Nippon Magnetis CG Series Instruction Manual

Electromagnetic separator

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Electromagnetic Separator
(Water cooled/Air cooled)
INSTRUCTION MANUAL 
1 5 0 - 1
1 5 0 H - 1
2 5 0 - 1
2 5 0 H - 1
3 0 0 - 1
3 0 0 H - 1
4 0 0 - 1
4 0 0 H - 1
WARNING
Model:CG/AT-CG
1 5 0 H H- 1
1 5 0 H HH - 1
2 5 0 H H- 1
2 5 0 H HH - 1
3 0 0 H H- 1
3 0 0 H HH - 1
4 0 0 H H- 1
4 0 0 H HH - 1
・Read and understand manual prior to installation or
operation of this Unit.
・Keep this instruction manual in a safe place for refer to
them whenever necessary.
Nippon Magnetics, Inc. 
1 5 0 - m i n i
1 5 0 X - 1
2 5 0 - m i n i
2 5 0 X - 1
3 0 0 X - 1
Publication 2020.07
Original instructions

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Summary of Contents for Nippon Magnetis CG Series

  • Page 1 Electromagnetic Separator Model:CG/AT-CG (Water cooled/Air cooled) INSTRUCTION MANUAL  1 5 0 - 1 1 5 0 H - 1 1 5 0 H H- 1 1 5 0 H HH - 1 1 5 0 - m i n i 1 5 0 X - 1 2 5 0 - 1 2 5 0 H - 1 2 5 0 H H- 1...
  • Page 2: Table Of Contents

    CONTENTS NOTICE TO USER INSTRUCTION MANUAL(1) ..............3 SCOPE OF WARRANTY AND DISCLAIMER ........4 INQUIRES ................... 4 INSTRUCTION MANUAL(2) ..............4 DEFINITION OF WARNING MARKS ..........5 SAFETY INSTRUCTION 1.1 SAFETY PRECAUTION ..........1-1 1.1.1 GENERAL NOTE ............... 1-1 1.1.2 INSTALLATION・OPERATION・INSPECTION ....
  • Page 3 3.4 INSPECTION ..............3-12 3.4.1 REPLACE THE AIR BREATHER ........3-12 3.4.2 COOLING WATER (WATER COOLED TYPE) ....3-13 3.4.3 INSULATING OIL ............. 3-13 3.5 SUPPLY AND DISCONNECT THE POWER ....3-14 3.5.1 SUPPLY THE POWER ............. 3-14 3.5.2 DISCONNECT THE POWER ........... 3-15 3.6 COMMISSIONING ............
  • Page 4 7.2.1 INSTALLATION SPACE AND WORK ......... 7-3 7.2.2 WIRING WORK ..............7-5 7.3 DISPOSAL ..............7-9...
  • Page 5: Notice To User

    NOTICE TO USER Thank you for purchasing a CG/AT-CG electromagnetic separator. This unit generate a high magnetic flux density and is free from magnetics leakage. In addition this unit is capable of efficiently removing iron powder from materials by passing through a magnetized screen while dispersing fine powder with poor fluidity by arranging a multi-layered screen with its tip at an acute angle into a cylindrical interior and giving them fine vibrations.
  • Page 6: Scope Of Warranty And Disclaimer

     SCOPE OF WARRANTY AND DISCLAIMER  The warranty period shall be one year from the date of delivery. The warranty solely covers free repair or replacement of those parts which, after having been carefully by the Manufacture's technical department, are recognized as being defective. However, the secondary warranty in such case is disclaimed.
  • Page 7: Definition Of Warning Marks

     Definition of warning mark In this manual, the following symbols are used to indicate items that must be observed in order to prevent danger to the user or damage to property and to use this device safely. Be sure to understand the contents thoroughly and follow the instructions.
  • Page 8 M EM O :...
  • Page 9: Safety Instruction

    -  1.  Safety instruction  -  1. SAFETY INSTRUCTION 1.1 SAFETY PRECAUTION 1.1.1 GENERAL NOTE DANGER ・ To use this device safely, be sure to read this manual and fully understand the contents before using this device. ・ Before operating the machine, familiarize yourself if with the position of the emergency stop button and how to operate it in case of danger.
  • Page 10 -  1.  Safety instruction    WARNING ・ Do not use the product in an explosive atmosphere. Failure to do so may cause a fire. ・ When removing or installing the Unit (CG), be sure to install the main breaker on the control panel to prevent danger and turn off the power supply on main breaker for prevent a danger.
  • Page 11 -  1.  Safety instruction  -  Precaution for Operation and Maintenance DANGER Effect of magnetic force ・ Keep away from the unit during operation. Keep magnetic cards, medical devices (pacemakers, etc), electronic devices, precision devices, etc away from each other. Failure to do so may result in loss of data or malfunction. Effect of Dust ・...
  • Page 12 -  1.  Safety instruction    CAUTION Insulating oil ( Handling and Storage Precaution ) ・ Do not drink. ・ Keep out of reach for children. ・ Wear protective goggles if there is a risk of touching your skin or entering your eyes. ・...
  • Page 13: Safety Device

    -  1.  Safety instruction  -  1.2 SAFETY DEVICE Several protective devices are installing to the device to ensure the safety of the operator. However, these protective devices are not perfect. Do not overestimate the safety devices or covers. Pay close attention to the operation. WARNING ・...
  • Page 14: Warning Label And Name Plate

    -  1.  Safety instruction    1.3 WARNING LABEL AND NAME PLATE The following warning label and name plate are attached to the Unit (CG) and equipment. Be sure to understand the contents of the warning label and nameplate before starting operation. When warning label become unreadable due to contamination or damage.
  • Page 15: Name Plate

    -  1.  Safety instruction  -  Location of Warning label 1.3.2 NAME PLATE The following nameplates are attached to the equipment and control panel. When making an inquiry, confirm the Model and Serial number on the name plate. ① ② ② ① 1-7 ...
  • Page 16 -  1.  Safety instruction    M EM O :...
  • Page 17: Overview

    - 2. Overview - 2. OVERVIEW This Magnetic separator has a structure that efficiently concentrates the magnetic flux generated inside the equipment to create a high magnetic flux density and is free from magnetic leakage. In addition, this electromagnetic separator is capable of efficiently removing fine iron powder from powdery raw materials by passing through a magnetized screen while dispersing fine powder with poor fluidity by arranging a multi-layered screen with its tip at an acute angle into a cylindrical interior and giving them fine vibrations.
  • Page 18: Parts

    -  2.  Overview  -  2.2 PARTS The figure below shows a general shape. The shape may differ slightly from the delivered machine depending on the specifications. Refer to the delivery drawing for details. AT-CG ① Screen ⑮ MagHammer ( option ) ⑨...
  • Page 19: Function

    - 2. Overview - 2.3 FUNCTION Name of parts Function 1set ① Screen Magnetizes the screen to attract magnetic material. When delivered, it is set in the screen case. Insulation oil temperature sensor. ② Thermometer Electromagnetic coils and insulation oil are ③...
  • Page 20: Specification

    -  2.  Overview  -  2.4 SPECIFICATION 2.4.1 SPECIFICATION (MAIN UNIT) Main unit (CG) Coil case : SS400 Screen case : SUS304 Screen : SUS430 + SUS304 Joining method : Adjust with a flexible material. Other : Refer to the delivery drawing for details. Outline of structure 1.
  • Page 21 - 2. Overview - Performance Please be aware that the processing amount and iron removal efficiency differ slightly depending on the ratio, size, moisture, and other factors of iron powder contamination. CG-H CG-HH CG-HHH CG-X Type 150HH 250HH 300HH 150HH 250HH 300HH 150-1 250-1 300-1 150H-1 250H-1 300H-1...
  • Page 22 -  2.  Overview  -  External Dimensions of Main Unit Refer to the delivery drawing for details.
  • Page 23: Specification(Equipment)

    - 2. Overview - 2.4.2 SPECIFICATION(EQUIPMENT) Oil pump This pump circulates the insulating oil inside the coil case externally, cools it with an oil cooler, and returns it back into the coil case again. Inside the TERMINALBOX Pay attention to oil leakage at the drain port. Drain port 2-7 ...
  • Page 24 -  2.  Overview  -  Vibrator Vibrates the screen case to prevent powder accumulation. Operation ・ Remove both weight covers of the vibrator and check the direction of rotation. (Adjusted at factory) ・  The two vibrators must rotate in opposite directions. If Vibrator does not rotate in the reverse direction, immediately stop the operation and replace the electricity terminal (1 side) When removing the weight cover, installation work, and adjusting the vibration...
  • Page 25 - 2. Overview - Oil cooler Water cooled type oil cooler Inside the cooler has a tube in which water flows to cool the insulation oil. Number Name Number Name Unit Baffle plate ① ⑥ Channel cover Packing ② ⑦ Channel cover Packing ⑧...
  • Page 26 -  2.  Overview  -  Air cooled type oil cooler Oil flows inside the radiator and cools the oil by blowing air to the outside of the radiator. ⑥  ①  ⑤  ⑤  ①  ③  ②  Number Name Number Name Frame Air vent plug ①...
  • Page 27 - 2. Overview - Damper chute The flow of raw materials can be temporally stopped, and the automatic discharging device and timer can be combined to perform repeated operation any time. Automatic type : By energizing the solenoid valve at the rear of the cylinder, the cylinder moves back and forth.
  • Page 28 -  2.  Overview  -  MagHammer MagHammer is a device to prevent the accumulation of powder on the screen. MagHammer is not a continuous rating, it is set to repeat hammering and pausing automatically. When MagHammer is operated, it stops for several seconds. This is not a malfunction. 2-12...
  • Page 29: Accessories

    - 2. Overview - 2.4.3 ACCESSORIES Name Remarks Air breather Eyenut Screen stand Option T shape handle Option Instruction manual 2-13   ...
  • Page 30 -  2.  Overview  -  M EM O : 2-14...
  • Page 31: Operation

    -  3.  Operation  -  3. Operation    3.1 PRECAUTION FOR OPERATION DANGER ⚠ Effect of magnetic force ・ Keep away from the equipment during operation. Keep magnetics cards, medical devices (pacemakers, etc.) Electronic devices, precision machinery, etc away from magnetic separator. Failure to do so may result in loss of data or malfunction.
  • Page 32 -  3.  Operation  -   The temperature of the coil rises at the operation time elapses, but after a certain period of time, the calorific value and radiated heat value become equal, and the coil temperature becomes in an equilibrium state. ...
  • Page 33: Function (Control Panel)

    -  3.  Operation  -  3.2 FUNCTION (CONTROL PANEL) This unit is operated on the control panel. The shape may differ from that of the delivered. Refer to the delivery drawing for details. 3.2.1 FUNCTION Electromagnetic Separator Control panel ① ⑦ ⑧ ⑨ ⑩ ②...
  • Page 34 -  3.  Operation  -  ① POWER SOURCE Lights up when the power is supplied. ② AUTO RUN Lights up during automatic operation. ③ OIL PUMP FAULT Lights up when the oil pump fails or error occurs. ④ MAGNETIZE FAULT (Excitation fault) Lights up when excitation fails or error occurs.
  • Page 35 -  3.  Operation  -  ⑯ Transformer (Option) Change the magnetic force. Setting values: 100%、75%、50%、25% Note: Only special specification control panel possible to switch the magnetic force. Magnetic force can be selected with the magnetic force switch on the control panel. However, the magnetic force cannot be switched during the excitation operation.
  • Page 36 -  3.  Operation  -  ㉜ MAG HAMMER OFF Stop the operation of the maghammer. ㉝ LAMP TEST Check the all lamp. ㉞ RESET ㉟ BUZZER STOP The buzzer stops. ㊱ BUZZER The buzzer sounds. ㊲ EMERGENCY STOP The power supply is cut off and the unit stops operating. ...
  • Page 37 -  3.  Operation  -  3.3 SETTING(SCREEN) Prepare for operation. 3.3.1 SETTING(SCREEN)  Flange fixing type Adapter pipe A The screen set angle is 90°at the time of shipment. Screen 1. Overlay the screen on the screen shaft as shown on the left.
  • Page 38 -  3.  Operation  -  4. Attach the eye nut to the top of the screen shaft. Eyenut 5. Slowly insert the screen into the screen case while hanging with the Eyenut. Screen case Diagram inside the screen case Insert it into the groove of the lower part. 6.
  • Page 39 -  3.  Operation  -  8. Install the screen case lid. When attaching the screen case lid, make sure that the O-ring is attached. Screen case lid. O-ring 9. Tighten the hinge bolt with wing nut to secure the screen case lid. Before starting operation, start the vibrator Wing nut and check that no abnormal noise is...
  • Page 40: Timer (Oil Pump)

    -  3.  Operation  -  3.3.2 TIMER (OIL PUMP) Set the timer for stopping the oil pump in order to cool the coil for a certain period of time after automatic operation stops. (Recommend time:30 minutes or more) About the timer Timers are installed in the control panel.
  • Page 41: Feeding Time(Atcg

    -  3.  Operation  -  3.3.3 FEEDING TIME(AT-CG) 1. Determine the amount of raw material to flow in one batch. ・Manual operation:Time until excitation is turned ON and OFF. ・Automatic operation: The set time of the timer of excitation to turn ON and OFF. Place a box to receive the sample at the product side and iron powder side of the electric magnetic separator.
  • Page 42: Inspection

    -  3.  Operation  -  3.4 Inspection    Before starting operation, perform the following inspections. ① ④ ② ③ Parts of Inspection Inspection item Air breather (2 locations) Replace the blind plug with air breather. ①  Cooling water pipe Check that the temperature is 25 or less 25L/min or ② ...
  • Page 43: Cooling Water (Water Cooled Type)

    -  3.  Operation  -  3.4.2 COOLING WATER(WATER COOLED TYPE) Confirm that the cooling water in the oil cooler is over 25 ℓ /min and that the temperature is 25°or less. ⚠CAUTION Condensation ・ Condensation may occur due to temperature difference form outside air. ・...
  • Page 44: Supply And Disconnect The Power

    -  3.  Operation  -  3.5 SUPPLY AND DISCONNECT THE POWER 3.5.1 SUPPLY THE POWER Note: operation may star in step 3 For details, see「3.7 Manual operation」and 「3.8 Automatic operation」 1. Open the control panel with use the handle. Select switch MAN-OFF-AUT Handle of the control panel door Breaker...
  • Page 45: Disconnect The Power

    -  3.  Operation  -  3.5.2 DISCONNECT THE POWER  Manual operation For details, see 「3.7 Manual operation」 and 「3.8 Automatic operation」 1. Press the stop button. All device will stop. Select switch MAN-OFF-AUT Operation button Stop button  Automatic operation Note: If there is no Automatic operation and stop switch on the control panel, all devices will not stop until the operation signal is turned...
  • Page 46: Commissioning

    -  3.  Operation  -  3.6 COMMISSIONING  Be sure to use this check before start to commissioning.  Check list. Description Criteria Result Replace the blind plug to air breather. Check the location of ※Above coil case and oil level gauge Air breather.
  • Page 47 -  3.  Operation  -  1. Turn the select switch to manual. MAN-OFF-AUT Select switch 2.  Press the manual operation button of each function. Machine will start the isolated operation. Excitation works only when the oil pump is in operation. Start operation of Excitation after starting operation of Oil pump.
  • Page 48: Automatic Operation

    -  3.  Operation  -  3.8 AUTOMATIC OPERATION 3.8.1 AUTOMATIC OPERATION/STOP (INSTALLED) 1. Turn the select switch to Automatic. MAN-OFF-AUT 2. Press the automatic operation button. Machine will start the Automatic operation. 3. Press the automatic stop switch. All operation going to stop except the oil pump. The oil pump will stop after all function are stop the working due to timer setting.
  • Page 49: Emergency Operation

    -  3.  Operation  -  3.9 EMERGENCY OPERATION 3.9.1 EMERGENCY STOP 1.Press the Emergency stop button. 2.The unit will stop the operation. 【In case of the unit does not have Emergency Stop】 1.Trun off the select switch to OFF 2.The unit will stop the operation. MAN-OFF-AUT Emergency Stop Button 3.9.2 RESTART...
  • Page 50 -  3.  Operation  -  M EM O : 3-20...
  • Page 51: Insulating Oil

    -  4.  Refill and Replacement of the Insulating oil  -  4. INSULATING OIL  4.1 REFILL AND REPLACEMENT OF INSULATING OIL In this unit, the insulating oil is cooled by water cooling or air cooling to circulate the inside of the coil case in order to keep the temperature inside the case, which becomes hot.at a constant temperature. Check the degree of deterioration of the insulating oil, if necessary, replace the insulating oil.
  • Page 52 -  4.  Refill and Replacement of the Insulating oil  -  Refill the Insulating oil Oil filling port 1. Check the amount of insulating oil with the oil gauge If insulating oil is less than reference level. Please refill the insulating oil. Reference level 2. Open the Oil filling port and refill the insulating oil within the reference level.
  • Page 53 -  4.  Refill and Replacement of the Insulating oil  -  Replacement of insulating oil Do not idling operation the oil pump for more than 30 seconds. It may cause the damage for the unit and equipment Estimated oil amount for each model CG-H CG-HH CG-HHH CG-MINI CG-X 1 50 -1 1 50 H -1...
  • Page 54 -  4.  Refill and Replacement of the Insulating oil  -  M EM O :...
  • Page 55: Periodic Inspection

    -  5.  Periodical Inspection  -  5. PERIODIC INSPECTION Be sure to perform periodic inspections to prevent problems with this device and maintain a condition of Unit WARNING ・ To use this device safely, be sure to read this manual and fully understand the contents before using this device. ・...
  • Page 56: Daily Inspection

    -  5.  Periodical Inspection  -  DAILY INSPECTION Perform daily inspection according to the periodic inspection list. Name Inspection item Timing of inspection Unit/ Coil Excitation voltage is within the reference Operation ① value. Unit / Coil Excitation current is within the reference Operation ②...
  • Page 57: Excitation Voltage And Current

    -  5.  Periodical Inspection  -  5.1.1 EXCITATION VOLTAGE AND CURRENT When operating the unit. Check the Voltmeter and Ammeter on the control panel to make sure that the value is within the reference level. Criteria for excitation voltage and excitation current. Criteria Rated value at time of cooling Excitation...
  • Page 58: Weekly Inspection

    -  5.  Periodical Inspection  -  5.2 WEEKLY INSPECTION Perform a weekly inspection according to the periodic inspection list. Name Inspection item Timing of inspection Vibrator Retighten the screws about once a week after Stop ① operation. If there is no looseness, retighten the screws at Maintenance.
  • Page 59: Inspection (Every 3 Months)

    -  5.  Periodical Inspection  -  5.4 INSPECTION (EVERY 3 MONTHS) Perform the inspection every three months according to the periodic inspection list. Name Inspection item Timing of inspection Screen Shaft No ratting in the screen case when putting the Stop ① screen into the screen case.
  • Page 60: Inspection (Every 6 Months)

    -  5.  Periodical Inspection  -  5.5 INSPECTION (EVERY 6 MONTHS) Perform the inspection every 6 months according to the periodic inspection list. Name Inspection item Timing of inspection The coolant volume is 25L/min or more at a Operation ① measurable point. Water cooling The inlet side cooling water temperature is Operation...
  • Page 61: Annual Inspection

    -  5.  Periodical Inspection  -  5.6 ANNUAL INSPECTION Perform an annual inspection according to the periodic inspection list. Name Inspection item Timing of inspection Screen case No significant damage. Stop ① Air breather No clogging due to harmful adhesion. Stop ② Insulating oil Degree of deterioration shall be "5.0"...
  • Page 62 -  5.  Periodical Inspection  -  ③ Inspection (Insulating oil) 1. Confirm that the deteriorates of the insulation oil is 5.0 or less with flapper sight glass. For further detail please refer to 3.4.3 Insulating Flapper sight glass ④⑤ Inspection (Insulation resistance) 1.
  • Page 63 -  5.  Periodical Inspection  -  ⑥⑦ Inspection (Vibrator) 1. Visually check the scale plate and the balance weight scale Check that the value is within 4 or 71 Fixed unbalance weight Indicator (Fixed) Adjustment unbalance weight Indicator (Adjustment) Vibrator 2. Check that the values of the weights of each vibrator are the same.
  • Page 64 -  5.  Periodical Inspection  -  ⑨⑩⑪⑫ Inspection (Control panel) 1. Visually check the inside of the control panel for contamination. (Inspection timing: Stop) If there is any contamination, clean it with an air blow. Visually check that the wiring is not damage. If there is any damage, replace the wiring.
  • Page 65: Maintenance

    -  5.  Periodical Inspection  -  5.7 Maintenance In addition to periodic inspections, daily cleaning and maintenance work is also required. Cleaning the screen If the raw material contains moisture or adhesiveness, the raw material will adhere to the screen and the iron powder adsorption effect will be reduced.
  • Page 66 -  5.  Periodical Inspection  -  M EM O : 5-12...
  • Page 67: Troubleshooting

    - 6. Trouble shooting - 6. TROUBLESHOOTING When a problem occurs, take appropriate measures refereeing to the failure reference table. Contact the representative if repair or replacement parts are required. In this case, please supply the following information. 1.Model/Specification (refer to the Name plate on the Unit) 2.Trouble point and condition 3.Part name and required quantity.
  • Page 68 -  6.  Trouble shooting  -  6.1 Magnetic separator performance deteriorates. If you feel that the iron removal efficiency is poor compared to the previous operation, investigate the device for abnormalities according to the following list. If there is no abnormality with this equipment as a result of the investigation, check whether there is any problem with the material or previous process.
  • Page 69: Receipt Of Goods・Installation・Disposal

    -  7.  Receiving・Installation・Disposal  -  7. RECEIPT OF GOODS・INSTALLATION・DISPOSAL  This sections the items to be checked when receiving the equipment, how to install it in the specified position, and how to dispose of it. CAUTION ・ The forklift must be operated by qualified personal. ・...
  • Page 70: Installation

    -  7.    Receiving・Installation・Dispose  -  7.2 Installation CAUTION ・ Use nylon slings to lift and unload the product. ・ Use the four eyebolt M30 to lift the unit. ・ Do not enter under the unit and equipment, In the unlikely event that a load fails, it may lead to a serious accident.
  • Page 71 -  7.  Receiving・Installation・Disposal  -  7.2.1 Installation space and installation work. ・ Keep the installation surface as flat as possible and fix it with a stationary or bolt. ・ Structure the frame so that it can sufficiency withstand the load of the main unit of the system. ・...
  • Page 72 -  7.    Receiving・Installation・Dispose  -  ① Plug 2. Remove the three plugs and replace the Air breather ②  Plug and Oil cap Removal sequence: ①→② 3. Wrap sealing tape around the air breather. Wrap a sealing tape Air breather 4. Attach the Air breather. Oil cap 5.
  • Page 73 -  7.  Receiving・Installation・Disposal  -  7.2.2 WIRING WORK DANGER Control panel Be aware of that the input-side circuitry of the main breaker MCCB1 is always energized without being ・ cut off by MCCB1, and there is a risk of electric shock. Do not open the cover of each terminal box while the power is on.
  • Page 74 -  7.    Receiving・Installation・Dispose  -  Perform each wiring under the following conditions. Power wire to Control panel Power supply Wire gauge Main breaker Earth Model Voltage Power supply current capacity (Ground) CG-150-1 CG-250-1 CG-300-1 CG-400-1 CV 3.5Sq IV 3.5Sq CG-150H-1 CG-250H-1 CG-300H-1 CG-400H-1...
  • Page 75 -  7.  Receiving・Installation・Disposal  -  Cable between the Unit (CG)and Control panel Maghammer Oil pump / Model Excitation IN / OUT Signal ( Option ) Vibrator CG-150-1 CG-250-1 CG-300-1 CG-400-1 CV 3.5Sq CG-150H-1 CG-250H-1 CG-300H-1 CG-400H-1 CG-150HH-1 CG-250HH-1 CG-300HH-1 CV 2Sq CV2Sq CVV1.25Sq CG-400HH-1...
  • Page 76 -  7.    Receiving・Installation・Dispose  -  Using this product as a CE Electromagnetic Compatibility Directive compliant product. Power cable to control panel Power supply Wire size Model Main breaker Earth Voltage Power supply current capacity (Ground) CE-CG-150-1 CE-362 CE-KMTW CE-CG-250-1 AWG12 AWG12 CE-CG-300-1 (Permissible...
  • Page 77 -  7.  Receiving・Installation・Disposal  -  7.3 DISPOSAL CAUTION Disposal ・ Dispose of the main body of the Unit (CG) and the control panel as industrial waste. ・ Dispose of the insulation oil by yourself or entrust it to an industrial waste disposal company that has been authorized by a public agency.
  • Page 78 -  7.    Receiving・Installation・Dispose  -  M EM O : 7-10...

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