INSTALLATION, OPERATION AND

MAINTENANCE

SUSPENDED PERMANENT MAGNETIC SEPARATOR

Model CP

Customer: DOMEC, SL
P/O: 008/18
W/O: 107609

Typical Suspended Permanent Magnets

Typical Manual Cleaning Typical Self Cleaning

Suspended Permanent Magnet Suspended Permanent Magnet

Document: IOM049-GBR Issue: 11 Date: 16/11/2017

 Table of Contents
1. INTRODUCTION ...................................................................................................................................... 4
1.1 RESPONSIBILITY ................................................................................................................................. 4
1.2 USING THIS MANUAL .......................................................................................................................... 4
2. GENERAL HEALTH AND SAFETY / WARNING NOTICES .................................................................. 5
2.1 HEALTH AND SAFETY FACTORS .......................................................................................................... 5
2.2 SAFETY ............................................................................................................................................. 5
2.3 LIFTING AIDS ..................................................................................................................................... 6
2.4 NOISE ............................................................................................................................................... 6
2.5 LETHAL VOLTAGES ............................................................................................................................. 6
2.6 MOVING MACHINERY .......................................................................................................................... 6
2.7 HEAT ................................................................................................................................................. 6
2.8 ELECTRONIC CARDIAC IMPLANTS ........................................................................................................ 6
2.9 ELECTROMAGNETIC COMPATIBILITY .................................................................................................... 6
2.10 W ARNINGS AND SAFETY INSTRUCTIONS .............................................................................................. 7
2.11 GUARDS AND BARRIERS ..................................................................................................................... 7
2.12 MAINTENANCE STAFF ......................................................................................................................... 7
2.13 RESPONSIBILITY ................................................................................................................................. 7
3. GENERAL RISK AND HAZARD ASSESSMENT ................................................................................... 8
3.1 GUARDS AND BARRIERS ..................................................................................................................... 8
3.2 STATEMENT OF DESIGNED METHOD OF OPERATION ............................................................................ 8
3.3 RISK AND HAZARD ASSESSMENT PARAMETERS ................................................................................... 8
3.4 RESIDUAL HAZARD IDENTIFICATION ..................................................................................................... 8
3.5 POSSIBLE HAZARDS AND RISK ASSESSMENT ....................................................................................... 8
3.6 KEYWORDS AND SYMBOLS ................................................................................................................. 9
3.7 SAFETY ADVICE ............................................................................................................................... 10
3.8 BELT MOTOR ................................................................................................................................... 10
3.9 GENERAL W ARNINGS ....................................................................................................................... 10
3.10 CORROSIVE MATERIALS ................................................................................................................... 10
4. PRINCIPLE OF OPERATION ................................................................................................................ 11
4.1 BACKGROUND .................................................................................................................................. 11
4.2 METHODS OF CLEANING .................................................................................................................. 11
5. INSTALLATION ..................................................................................................................................... 12
5.1 RESPONSIBLE PERSONS................................................................................................................... 12
5.2 OPERATIVES (SELECTION AND ERECTION).......................................................................................... 12
5.3 TRANSPORT AND HANDLING ............................................................................................................. 12
5.4 LIFTING............................................................................................................................................ 13
5.5 GENERAL......................................................................................................................................... 14
5.6 MAGNET POSITION ........................................................................................................................... 14
5.7 MANUAL CLEANING POSITION 1 ........................................................................................................ 15
5.8 SELF CLEANING POSITION 1 .............................................................................................................. 15
5.9 POSITION 2 ...................................................................................................................................... 16
5.10 SUSPENSION HEIGHT ....................................................................................................................... 17
5.11 BURDEN DEPTH ............................................................................................................................... 18
5.12 EMERGENCY OFF PUSH BUTTON ...................................................................................................... 18
5.13 LIGHTING ......................................................................................................................................... 18
6. COMMISSIONING.................................................................................................................................. 19
6.1 SELF-CLEANING SEPARATORS .......................................................................................................... 19
7. PREVENTIVE MAINTENANCE ......................................................................................................... 20
7.1 ROUTINE MAINTENENCE ................................................................................................................... 20
7.2 DAILY .............................................................................................................................................. 20
7.3 W EEKLY .......................................................................................................................................... 20

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 7.4 MONTHLY ........................................................................................................................................ 20
7.5 3 MONTHLY ..................................................................................................................................... 20
7.6 YEARLY ........................................................................................................................................... 20
7.7 GENERAL SAFETY RULE ................................................................................................................... 21
7.8 MANUAL CLEANING SEPARATORS ..................................................................................................... 21
7.9 SELF-CLEANING SEPARATORS .......................................................................................................... 21
7.10 VULCANISED BELT ........................................................................................................................... 21
7.11 LACED BELT .................................................................................................................................... 22
7.12 BEARING RELUBRIATION ................................................................................................................... 22
7.13 DRIVE COUPLING ALIGNMENT ........................................................................................................... 23
8. TROUBLESHOOTING AND RECOMMEDED SPARES .................................................................. 24
8.1 MANUAL CLEANING UNITS ................................................................................................................ 24
8.2 SELF CLEANING UNITS ..................................................................................................................... 24
8.3 RECOMMENDED SPARES - REFER TO APPENDIX D ............................................................................. 24
9. DISPOSAL OF SYSTEM ................................................................................................................... 25
9.1 GEAR UNITS .................................................................................................................................... 25
9.2 MOTOR UNITS.................................................................................................................................. 25
9.3 MAGNETS ........................................................................................................................................ 25
10. APPENDIX A - COPY OF DECLARATION OF CONFORMITY ...........................................................
11. APPENDIX B - MECHANICAL DRAWINGS.........................................................................................
12. APPENDIX C - ELECTRICAL ...............................................................................................................
13. APPENDIX D –SPARES/ CONSUMABLES LIST AND DRAWINGS ..................................................
14. APPENDIX E –DRIVE SPECIFICATION ..............................................................................................
15. APPENDIX F – OTHER RELEVANT INFORMATION ..........................................................................
16. APPENDIX G – ATEX INFORMATION .................................................................................................
17. APPENDIX H – OEM INFORMATION ..................................................................................................

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1. Introduction
1.1 Responsibility
Eriez Magnetics Europe Ltd will not be responsible for any malfunction of equipment as a result of the
customer’s failure to follow the instructions detailed in this manual. If you have any queries regarding
the information or instructions given in this manual, do not hesitate to contact your Eriez Magnetics
Europe Ltd representative.

1.2 Using this Manual

This manual is intended solely for Eriez Magnetics, “Suspended permanent magnet separator CP”.
The specific Works Order Number identifies the Eriez project which is shown on the cover page:

This manual consists of numerous chapters. If you are reading this manual for the first time, it is
recommended that you read each chapter in order. The chapters are as follows:

- Introduction
- General Health and Safety / Warning Notices
- General Risk and Hazard Assessment
- Principle of Operation
- Installation
- Commissioning
- Preventative Maintenance
- Troubleshooting and Recommended spares
- Disposal of system
- Appendices

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2. General Health and Safety / Warning Notices
WARNING

This chapter contains important safety related information. It is strongly recommended that you
familiarise yourself with the information in this chapter before proceeding through this user manual.
Failure to do so could lead to the risk of injury or death.

2.1 Health and Safety Factors

There are several factors which have a bearing on the Health and Safety aspects concerned with the
installation of this equipment. These are as follows:

Weight The weight of the components

Noise levels may exceed the levels at which hearing protection is
Noise levels (at workstation)
required
Voltages Lethal voltages are used in the equipment
Moving machinery Moving components are present in this equipment
High temperatures are generated during the operation of this
Heat
equipment
The magnetic field created by this equipment can interfere with
Magnetic fields
medical implants which may lead to catastrophic failure of the device

2.2 Safety
The electrical equipment employed in this product operates using potentially lethal electrical power
and therefore should be treated with the utmost caution and respect. To avoid the possibility of
personal injury or even death, the following points must be closely observed:

WARNING

i) Never allow the equipment to be operated by untrained personnel.

ii) Never allow the operation, maintenance or rectification of the equipment or its
components to be carried out by personnel other than those who have been suitably
trained and declared competent to carry out such tasks.

iii) Never put the equipment back into use following maintenance or rectification until it
has been checked by suitably trained and qualified staff and declared as safe to do so.

iv) Never operate the equipment with any guards, panels or doors removed or open.
Always ensure that they are in a serviceable condition, correctly secured and locked
prior to switching on the equipment.

v) Never modify the equipment or its components so that they will operate with any of the
safety features disabled i.e. short circuited, linked out or by-passed in any way.

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2.3 Lifting Aids
Personnel are to be aware of the weight of the equipment and its components and are strongly
advised to use trained personnel and mechanical lifting aids wherever possible. To avoid the risk of
injury, personnel are to ensure that prior to attempting an unaided lift the weight involved does not
exceed any recommended limits identified by legislation, or any other relevant guidance, and that
suitable protective clothing is worn.

2.4 Noise
Eriez Magnetics Europe Ltd has taken all reasonably practical measures to reduce noise to levels
which are safe and without risk to the health of a normally fit operator. It is, however, possible that a
noise level in excess of 80dBA may occur in the vicinity of the equipment. Customers should make
sound level measurements of the equipment when installed and operating under normal load
conditions within the rating of the equipment. This will take into account the equipment and its
environment and enable the appropriate level of action to be determined in accordance with
legislative guidelines applicable in the area of installation.

2.5 Lethal Voltages

Lethal voltages may be employed in this equipment and Warning Signs are displayed.

2.6 Moving Machinery

In some machinery linear moving components can be employed during the operation of the
installation. The fitting of guards etc. to prevent access by operators is strongly recommended. Any
additional guarding required due to additional hazards presented by the customer’s environment /
machinery is the responsibility of the customer.

2.7 Heat
During the operation heat may be induced into the equipment and its components, therefore direct
contact with the equipment during or immediately following operation of the equipment should be
avoided without handling equipment and protective clothing.

2.8 Electronic Cardiac Implants- equipment that contain magnets

It is possible for electronic cardiac implants to be affected by extraneous magnetic
fields radiated by magnets and similar devices. Personnel, including visitors, fitted
with such devices should therefore not stand in the immediate vicinity of the
magnetic separator. Further information should be sought from the appropriate area
medical authority or from information which can be sourced from the manufacturer of
the implant. If in doubt a distance of 3 meters radius, is to be observed at all times. It
is the customer’s / operators responsibility to ensure that all personnel, including visitors are made
aware of this hazard.

2.9 Electromagnetic Compatibility- equipment that contain magnets

2.9.1 This equipment has been so constructed that it does not cause excessive electromagnetic
interference and is not unduly affected by electromagnetic interference.
2.9.2 This equipment should not be operated with any doors or panels open as this may reduce the
effectiveness of the electromagnetic radiation and immunity screening.
2.9.3 Regular maintenance procedures as outlined elsewhere in this manual should be observed.

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2.10 Warnings and Safety Instructions
The need to observe the warnings and safety instructions at all times cannot be emphasised too
strongly and, in particular, the potentially lethal consequences of working on an electrical component
with the mains supply switched on, and the risk of burns due to the temperature of treated wire and
operating electrical equipment.

2.11 Guards and Barriers

2.11.1 The equipment supplied by Eriez Magnetics Europe Ltd is fitted with guarding as required to
meet with the requirements of the Machinery Directive as listed in the Certificate of
Conformity.
2.11.2 All our suspended magnetic separators are intended to be incorporated into an existing facility
or machinery determined by the end user.
2.11.3 It is the customer’s responsibility to install guards and barriers as required to prevent
unauthorised access to the installation and protect the operators from any hazards present
once the installation is complete.
2.12 Maintenance Staff
Only suitably qualified members of staff should attempt to maintain or rectify the installation or its
components. It is the responsibility of the customer’s qualified representative to ensure that following
any maintenance or rectification tasks, all guards, safety interlocks and earthing circuits are correctly
fitted, fully functional and the installation is in a safe condition prior to being operated.

2.13 Responsibility
Eriez Magnetics Europe Ltd cannot accept any responsibility for accidents or damage caused by
over-riding the safety interlock circuits or non-compliance with any warnings issued in this user
manual.

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3. General Risk and Hazard Assessment
3.1 Guards and Barriers
The equipment supplied by Eriez Magnetics Europe Ltd is intended to be incorporated into an
existing facility at the end users site. In some machinery hot surfaces and moving components can
be exposed during the separation process, it is the customer’s responsibility to install guards and
barriers as required to prevent unauthorised access to the installation and protect the operators from
any hazards present once the installation is complete.

3.2 Statement of Designed Method of Operation

3.2.1 The installation was designed following a requirement from the customer on the method of
operation of this installation. It is the responsibility of the customer to take responsibility for
any associated hazards as a result of this requirement.
3.2.2 It is the responsibility of Eriez Magnetics Europe Ltd to make the customer aware of any
hazards that may exist within the parameters specified.
3.2.3 The installation is designed to extract and separate tramp iron from a contaminated conveyor
feed of substances. The process is continuous.

3.3 Risk and Hazard Assessment Parameters

3.3.1 The parameters for risk and hazard evaluation for the installation during normal working
operation have been taken from the following instructions: Machinery Directive Risk
Assessment.
3.3.2 It is the full responsibility of the customer to ensure that the surrounding environment is made
safe for the operators, following all the recognised safety standards.
3.4 Residual Hazard Identification
3.4.1 This manual is only concerned with any hazards that may concern the operators within the
parameters specified above.
3.4.2 Where possible protection has already been provided (i.e. selection of certified components)
and so therefore these are no longer considered a hazard.
3.5 Possible Hazards and Risk Assessment
Separate risk assessments have been carried out and are all stored as part of the equipment
technical file.

DO NOT install commission or operate this machine until this manual has
been carefully read.

This suspended permanent magnet has been designed to be “safe” when operated
and maintained under the guidance of this manual.

FIRE WARNING. Materials may get extremely hot and if mixed with
combustible material could cause a fire.

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3.6 Keywords and Symbols
Please pay special attention to sections of text with these allocated symbols:

General symbol for: Danger! Caution! Attention! Important!

Risk of Electrical Shock Hazard.

Risk of Body Crush Hazard.

Injury by rotating blades Hazard.

Lifting Hazard

Body Crush / Tip over Hazard

This equipment contains Magnetised material and must be treated with the
UTMOST caution to safeguard against injury.
Do not allow the pole faces to face each other. Opposite polarity poles will
come together with considerable force.

Before handling this equipment personnel with pacemakers or implants

should confirm that their implants are not affected by magnetism. If in
doubt do not approach within 3m radius of the magnet.

Take care when using ferrous tools or ferrous parts near the magnet as
they can be attracted to the magnet with considerable force.

Do not place pre-recorded tapes, computer disks, or credit cards near

the magnet box since this could cause erasure.

Do not drill or weld near the magnetic unit without first seeking the
advice of: ERIEZ MAGNETICS EUROPE LIMITED

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3.7 Safety Advice

The SAFETY ADVICE section on the next page MUST BE READ before
any work is attempted.

3.8 Belt Motor

This may be controlled locally or remotely and could start up without

warning.

3.9 General Warnings

3.9.1 When machinery is energised the operators should listen for any abnormal banging sound or
extreme vibration. If this is observed the machine should be de-energised and maintenance
staff informed.

3.9.2 Warning Plates, Caution Plates and Safety labels on the equipment must not be removed or
painted over. It is important these warnings and cautions are legible and complied with.

For equipment that can generate a strong magnetic field operators should take the
necessary precautions when handling ferrous material in the vicinity. Tramp iron may be
attracted suddenly and unexpectedly to the magnet surface with the possibility of finger or
limb entrapment, resulting in injury.

3.10 Corrosive Materials

Equipment parts used are appropriate to the intended mechanical and thermal stresses
and capable of withstanding attack by existing or foreseeable aggressive substances.

The equipment is designed in accordance with Directives and standards as stated on

Declaration of Conformity and good engineering practice. It’s the User’s responsibility, to
ensure chemical compatibility with the materials used.

If the equipment is likely to come into contact with aggressive substances, then it is the
responsibility of the user to take suitable precautions that prevent it from being adversely
affected, thus ensuring that the type of protection is not compromised. Aggressive
substances - e.g. acidic liquids or gases that may attack metals or solvents that may affect
polymeric materials.

Suitable precauions – e.g. regular checks as part of routine inspections or establishing

from the materials data sheet that it is resistant to specific chemicals.

CAUTION!
Machines can produce a strong magnetic field that will quickly attract
magnetic tools and items. Extreme care must be taken to keep all
magnetically attractive items away from the machine to avoid injury.

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4. Principle Of Operation

4.1 Background
Suspended, permanent magnet, heavy-duty separators are designed for use over a moving bed of
material from which iron is to be removed. The units contain blocks of permanently magnet material,
arranged to produce a powerful magnetic field. The block arrangement determines the magnetic
circuit configuration.

4.2 Methods of Cleaning

Two simple methods of cleaning the extracted ferrous material from the surface of the magnet are
available; Manual cleaning (Figure 1) or Self Cleaning (Figure 2). There are a wide range of sizes
available for either style and separators can be mounted in- line with the conveyor belt (Position 1)
or across the conveyor belt (Position 2) to suit customer requirements.

Manual cleaned magnets are designed for use when tramp iron contamination levels are low.
Periodically, it is necessary to remove the accumulation of tramp iron, either by hand or with a
moveable stripper plate.

Where large amounts of tramp iron require separation, self-cleaning magnets are more practical.
The construction of the magnet box is the same as for the manual cleaning magnet, with the
addition of a short belt conveyor built around the assembly to provide an automatic discharge for the
tramp iron.

A rotation sensor and / or belt alignment switches may be fitted to a self-cleaning unit as an option.
The use of this equipment allows the use of remote monitoring to ensure that the self-cleaning belt is
operating as required

Figure 1 Figure 2

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5. Installation
5.1 Responsible Persons
Responsible persons who are responsible for the processes involved in the design, selection, and
erection of equipment installations and shall possess, at least, the following:

The possession of sufficient knowledge, experience, skills and training to enable the person to know
what he or she is doing and to be able to carry out a task in the way in which a person competent in
the activity would expect it to be done and to have an appreciation of one’s own limitations. It does
not necessarily require a particular level of qualification.

5.2 Operatives (selection and erection)

Operatives shall possess, to the extent necessary to perform their tasks, the following:

 Understanding of the general principles of the equipment;

 Understanding of the general principles of operation;
 Understanding of the equipment design;
 General understanding of inspection and maintenance requirements.
 Familiarity with the particular techniques to be employed in the selection and erection of this
type of equipment.
 Understanding of the importance of permit to work systems and safe isolation techniques in
relation to electromechanical equipment.

5.3 Transport and Handling

The transport organisation is always liable for any damage during transit to the goods that have
been entrusted to the same. Before preparing the unit for installation and commissioning, a
thorough visual inspection must therefore be carried out to check that the packaging is intact
and that the unit presents neither visible damage nor oil leak. Also ensure that the units
correspond to the order that was placed.

Any damage or complaints must be reported to Eriez and to the carrier by recorded delivery letter
within 8 days from receiving the goods. Should one or more components be damaged, do not
proceed with starting up the unit and inform Eriez of the problem, agreeing with the latter the
actions to be taken.

Preferably remove the packaging at the actual place of installation.

Internal handling must be carried out with the utmost care, without using unit components as
handholds. To avoid damage it is essential when moving the units that they always remain in
the position envisaged for their operation.

Do not leave packaged units in places exposed to strong sunlight, since the internal temperature
could reach safety device tripping values.

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5.4 Lifting

Lifting should preferably be carried out with a lift truck. Use a spreader beam if belts or ropes are used
for slinging, making sure that there is no pressure on the upper edges of the units or the packaging.

Example of lifting with a lift truck: - Insert protection for the outer structure of the unit, for
example a sheet of cardboard or polystyrene (A). - Make sure that the forks of the lift truck
project at least 100 mm (B) from the other side of the unit.

Example of lifting with straps:

Place the lifting pipes like the figure.

Place rigid structures on the upper edges of the unit so as to ensure it is not damaged (only in the
case of one point at which the force acts).

Tighten the hoisting straps gradually, ensuring that they are correctly positioned.

Begin hoisting the unit.

Cautions \ Checks Unloading

All Models
Care must be taken when un-crating the unit to avoid damage to the equipment.

Before operation, inspect the area and remove all magnetic material within the vicinity of the
magnet.

Ensure the main frame is visibly square and is not twisted.

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5.5 General
When unpacking, take care to avoid damage to the equipment and possible personal injury - the
magnet assembly is very powerful and permanently charged. Remove loose ferrous material
closer than 600 mm to the magnet box. Spanners and other tools within the vicinity where the
equipment is to be installed could become magnetically induced and be attracted to the magnet box
with considerable force.

Also, when installing Suspended Permanent Magnetic Separators check that the unit is in the
correct orientation, with the heavy steel end poles at right angles to the direction of material flow.

Electric drives must be fitted with appropriate overload protection.

Typical Installation (chains not of Eriez supply)

5.6 Magnet Position

The preferred installation of a suspended magnet is over the trajectory of the product material
where it discharges from the belt conveyor. This position is referred to as Position 1, (Figures 3
and 4). For optimum separation in Position 1, there must be provision to adjust the location of
the magnet in relation to the material trajectory. The centre of the magnet must be over the head
pulley to ensure optimum performance.

A separator mounted over a moving bed of material at right angles to the conveyor is referred to as
Position 2 (Figures 5 and 6 ). This installation usually requires a stronger magnet than Position
1 since tramp iron at the bottom of the burden is more difficult to extract

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5.7 Manual Cleaning Position 1 (In line)

Figure 3

The installation of a magnetic head pulley below the magnet will significantly reduce the separation
performance of the magnet.

A non-magnetic head pulley should be installed, regardless of the speed of the conveyor.

5.8 Self-Cleaning Position 1 (In line)

When installing a self-cleaning unit, examine the area to ensure there is adequate clearance
for the belt to run and that provision has been made to collect discharged tramp iron. A hinged
non-magnetic splitter, adjustable in length, will be required to prevent extracted tramp from re-
entering the non-magnetics.

Figure 4

A self-cleaning magnet in position 1 may require an extension magnet to ensure that material is not
discharged prematurely back in to the product flow.

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5.9 Position 2 (Cross Belt installation)
A separator mounted over a moving bed of material at right angles to the conveyor is referred to as
Position 2 (Figs. 5 and 6 ). This installation usually requires a stronger magnet than Position 1
since tramp iron at the bottom of the burden is more difficult to extract.

• The efficiency of magnetic separators in Position 2 is dependent on many factors including the
speed of the conveyor carrying the feed. As conveyor speed increases above 100m/min,
separation efficiency may fall.

• Conveyor idlers beneath the separator in Position 2 must be non-magnetic.

• Manually cleaning suspended magnets should be installed on the centreline of the material
conveyor, Figure 5. Self-cleaning suspended magnets should be installed with the trailing edge of
the magnet box immediately above the outer edge of the conveyor idler on the non-discharge side.
Refer to Figure 6.

Self-cleaning cross belt magnets must be installed parallel to the belt at the same angle as the
conveyor but at a maximum inclination of 25 degrees. The SC2 position.

Manual Clean Position 2 (Cross Belt)

Figure 5

Self-Clean Position 2 (Cross Belt)

Figure 6

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5.10 Suspension Height

The magnetic strength and configuration of a Suspended Permanent Magnetic Separator is selected
for a specific suspension height and application. The suspension height quoted should be considered
a maximum. The suspension height is measured from the face of the magnet block to the bottom point
of the customer’s feed conveyor belt.

When setting the suspension height, Figure 7, lower the magnet as close as possible to the top of the
burden, without interfering with the material flow. If the unit is self-cleaning, ensure that the separator
belt is clear to operate freely whilst carrying tramp iron. Failing to do this could result in tramp iron
being knocked back into the non-magnetics.

A clearance of 75 mm between the belt and the top of the product burden or trajectory should be
maintained for self-cleaning units; this clearance can be reduced to 50 mm for manually cleaned
units.

WARNING

Do not over-tighten the self-cleaning belt as this could put excess strain and cause damage to the
bearings and / or the pulleys. The equipment is designed to operate with belt sag of approximately 25
mm.

Suspension Height Self-Cleaning – Position 2

Figure 7

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5.11 Burden Depth
One factor in achieving optimum separator performance is to control the burden depth.

• Position 1 installation. The installation location is calculated on product throughput. Any

variation from this will change the trajectory of the product material with respect to the working
surface of the magnet and could result in poor separation.

• Position 2 installation. A plough or leveller installed before the magnet will remove high spots
or surges in material flow.

5.12 Emergency Off Push Button

Machines that require an emergency stop are fitted with a dual channel emergency off push button so
as to conform to the requirements of the machinery directive.
The emergency off is for incorporation into either the customer’s main safety system, or, if Eriez have
supplied the controls, it will be wired back to the Eriez control box to form part of the machinery safety
system. This can then be linked to the customer’s safety system.
If the control system is supplied by the customer, then it is the scope and responsibility of the
customer/installer to ensure an appropriate emergency stop system is utilised before powering the
machine.

5.13 Lighting
Lighting is not provided with the product. This manual indicates that proper illumination is required to
safely operate the machine. There are no special lighting requirements to operate or maintain the
machine. Normal illumination found in factories or workshops is sufficient.

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6. Commissioning
Note: The first thing to be checked before any movements of the machine is the emergency off
and guard switches, until you are satisfied these switches are fully operational do not proceed
with the commissioning.

Note: If required, Eriez is able to provide an engineer to check the controls and adjustments before
start-up. The engineer will ‘fine tune’ the splitter position to achieve maximum yields and demonstrate
to personnel the operation of the plant. Service rates are available from Eriez by request.

6.1 Self-Cleaning Separators

After installation, examine for any obvious visual damage; in particular check that the frame is
square and has not been twisted.

Always prove the safety system before anything else. Always make sure that you are in complete
control of the equipment, so with this type of machine, prove the emergency off removes all supplies
to the motors etc.

Momentarily close the power supply switch to the belt drive and check that the belt is tracking
properly and is not wandering laterally. Never start the belt drive and allow it to run
continuously until the belt is properly tracked. If the belt moves to one side or the other, note the
direction and adjust as follows:

 Self-cleaning magnet belts run on two pulleys, one fixed and the other adjustable. The
adjustable tail pulley has approximately 100mm of take up available for both belt stretch and
tracking. To track the belt, the tail pulley should be adjusted to tighten the belt on the same
side to which the belt is seen to move towards.

 Ensure the belt direction is correct, as incorrect operation of the belt would negate any
warranty.

 Extreme care should be taken.

WARNING

Belt is designed to operate with a belt sag of 25mm, over-tightening of the belt will cause damage to
the bearings, couplings and / or pulleys and invalidate the warranty.

Typical Belt Typical Measuring Typical Belt Sag 25mm

Adjuster Position Figure 10
Figure 8 Figure 9

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7. Preventative Maintenance
7.1 Routine Maintenance
Before carrying out any maintenance on the Separator, refer to
WARNING Chapter 2, General Health and Safety/ Warning Notices, and Chapter
3, General Risk and Hazard Assessment, in this manual. All
maintenance personnel must be suitably trained and passed as
competent. All personnel should be made aware of the location and
operation of the Emergency Stop button.

Before carrying out any maintenance, ensure that the Separator is

WARNING rendered safe, with services switched off and isolated, prior to
commencing maintenance tasks.

Permanent Magnets are Permanent! The magnet will be ‘live’ even

WARNING with all power isolated. Extreme care must be taken at all times.

Note: Normal maintenance does not require the customer or user to gain access inside the
Separator’s Magnet Enclosure.

7.2 Daily
 Check for unusual operating noises.
 Check that the dust level isn’t excessive.
 Remove any trapped tramp iron (protective gloves required).

7.3 Weekly
 Check the level of dust deposited and clean to an acceptable level to ensure that no
overheating occurs.
 Remove any trapped tramp iron (protective gloves required).
 Check for signs of wear or impact on the face of the magnet (Manual Clean only).

7.4 Monthly
 Remove any trapped tramp iron (protective gloves required).
 Check Belt for wear, tracking, and tension.

7.5 3 Monthly
 Lubricate bearings, refer to section 7.12. DO NOT over grease.

7.6 Yearly
 An annual full service by a qualified engineer is recommended.
 If an electric drive is fitted, check the oil level in gearbox and refill as necessary, refer to
Appendix H for OEM manual.
 If a hydraulic drive is fitted check fittings and seals for leaks, no other maintenance is
necessary under normal conditions.

Document: IOM049 Issue: 13 Date: 16.03.2018

20
7.7 General Safety Rule
Before carrying out inspections, maintenance and controls, scrupulously comply with all that is listed
below:

 Check that the power on/off switch is put to off and padlocked. If the company is running a tag
out system, ensure that you get your name added to the list of workers ensuring no-one can
put power back on without your signature.

 Check that there are no moving parts powered from auxiliary supplies.

 Check for potential hazards from other items of equipment being started.

 Observe the accident-prevention regulations.

 Put on adequate personal protective equipment (gloves, goggles, etc.)

 Except for visual inspections, all the operations are to be carried out solely by specialised and
expert personnel; otherwise the warranty is rendered invalid.

7.8 Manual Cleaning Separators

No maintenance is required.

7.9 Self-Cleaning Separators

 Belt tracking should be checked frequently and adjusted as necessary. Refer to Chapter 6
Commissioning
 Lubricate the bearings on a schedule consistent with other equipment in use at the site for the
product and environment. At least every 3 Months as per the maintenance schedule.

 If the unit is installed within a separate enclosure, provision must be made to the construction
of the enclosure to gain easy access to moving parts.

 Check the self-cleaning belt for damage and, if necessary, replace as follows:

7.10 Vulcanised Belt

Replacing a vulcanised belt requires the self-cleaning gear to be dismantled after the separator
has been removed from its installation. This is a major operation and is not always practical.
An alternative method is to replace the belt in situ.
 Slacken the bolts securing the non-drive pulley.

 Slacken the belt tensioning screws.

 Cut through the damaged belt and remove it.

 Wrap the new belt and vulcanise.

 Re-tension the belt; allowing for belt sag; refer to Chapter 6 Commissioning

Document: IOM049 Issue: 13 Date: 16.03.2018

21
7.11 Laced Belt
To replace a laced belt proceed as follows:

 Slacken the bolts securing the non-drive pulley.

 Slacken the belt tensioning screws.

 Remove the braided stainless steel wire.

 Re-tension the belt, allowing for belt sag; refer to Chapter 6 Commissioning

 Re-track; refer to Chapter 6 Commissioning.

 Tighten the bearing securing bolts.

7.12 Bearing Relubrication

Relubrication of the bearings is not normally necessary except when operating at extremes of
temperature, speed and loading, or where excessive wet or dirty conditions exist. The relubrication
frequency varies with the type and quality of grease used as well as the operating conditions;
therefore it is difficult to establish a general rule.

The performance of a bearing is greatly influenced by the quantity of grease. In order to avoid
overfilling, it is advisable to replenish the grease while the machine is in operation. Use only Shell
Alvania S2 grease or equivalent.

 There are 4 bearings per separator as indicated in Figure 11.

 To prevent damage to seals only manual grease pumps should be used. DO NOT use
pressurised pumps or automated greasing systems.

 Remove bearing protector caps, if fitted, so that the bearing inserts can be observed.

 Attach grease pump to nipple on first bearing as indicated in Figure 12.

 Continue to insert grease until a little oozes out from beneath the sealing lip on the inner ring
for optimum performance

 Repeat process for the remaining 3 bearings.

 Re-fit protector caps if applicable.

Figure 11 Figure 12

Document: IOM049 Issue: 13 Date: 16.03.2018

22
 7.13 Drive Coupling Alignment (Hydraulic Motor)
It is essential that the drive coupling fitted to the hydraulic drive models is correctly aligned to prevent
damage and failure of the coupling. Both coupling halves are designed to fit together in one position
only due to one half close fitting into a recess in the other half. A locating pin between both coupling
half faces further ensures alignment. The hydraulic motors are mounted on a support bracket and
are fixed in position with bolts and dowels.

Note: Over-tensioning of the belt or impact to the drive pulley can cause mis-alignment.

Recess to help assembly of Locating Pin Joint between coupling

both coupling halves Ensure nuts &
bolts are tight halves
of

Figure 13

Document: IOM049 Issue: 13 Date: 16.03.2018

23
8. Troubleshooting & Recommended Spares
8.1 Manual Cleaning Units

PROBLEM PROBABLE CAUSE SOLUTION

a) Magnet face is a) Examine the face of the magnet for

overloaded with excessive quantities of extracted tramp
extracted iron. iron. Discharge more frequently as
required.

1. Magnet
b) Magnet set too far b) Check the clearance between the magnet
will not
from the burden. face and the burden. Refer to
attract iron
SUSPENSION HEIGHT and set
accordingly.

c) Magnet set too close c). If the magnet is set too close, material
to the burden. surges can act as a wiper and remove iron
from the magnet surface. Check clearance
and adjust. Refer to SUSPENSION
HEIGHT.

8.2 Self-Cleaning Units

PROBLEM PROBABLE CAUSE SOLUTION

a) Not sufficient a) Position 2 installation: Check the clearance

clearance for the between the bottom of the magnet box and
1. Tramp iron to be the edge of the conveyor belt for maximum
iron discharged. iron size to clear. Adjust as necessary.
entering
the
b) Splitter b) Position 1 installations: Adjust the splitter
product
improperly angle and length to suit.
positioned.

8.3 Recommended Spares

Refer to Appendix D

Document: IOM049 Issue: 13 Date: 16.03.2018

24
9. Disposal of System
Dispose of the unit according to local, national and international guidelines.

9.1 Gear Units

Dispose gear units in accordance with regulations in force regarding respective materials
 Steel Scrap
 Housing Parts
 Gears
 Shafts
 Roller bearing

 Parts of the worm gears are made of non-ferrous metals. Dispose of the worm gears as
appropriate.

 Collect waste oil and dispose of it according to the regulations in force.

9.2 Motor Units

Dispose of the Motors in accordance with regulations in force regarding respective materials.

 Iron
 Aluminium
 Copper
 Plastic
 Electronic Components
 Oil and Grease (not mixed with solvents)

9.3 Magnet

Dispose of all equipment and packaging according to applicable local, regional, national and
international regulations.

Document: IOM049 Issue: 13 Date: 16.03.2018

25
Appendix A - Copy Of Declaration Of Conformity
 EC Declaration of Conformity
Declaration by the manufacturer in accordance with EC Engineering Guideline 2006/42/EC.
The equipment should not be modified without our approval, as this declaration will lose its authority.
WO Number: 107609
Serial Number: 107609 .
Customer: sinderya
Equipment: 1xCP20/100SC2/305cc/2008/A/STD/E0007143/105357
Customer Reference: 008/18

Manufacturer: Eriez Magnetics Europe Limited

Greenway, Bedwas House Industrial Estate, Bedwas, Caerphilly
CF83 8YG, United Kingdom
Managing Director: Mr John Curwen

Applicable Directives: Standards Used Reference:

2006/42/EC BS EN ISO 15607
2014/30/EU BS EN 9606 Pt 1
2014/35/EU BS EN ISO 12100
BS EN 13849-1
BS EN 60204-1

Certificate of Adequacy Reference: N/A

Approved Authority: N/A
A technical construction file for this equipment is retained at the above address.
Authorised Signatory:

for and on behalf of Eriez Magnetics Europe Limited

Name: Glenn Kiernan
Status: Engineering Manager

Date of Issue: 31 July 2018

The above equipment is manufactured in accordance with the essential Health and Safety requirements of the EC
Appendix B - Outline Drawings
 8 7 6 5 4 3 2 1
2150
467 1100

F F
ACTUAL POSITION OF E-STOP SWITCH
TO BE DETERMINED BY CONTRACT &
APPROPRIATE TO CUSTOMER INSTALLATION

E E

ISOMETRIC VIEW (1 : 15)

D 1357 OVERALL D
4 EYENUTS FITTED PLAN VIEW (1 : 10)
48 EYE, 16 SECTION 1000 OUTSIDE FRAME

925 SUSPENSION CENTRES

850 INSIDE FRAME

1017 120 TAKEUP 320 PULLEYS

150
A
428

C C

241
B

526 MAGNET
DISCHARGE
750 BELT
1046 MAGNET 50 HIGH CLEATS 800 PULLEYS
235 1590
END VIEW (1 : 10)

SIDE VIEW (1 : 10)

LOCKING NUT
FINISH - RAL 2008 OR CUSTOMER SPECIFICATION
NUT WELDED TO ADJUSTER
B B
SUSPENSION - BY CUSTOMER

PULLEY FLANGE = 12
DRIVE - HYDRAULIC - 305cc
0
14
INIT

PST

PST
AW

RD
TH

WEIGHT: 1050KG APPROX

ERIEZ MAGNETICS EUROPE LTD
24/04/2014
23/01/2015

18/02/2015

19/06/2015
07/07/2016
DATE

BEDWAS HOUSE IND. ESTATE, BEDWAS, CAERPHILLY, CF83 8YG

TEL. (+44) (0)29 20868501, FAX. (+44) (0)29 20851314
EMAIL. [email protected]
TITLE: CP20/100 SC2A Hydraulic Outline PROJECTION:
M16 ADJUSTER SCREW
Added upper pinch guards &
second lower blank cover

FOR: Eriez Standard

Finish was RAL 2008
Revised BOM layout

WEIGHT ADDED
ADDED E-STOP

DRN: Phil Toogood DATE: 25/10/2013 CHK: DATE:

DESCRIPTION

A2 SCALE: NOT TO SCALE NOTICE:

This drawing, including the principle of design, is the property of and is submitted by
ORDER #:
A 20 ERIEZ MAGNETICS with the agreement that it is not to be reproduced, copied or loaned,
in part or whole. It is not to be used in any manner that may constitute a detriment A
EQUIP #: 108A
PULLEY HUB directly or indirectly to Eriez Magnetics. Acceptance of this drawing will be constructed as
PULLEY ADJUSTER REF DRN #: an agreement to the above.
B (1 : 5)
A (1 : 4) DRAWING NUMBER: REVISION:
ENGINEERING ASSEMBLY PARTS LIST TOLERANCE: E0007143
DRG PART NUMBER DESCRIPTION STANDARD MANUFACTURING
DIMENSIONS IN MM SHEET: 1 OF 1 5
REV
1
2

4
5

Yes E0007144 CP20/100 SC2A Hydraulic Assembly UNLESS OTHERWISE NOTED

8 7 6 5 4 3 2 1
Appendix C – Electrical
N/A
Appendix D – Spares/ Consumable list and drawings
 8 7 6 5 4 3 2 1
ENGINEERING ASSEMBLY PARTS LIST
ITEM DESCRIPTION ITEM QTY PART NUMBER MATERIAL
1.1 Frame - CP20/80-100 SC2 1 E0005199
1.2 Magnet Assembly - CP20/100 SC2 (6 Hole) 1 E0005178
1.3 Drive Pulley - CP20/CP15 Hydraulic 1 E0000005
F 1.12
F
1.3 1.21 1.18 1.21 1.10 1.5 1.8 1.6 1.4 Non Drive Pulley - CP20/CP15 1 E0000004
1.7
1.5 Eriez Standard Rigid Coupling Assembly 1 E0001996
1.6 Primary 305cm /rev Hydraulic Drive 1 E0005793 Motor Default
1.7 Hydraulic Motor Mounting Assembly 1 E0000008
1.9 1.8 Motor Mount Location Plate Assembly 1 E0000011
1.9 Hydraulic Motor Mount Coupling Guard 1 E0000012 Steel-MS
1.10 Bearing Spacer Plate - MS - NP40 4 E0000003 Steel-MS
1.11 Bearing Takeup Assembly - MS - NP40/NP60 2 E0005590
1.20 1.12 UCP208 Bearing (NP40 Equivalent) 4 E0000279
1.13 UCP208 Bearing Outer Cap 3 E0000277 Steel-MS
1.14 Deflector - CP & TP20/80-100 SC2 LH 1 E0004079
1.21 1.15 Deflector - CP & TP20/80-100 SC2 RH 1 E0004080
1.16 Deflector Blank Plate - CP & TP20/80-100 SC2 2 E0004081 SS-304
1.13
E 1.17 Deflector - CP & TP20/80-100 SC2 LH Upper Pinch 1 E0001219 Steel-MS E
1.18 Deflector - CP & TP20/80-100 SC2 RH Upper Pinch 1 E0001220 Steel-MS
1.19 CP & TP20/80-100SC2 Belt (4185 mm) 1 E0001221 Rubber-EP4003
1.12 1.21 Nut Eye - M20x2.5 - 40 Ring I/D x 16 Section - Steel-BZP-8.8 (DIN582) 4 E0002120-M20-2.5 Steel-BZP-8.8
1.20 Siemens Push Button Switch (3SB3801-0EG3) (RS 742-9281) 1 E0011385 Generic
1.10

1.17
1.1
1.14

1.11
1.10

1.15
D 1.12
D

1.16

1.13

1.16
1.4
1.21

1.10

1.12
1.11

C 1.13
C
1.2

ASSEMBLED VIEW (1 : 15)

1.19

B B
INIT

PST

RD

ERIEZ MAGNETICS EUROPE LTD

18/02/2015

19/06/2015
DATE

BEDWAS HOUSE IND. ESTATE, BEDWAS, CAERPHILLY, CF83 8YG

TEL. (+44) (0)29 20868501, FAX. (+44) (0)29 20851314
EMAIL. [email protected]
TITLE: CP20/100 SC2A Hydraulic Spares List PROJECTION:
Added upper pinch guards &
second lower blank cover

FOR: Eriez Standard

ADDED E-STOP

DRN: Phil Toogood DATE: 25/10/2013 CHK: DATE:

DESCRIPTION

A2 SCALE: NOT TO SCALE NOTICE:

This drawing, including the principle of design, is the property of and is submitted by
EXPLODED VIEW (1 : 15) ORDER #:
A EQUIP #: 108A
ERIEZ MAGNETICS with the agreement that it is not to be reproduced, copied or loaned,
in part or whole. It is not to be used in any manner that may constitute a detriment
directly or indirectly to Eriez Magnetics. Acceptance of this drawing will be constructed as
A
REF DRN #: an agreement to the above.

DRAWING NUMBER: REVISION:

TOLERANCE: E0007143-SLH
STANDARD MANUFACTURING
DIMENSIONS IN MM SHEET: 1 OF 1 2
REV

UNLESS OTHERWISE NOTED

8 7 6 5 4 3 2 1
Appendix E – Drive Specification
 8 7 6 5 4 3 2 1
DRIVE SPECIFICATION FOR CP MAGNETIC SEPARATOR

F UNIT SELECTED: Primary Fluid Power F

MODEL: E0005793

CAPACITY: 305cm³/rev

SHAFT: Ø32mm

Continuously rated
E E
KEYWAY: For 10 x 8 Key

D D

C C

B ERIEZ MAGNETICS EUROPE LTD B

BEDWAS HOUSE IND. ESTATE, BEDWAS, CAERPHILLY, CF83 8YG
TEL. (+44) (0)29 20868501, FAX. (+44) (0)29 20851314
EMAIL. [email protected]
TITLE:Primary 305cm³/rev Hydraulic Drive PROJECTION:

FOR: CP/TP Standard

DRN: Phil Toogood DATE: 03/05/2013 CHK: Wayne Jones DATE:24/05/2011
A3 SCALE: NOT TO SCALE NOTICE:
This drawing, including the principle of design, is the property of and is submitted by
ORDER #: ERIEZ MAGNETICS with the agreement that it is not to be reproduced, copied or loaned,
EQUIP #: 108A in part or whole. It is not to be used in any manner that may constitute a detriment
directly or indirectly to Eriez Magnetics. Acceptance of this drawing will be constructed as
REF DRN #: CP-CL305HYD an agreement to the above.

A EST. WEIGHT #: 12.4 kg DRAWING NUMBER: REVISION:

A
TOLERANCE: E0005793
STANDARD MANUFACTURING
DIMENSIONS IN MM SHEET: 1 OF 1 0
UNLESS OTHERWISE NOTED DRAWING STATUS: Released
8 7 6 5 4 3 2 1
Appendix F – Other Relevant Information
N/A
Appendix G – ATEX Information
N/A
Appendix H – OEM Information
N/A