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
5. Installation prerequisites
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
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
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.
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
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
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