Installation and Maintenance Manual For Dings Stationary Electro Overhead Magnets Revised January 19, 2011
Table of Contents General Information ......................................................................................................... 1 Installation Procedures Unpacking and Handling.......................................................................................... 2 Magnet Storage ....................................................................................................... 3 Magnet Installation ......................................................................................
General Information Magnet Dings Model: Stationary Electro Magnet Dings Part Number: Dings Serial Number: Gallons of Oil in Magnet: Rectifier Dings Model: Dings Part Number: Warnings: This Dings magnet emits a powerful magnetic field when energized. The magnet must be positioned within an inaccessible or guarded area so that no contact can be made with the magnet while it is in operation. The surface of the magnet box may reach temperatures of up to 230ºF (110ºC) while operating.
Unpacking and Handling Upon receiving, check all packaged material for shortage of parts and possible damage. Report shortages and damage to the carrier who delivered shipment. The magnet was shipped fully assembled, ready for operation. Electrical connection is required to a suitable source of direct current such as a rectifier. Magnet This Dings electromagnet was shipped using a pallet or 4” x 6” wooden beams as supports under the two sides of the magnet.
Recommended Storage of Overhead Magnets 1) It is essential to keep moisture out of magnet cooling oil. 2) The following precautionary procedures are recommended: a) Store magnet indoors in a low humidity, even temperature environment if possible. b) Keep water and any other form of moisture away from the magnet while in storage. 3) This is a procedure for indoor storage only. Outdoor storage is definitely not advised and will null and void our warranty on the magnet assembly.
INSTALLATION An electro overhead magnet is built in 2 types: Inline and Crossbelt. An Inline type is installed over a conveyor head pulley so that the single turnbuckle parallel to the travel direction of material falling off the conveyor. The head pulley must be made from non-magnetic material. A Crossbelt type is installed over a conveyor so that the single turnbuckle side of the magnet at a right angle to the travel direction of the material on the conveyor.
Electrical Connections Electro Overhead Magnets operate on direct current. The DC connections to the magnet are made in the terminal box located on one side of the magnet. Polarity is not important. The DC current is supplied by a rectifier. Do not ground the DC circuit or the magnet will be damaged. Switching should be done on the input (AC) side of the rectifier. This will avoid excessive arcing and high inductive voltages which develop when a magnet coil circuit is opened.
RECTIFIER INPUT OVER-CURRENT PROTECTION All rectifiers contain a transformer. A transformer has all the same component parts as a motor, and like a motor, exhibit a current inrush when energized. This inrush current is dependent upon where in the sine wave the transformer was last turned off in relation to where in the sine wave the transformer is when you energize it.
MAINTENANCE LUBRICATION SCHEDULE FOR OVERHEAD ELECTRO MAGNET ITEM Magnet Transformer Type Cooling Oil QUANTITY BRAND & GRADE Gallons Fina Diekan 410 or equivalent INTERVAL Check for volume every 3 months. Replace oil every 2-3 years** **Note: The oil should be laboratory tested every 12 months for moisture, contaminants, and dielectric strength.
Periodic inspection and maintenance are required. Check magnet body for oil leaks. Check pressure relief valve (breather) on top of magnet. It should be free of dirt and obstructions. Oil seepage from breather is no cause for alarm. It may result from overfilling. OIL CHANGE OR REFILL CAUTION: Allow oil to cool completely before servicing. Oil level should appear at oil level plug hole when magnet is level. Oil should remain clear and free of contaminants. Sludge in oil will greatly reduce service life.
ELECTRICAL TROUBLESHOOTING Before starting, first follow this preliminary checklist: 1. Check all fuses and/or circuit breakers. For fuses, use a dual element time delay fuse with a maximum of 175% of the full load current to protect the input side of the rectifier. If 175% of full load amps does not correspond to a standard fuse size, select the next larger standard fuse size (but do not exceed 225%). For circuit breakers, use a n inverse time circuit breaker with a maximum of 250% of full load current.
STEP 2 Turn off and lock-out the power to the rectifier. Disconnect the three leads from the transformer to the diode assembly inside the rectifier cabinet. Turn on the power to the rectifier. Measure the AC voltage at the output of the transformer inside the rectifier cabinet.
STEP 5 Turn off and lock-out the power to the rectifier. Disconnect the two leads from the rectifier to the magnet at the magnet box terminals, using caution not to rotate the studs in the feed through terminals as the internal connections may be damaged. The magnet must be cold for the following tests. Using the watts and the volts from the nameplate on the magnet, square the nameplate DC volts (115 VDC or 230 VDC) and divide by the nameplate watts to get the target ohm reading.
Send readings to Dings Company for evaluation and recommendations: Phone: 414-672-7830 Fax: 414-672-9421 E Mail: magnets@dingsco.com When changing the diode assembly, it is highly recommended that the surge suppressor be changed as well.
