X

About the Manual

1. General Details 2. Unloading & Handing

3. Storage

4. Description

5. Installation prerequisites

6. Installation

7. Operation

8. Maintenance

9. Fault finding procedure

10. Record of maintenance checks 11. Maintenance schedule

12. Lubrication details

13. Spare parts list

14. G. A. drawing of the Magnetic Separator

15. Electrical drawing of the Control Panel

14

This manual is written to provide instructions

to install, operate and maintain the equipment

avoid malfunctioning and damage.

Theseinstructions should be followed with due

attention and maintenance records must be

duly filled in a given format after necessary

checks are carried out.

In case of doubts about any instruction, the

same must be clarified informing the supplier.

Record of maintenance is very vital as it pro-

vides clues to the existing or forthcoming prob-

lems. In case of suspicious observations, the

supplier should be immediately informed so

that preventive measures can be taken before

real damage occurs.

About the MANUAL

Any suggestions to improve the

presentation of the manual are

Welcome with thanks.

3(2) INSTRUCTIONS FOR UNLOADING AND HANDLING OF MAGNETIC SEPARATOR

The magnetic separator is supplied in wooden crate and the same is fixed in such a way that

movement of the magnetic separator is prevented during transport.

For unloading the magnetic separator when received at site the same should always be handled

through Iifting lugs provided on either end poles of the magnetic separator. The same should

always be used for removing the box from transport carrier or for transporttion of separator from

one place to another.

If the electro magnetic separator is to be installed immediately, the same should be taken at the

place of installation in crate and if the separator is to be installed later on, the same should be

taken to at a proper storage place inside the crate. In both the cases the crate shall be broken/

opened and the separator can either be installed or stored as per the respective instructions.

(3) INSTRUCTIONS FOR STORAGE OF ELECTRO MAGNETIC SEPARATOR

The following instructions should be follwed for storage of the Electrc Magnetic Separator :

1. The electro magnetic separator should be stored such that it is protected from humidity, rain

and floods. The same should be stored in a closed, dry room.

2. Damaged paint coatings and rust preventing should be rectified.

3. The electro magnetic separator should be heated up from time by direct current (to be

supplied though respective control panel) and has to be lept under operating condition for

several hours. The normal frequency of heating should be atleast twice in a month in dry

seasons and atleadt four times in a moth during monsoon.

4. The insulation resistance of the magnetic coils should be checked regularly with the help of

500V Meggar. If the insulation resistance is found below 0.3M Ohm., when measured in cold

condition, the same should be improved by drying the coils according to the instruction in the

maintenance section of manual.

(4) DESCRIPTION OF MAGNETIC SEPARATOR

Overband magnetic separator are ideal for the contiguous separation of ferrous items from large

volumes of material carried by conveyor belts or vibratory feeders. Typical applications include

removing tramp iron from processed fertilizer or foundry sand or recovering valuable metal from

domestic and industrial refuse. They can also be used to protect Crushers, Shredders and other

process equipments by removing potentially damaging tramp iron. Magnetic Separators are

mounted over a conveyor either in line with it or, transversly across it. Ferrous items are lifted

magnetically from the feed conveyor

4and are retained magnetically against the moving belt of the separator while it transfers

them clear of the magnetic field to a discharge chute.The principal components of Mag

netic Separators are as under.

a) Frame Works : Robustly constructed from mild steel channels welded to provide a rigid

support for the magnet unit and moving parts.

b) Magnet Unit : It is a heavy duty totally enclosed unit, wound with high conductivity

Aluminium/Copper wire suitably insulated to relevant specification and securely held to

the magnet core.

c) Idler Pulleys : Pulleys are constructed of steel. Their ends are sealed to prevent dust or

other foreign dobies becoming lodged inside. Pulleys run in first grade self aligning

sealed for life ball bearing plummer blocks.

d) Belt : High quality nylon/terylene construction, with synthetic rubber covers, fitted with

cleats.

e) Drive : A totally enclosed, incorporating special PBL make Hollow Shaft Geared Motor

compact and sturdy construction for slow speed and high torque application.

f) Oil cooled magnet is provided with pressure relief valve and drain plugs.Both should be

checked for proper operation.

5) INSTALLATION PREREQUISITES

1. The packing must be opened carefully to avoid damage to the equipment.

For Oil Cooled Magnets, Oil should be filled upto required level in the magnet if it is oil

cooled after testing the oil for BDV. if BDV value is less than 25 KV it should be filtered

for improving BDV and then used.

2. In case of longer storage times the equipment must have been periodi cally warmed up.

3. Safe lifting and transport facilities must be employed to avoid damage.

4. Non-magnetic chute, idlers and pulley (required for inline magnetic separator) should

be fixed before installing the magnet.

5. Installation of control panel at a suitable place must be completed before hand. Required

power supply must be available to the panel. The power supply should be from a suitable

feeder, which is not connected motor(s) of heavy rating(s) to avoid fluctuation in supply.

Voltage available must be as per control panel requiement and must be measured before

connecting supply to the control panel.

6. All cables from the control panel to the magnet should be properly rated as per standard

practice to avoid excessive line drop and undue heating. Their continuity and insulation

must be checked before applying power. All cables should be laid out for operational

safety of the equipment. Break in cables can damage the magnetic separator, if it goes

unnoticed over a period of time.

57. All cable connection should be with properly sized lugs and must be extremely tight. Loose

connection can damage the magnet.

6) INSTALLATION

1. Before installation of the magnet, check up coil resistance and insulation resistance between

coil and body. If the insulation resistance is less than 1 M dont install the magnet. Check for

water ingress and if required dry up by heating the coils at a 2/3rd of its normal operating voltage

for few hours to improve IR value.

2. It is Assumed that all provisions are made the purchaser for mounted off the supporting frame

work using the fixing holes provided on the fixing pads as shown on drawing.

3. The overband cross belt magnetic separator should be mounted of the supporting frame work

using the fixing holes provided on the fixing pads as shown on drawing.

4. Adjust the operating gap as mentioned in the drawing by adjusting screw on the frame work.

Please ensure same operating gap through out the cross sectional area of OBMS. This can be

checked up by measuring distance between bottom of OBMS and conveyor frame work at four

corners.

5. The operating gap must not exceed the recommended value for the OBMS. The operating gap

indicated in the drg. is as per specification furnished by the purchaser. In case of any change.

PBL should be contacted before changing operating gap of OBMS.

6. The operating gap can be reduced to some extent depending upon type and loading of material on

conveyor, there by increasing efficiency of extraction, provided the conveyed material flows under

the separator belt without obstructions and larger size of tramp iron to be exracted, does not

cause a jam between the two belts when tramp iron is being extraced.

7. In order to prevent damage due to excessive burden, restricting structures to limit burden height

to a safe limit must be arranged ahead of the OBMS.

8. Discharge chute which is to be provided by purchaser should be of non magnetic material. It

should be fitted under the edge of the main conveyor and should extend the distance the sepa

rator overhangs form the main conveyor as shown in drawing. Chute construction must ensure

no jamming up of tramp metal pieces. All structures in magnetic zone should be of non magnetic

material.

9. Top up oil level in gear box with proper type and quantity of oil.

10. Check the alignment of gear box, motor and other drive elements. Tighten up the mounting bolts.

11. Install the control panel at a required place. The inter connection power and control cables of

suitable cross section should be used as perrequired currents.

12. Ensure sufficient air circulation around, both the magnet and the panel.

613. Connect the magnet structure to protective earth to avoid electrical shock.

14. Electrical panel should also be connected to the protective earth.

7) OPERATION

1. Check up A.C. and D.C. Voltage of panel as per wiring diagram.

2. The magnet unit should be connected to D.C. output terminals of control panel. Check for

correct polarity before connecting. The drive motor should also be connected to the A.C.

output terminals of control panel. as shown in wiring diagram. All connections must be with

proper lugs and must be very tighty fixed.

3. The switching should be carried out on A.C. supply so that rectifier unit absords back E.M.F.

of coil of magnet unit.

4. Check up the sequence of operation of OBMS and conveyors as per the wiring diagram.

5. Switch on the OBMS and check that tramp iron is being extracted and discharged correctly.

Pass tramp iron pieces of different sizes and shapes at different positions on conveyor and

ensure that they are lifted by magnet. If required the operating gap can be reduced slightly.

6. The cleats on the belt of the magnetic separators are to assist the extraction and discharge

so that when iron is attracted, it is carried to discharge chute.

7. Check running of belt and adjust belt tension by adjusting take up bearings by means of

tensioning screw belt runs centrally on main pulley.

8. MAINTENANCE

General

The important aspect of maintenance of any magnetic equipment operated on D.C. supply is that

the electrical connection should be highly reliable. Interruption of supply results into heavy spark

ing causing damage to windings or termination, thus resulting in open coils.

Another important aspect is vibration of the structures. Due to excessive vibrations, the termina

tions get loose or broken. Breakage results from fatigue in heavy and stiff conductors. There are

several points to the occurance of interruption and if carefully observed, they can be detected

before real damage is done. There are :

1. Fluctuation in Ammeter reading of control panel.

2. Presence of spark debris due pitting effect of flashovers at terminals.

3. Loose connections of cables.

74. Occassional shorting of cores in the cable noticed by IR checks. Apart from this, smooth running

of cleaning conveyor, which calls for regular maintenance of the beltdrive, is also important.

5. For Oil Cooled Magnets, check the oil level periodically at regular intervals and if required Top up

to the level by pouring additional oil. Check for Break-down voltage (should be greater than 25 KV)

once in 6 months and filter the oil if required or replace it if BDV does not improve.

The following are included in the scope of maintenance

A) Separator as a complete unit

The cleaning belt should run smoothly without any obstructions.

Cleaning belt should be in good condition with all cleats attached to it. Replace the belt if itis wear-out.

Ensure that the material does not hit the belt in normal running.

Check all coils for continuity and possible earthing by Meggar. Record resistance of eachc oil.

Check that the belt tracks properly. If required adjust the tension of the belt.

Check for correct operating height.

For Oil Cooled Mangets :

Check for oil level and BDV of the oil.

Check for leakage of oil.

Check for pressure relief valve and oil gaskets.

Check the oil temperature in hot steady state condition. It should not exceed 95C.

B) Electrical connections and cables

Check insulation resistance of cables by meggar.

Ensure that all cable terminations are with proper lugs only.

Check for reliably tightened connections.

Clean the junctions box if there is dust inside and ensure that it is properly closed with gasketto avoid dust ingress.

Clean the terminals with contact cleaner if oxide formation is there.

Check for pretective earth connection to the magnet structure.

8C) Control Panel

Check if there is excessive vibration on the panel. Check, arrange of replace antivibrationpads if necessary.

Check for loose connection of cables and interconnections in panel.

Check for damaged operating/indicating elements like isolators, switches, lamps, meters etc.Replace if damaged beyond repairs.

Check for acceptable voltage levels of the incoming supply.

Check for output voltage and current.

Check for proper earthing of the panel.

Check for proper closing of doors and locks. Repair or replace if required.

D) Tramp metal chute

Tramp metal chute should be periodically seen to check occassional accummulation of trampmetal pieces, which may, if not cleared, cause damage due to falling of the tramp metal piece

in the main stream. Ensure that the chute is non magnetic.

E) Lubrication

Lubrication of bearing blocks should be periodically implemented to facilitate smooth runningof the pulleys.

F) Performance of the Unit

Check if lifting/separation of tramp pieces is satisfactory.G) Record of maintenance

A log book should be maintained to record maintenance details.

A good record with detailed odservations can help to find out the reasons of malfunctioning of

the equipment. Record of excitation voltage, current, IR values must be maintained to facili

tate repairs and removal of the causes of malfunction.

In case of any modification carried out without prior consent of POWERBUILD or in case of

equipment being operated beyond specification POWERBUILD and the USER should be

notified immediately and equipment should be disconnected from supply, if necessary.

Maintenance schedule attached herewith must be followed without lapse and all records should

be available for guarantee/warrantee claims.

We stand guarantee/warrantee subject to our equipments being installed, commissioned and

maintained as per instructions of the installation, operation and maintenance manual,

9PBL also assumes no responsibility for the parts lost or damaged during transit, storage,

erection and operation.

(9) FAULT FINDING PROCEDURE

Following fault finding procedure should be followed.

1. Check up the continuity of coil shows open circuit inform Power Build Limited.

2. If the continuity of coil is O.K. measure the resistance or each coil by means of precision

bridge (KELVINS) and compare with the original values. It may be noted near that the values

of coil resistance may be different in winter and summer due to the effect of temperature.

The deviation of 5 to 10% will cause no problem to OBMS.

3. Check the resistance between body and coil. If this value is less than 1 Mega. Ohms heat up

the coil till the value is reached to 1 Mega Ohms. Heating can be effected by supplying the

coil with voltage of around 60-70% of rated value continuously under observation. the heating

should be continued till megger value improves to the level mentioned above.

4. If the lifting capacity is reduced, please check up excitation voltage and current. Also check

for overheating of oil. Measure oil and body temperatures. Oil temperature should not exceed

95C and body temperature should be within 65C. Excessive heating may be due to short

circuited coil or due to insufficient oil in case of oil cooled magnets. Any observation from

standard values of D.C. voltage, current, body temperature, oil temperature (for oil cooled

magnets Coil resistance etc. should be noted down and informed in case if PBL assistance

is required.

5. If above mentioned checks do not indicate any fault, test the control panel for any possible

fault, like short circuited of open diode, transformer fault etc.

6. Infrom PBL if no fault is located even after doing all above.

10) RECORD OF MAINTENANCE CHECKS OF ELECTROMAGNETIC EQUIPMENT :

A) Magnet as a complete unit :

1. Equiment running smoothely (state in detail separately Yes [ ] No [ ]

if there is problem) ?

2. Excitation voltage at the equipment ? Volts DC

3. Any fluctuation observed while measuring voltage ? Yes [ ] No [ ]

4. All connections of cables as observed. Loose [ ] Tight [ ]

(tighten if they are loose)

5. Resistance of the coils as measured C1

Ohm

C2

Ohm

C3

Ohm

C4

Ohm

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6. Any coil found connected to earth by meggar ? Yes [ ] No [ ]

(If Yes, give the number of coil.)

7. Operating height maintained mm

8. Oil Level OK [ ] Not OK [ ]

9. BDV of oil OK [ ] Not OK [ ]

B) Cables and Electrical Connections

1. All connections found healthy Yes [ ] No [ ]

2. Insulation resistance and continuity of cables OK [ ] Not OK [ ]

(Replace cable if it is faulty)

3. Junction box/es closing properly ? Yes [ ] No [ ]

4. Any oxide formation at terminals ? Yes [ ] No [ ]

C) Control Panel

1. Any loose connection ? Yes [ ] No [ ]

2. Any indicating/measuring/control element missing ? Yes [ ] No [ ]

(if yes, give details)

3. Incoming supply voltage Volt 3 phase AC

4. DC Output voltage Volts DC

5. Current drawn by the magnet in normal running A DC

6. Is panel properly earthed ? (If required connect properly) Yes [ ] No [ ]

7. If the door/lock closing properly? Yes [ ] No [ ]

D) Tramp Metal Chute

Is it cleaned periodically? (state if there is a problem) Yes [ ] No [ ]

E) Lubrication/Oil Filling

1. Lubrication done as per schedule ? Yes [ ] No [ ]

2. Is the level of oil in gear box OK? Yes [ ] No [ ] NA [ ]

F) Performance of the unit (If not OK give details) OK [ ] Not OK [ ]

(G) Any other comments :

Checked by : Date :

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12) LUBRICATION

Following parts require regular lubrication and the lubrication schedule given should be

followed strictly for efficient running of equipment :

1. Geared Motor : A sperate manual for PBL geared motor is enclosed

and user is requested to follow this for lubrication.

2. Bearing : Bearing blocks incorporated in our equipment are

of self lubrication type and are charged with correct

amount of grease for normal application. As such

they do not require re-lubrications in normal work

in conditions. In case a re-lubrication is desired, a

correct quantity of grease can be pumped through

grease nipple.

Approved lithium - based grease should be used

for re-lubrication. Following greases are recon

mended.

Type of Grease Supplier / Manufacturer

Alvania R - 3 Shell MEX & B.P. Ltd.

Alvania R - A Shell MEX & B.P. Ltd.

B. Energress LS3 Shell MEX & B.P. Ltd.

Beacon 3 Essco-Petroleum Co. Ltd.

Halycon 3 TH New Some & Co. Ltd.

Lupus 3 Walker (Century Oils)

13) SPARE PARTS FOR OVERBAND MAGNETIC SEPARATOR

1. Head pulley bearing : 2 Nos.

2. Takeup bearings : 2 Nos.

3. Belt fitted with cleats : 1 Nos.

4. Spare for geared motor : As per its manual

14) Spare parts for control Panel :

1. 3 phase, Full-wave Bridge : 2 Nos

Rectifier Stack

2. Complete set of Fuse links : 2 Sets

from min. to max. ratings

3. Isolator/Switch fuse unit : 2 Nos

4. A.C./D.C. Contactors : 2 Nos each for different ratings.

5. Temperature Relay : 1 Nos

(Amplifier relay unit)

6. Set of Indicating lamps with bulb : 3 Sets

7. Set of push buttons : 3 Sets