Manual - Magnetic Separator

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Manual - Magnetic Separator

Text of Manual - Magnetic Separator

  • 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 th