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Over-belt magnetic separator UME … C

Maintenance

GB_UME 75-135 ... C-03-US

10.4.4 Adjustment instructions for central running of the discharge belts

Extract from the work instruction AA KO 13-01 of 9/25/2006

Fig. 23: UME with 2 support rollers

Behavior of the attachment upon adjustment of a bearing

side

1) Support roller (3) in direction "A"

Discharge belt in direction "C"

2) Support roller (3) in direction "B"

Discharge belt in direction "D"

3) Belt drum (2) in direction "A"

Discharge belt in direction "C"

4) Belt drum (2) in direction "B"

Discharge belt in direction "D"

Item 1 – drive belt

Item 2 – belt drum/ tensioning drum

Item 3 – support roller

Summary of Contents for UME 115 130 C

Page 1: ...ail sales steinert de www steinert de INSTRUCTIONS OF INCORPORATION EN Machine Type Serial no Job no Customer Over belt magnetic separator UME 115 150 C 18 0077 060 01 18 0077 090 01 18 0077 100 01 A1180077 WTT B V Münsterstraat 14 NL 7575 ED Oldenzaal KKS no 1020AT203 Order no WTT 20180031 Order date 2018 01 24 Project name 14246 Jieyang Project Final customer Year of manufacture 2018 TRANSLATION...

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Page 3: ...C o Over belt magnetic separator UME C Implementation example Read the instructions and the supplier s documentation in the Appendix before starting any work ...

Page 4: ...ent prevention regulations and general safety regulations The illustrations in these operating instructions are for the purpose of information and basic understanding They may differ from the actual model of the machine Deriving requirements from the illustrations in the present operating instructions is not possible Translation of the original Operating Instructions Printed in Germany Copyright S...

Page 5: ... field strength limits for the protection of persons 15 3 2 CE label 15 3 3 Responsibility of the owner 16 3 4 Staff requirements 17 3 4 1 Qualification 17 3 4 2 Unauthorized persons 17 3 5 Personal protective equipment PPE 18 3 6 Safety devices 19 3 6 1 Guards 19 3 7 Behavior in case of danger or accident 19 3 8 Environmental protection 21 3 8 1 Lubricants 21 3 9 Labeling 22 4 Intended use 23 4 1...

Page 6: ...ial 35 8 2 Installation 36 8 3 Commissioning 37 8 4 Connection to the power supply 37 8 4 1 Power supply 38 8 5 Inspections 39 9 Faults 40 9 1 Behaviour in case of malfunctions 41 9 1 1 Troubleshooting work 41 9 2 List of mechanical faults 42 10 Maintenance 43 10 1 Safety 43 10 2 Cleaning 44 10 3 Maintenance schedule 45 10 4 Checking replacing the discharge belt 47 10 4 1 Replacing the discharge b...

Page 7: ...bly 57 11 1 Disassembly 58 11 2 Disposal 58 12 Appendix 59 12 1 Dimension sheet 59 12 2 Belt change device 61 12 3 3 phase motor 63 12 4 Gearbox 65 12 5 STUME operating instructions 67 12 6 Wiring diagram 69 12 7 Spare parts list 71 12 8 Declaration of incorporation 73 13 Index 75 ...

Page 8: ...Over belt magnetic separator UME C Overview 8 GB_UME 75 135 C 03 US ...

Page 9: ... of operation of the machine Observe the instructions for the integrated components see Appendix 1 2 Restricted liability All information and notes in the present instructions are based on valid standards and regulations current state of technology and our long standing experience and expertise The manufacturer will not assume liability in case of non adherence to instructions Misuse employment of...

Page 10: ...of are prohibited unless a written approval of the originator has been obtained Noncompliance will cause indemnities We reserve the right to claim additional indemnities 1 4 Spare parts NOTE Wrong spare parts Material damage Use only genuine spare parts from the manufacturer H_FE_01_EN US 00 The spare parts list is located in the appendix 1 5 Warranty conditions The warranty conditions are availab...

Page 11: ...tuation that if not avoided will cause death or severe injuries WARNING Indicates a potentially dangerous situation that if not avoided will cause death or severe injuries CAUTION Indicates a potentially dangerous situation that if not avoided will cause less severe or light injuries 2 2 Notes damage to property and the environment NOTE Indicates a potentially dangerous situation that if not avoid...

Page 12: ...or UME C Symbols 12 GB_UME 75 135 C 03 US 2 4 Other symbols Work instructions Structure of the work instructions Instructions for work Indicates result if applicable Lists Structure of unnumbered lists List level 1 List level 2 ...

Page 13: ...work on the electrical system must be carried out by trained electricians Only operate the system if no unauthorized changes have been made and it is in perfect technical condition When insulation damage is found interrupt the power supply and have insulation repaired immediately Never bypass or disable fuses Always replace blown fuses with fuses of the same rating G_ES_02_EN US 00 DANGER Static m...

Page 14: ...rom heights Risk of severe injuries or even death If large height differences 1 5 m are to be overcome safety belts and fall protection devices must be used Make sure that at least one other expert is in close proximity in order to ensure safety in emergencies G_AH_02_EN US 00 WARNING Noise Hearing loss Wear hearing protection Do not enter the noise area unless it is strictly necessary Use suitabl...

Page 15: ...red values at approx 1 m distance from a magnet with the highest field strength and a power of 70 kW were less than 100 mT Sources DIN EN 45502 2 1 2004 08 VDE 0750 10 1 2004 08 Active implantable medical devices BG Regeln nationwide cooperative rules version 08 2004 3 2 CE label The over belt magnetic separator is a partial machine and does not fulfill the conditions of the machinery directive in...

Page 16: ...he machine and implement them in the form of machine standard operating procedures SOPs Check during the entire operating time of the machine whether the work instructions meet the current versions of the regulations and amend the work instructions if applicable Clearly define and assign the responsibilities for installation operation maintenance and cleaning Make sure all persons working on the m...

Page 17: ...per behavior Specialist staff are capable of performing the tasks assigned to them and of recognizing and avoiding potential hazards due to their training knowledge experience and knowledge of commonly applicable regulations Authorized electricians are capable of performing work on electrical systems recognizing and avoiding potential hazards due to their training knowledge experience and familiar...

Page 18: ...chine Heed the instructions regarding PPE on display in the work area Do not wear rings chains or other jewelery Use protective clothing Use safety shoes Use eye protection Use hearing protection Use a helmet Use breathing protection For particular work When performing special work use the following personal protective equipment Use safety belt Safety harnesses may only be used by specially traine...

Page 19: ...iance with the applicable safety instructions see also DIN EN ISO 13857 Safety distances to prevent hazard zones being reached by upper and lower limbs The machine owner is obliged to integrate the machine into the emergency stop design of the complete plant and to retrofit additional safety devices if necessary Commissioning is not permitted until the plant in which this machine is to be fitted a...

Page 20: ...CY STOP immediately by pressing the nearest EMERGENCY STOP button Evacuate any persons from the danger area Initiate first aid measures Switch off the master switch and secure it against switching on Alarm a doctor and the fire brigade if necessary Inform the person responsible on site Keep access paths for emergency vehicles clear After rescue Inform responsible authorities if demanded by the sev...

Page 21: ...mful to the environment are released Remove contamination Inform the responsible local authority H_SSF_01_EN US 00 NOTE Electric scrap electronic components lead components Environmental damage Have disposal carried out by authorized specialist companies H_EEB_01_EN US 00 3 8 1 Lubricants Make sure lubricants and greases do not reach the environment Have lubricants and greases disposed of by a was...

Page 22: ...tion signs in the work area They refer to the immediate vicinity of the place where they are affixed WARNING Illegible safety signs Risk of injury Replace unreadable safety signs immediately W_US_01_EN US 00 Observe operating instructions Warning of magnetic field Forbidden for persons with pacemakers Center of gravity ...

Page 23: ...n off a safety area around the machine plant so that endangerment during automatic operation is not possible 4 1 Place of use Over belt magnetic separators are mostly suspended at a defined working distance above a conventional conveyor belt system or are installed above conveyor troughs or chutes Observe the operating conditions refer to the technical data NOTE Frost Material damage Cover Do not ...

Page 24: ... kW 3 0 Frequency 50 Hz Supply voltage triangle star V DS 220 230 380 400 Rated current triangle star 11 5 6 6 Output speed Gearbox rpm 132 60 Hz Supply voltage triangle star V DS 254 277 440 480 Rated current triangle star 9 2 5 3 Output speed Gearbox rpm 160 Protection classes Magnet IP54 Terminal boxes IP54 Motor IP55 Weight approx kg 1550 1750 2050 2450 3350 3850 Dimensions See dimension sheet...

Page 25: ...hout interruption 24 hours 5 3 Emissions Specification Value Unit Noise emission when idling 75 dB A Noise emission when operating 75 dB A Depending on the goods conveyed a higher noise level may be reached Implement suitable hearing protection measures 5 4 Type plate Fig 1 Type plate The type plate is located on the base chassis and contains the following data Manufacturer with address Type Year ...

Page 26: ...fications Mobil SHC 634 Shell Omala S4 GX 460 Roller bearings of drive motor Closed bearing type 2Z or 2RS cannot be relubricated Mineral based roller bearing grease Esso Polyrex EM for ambient temperatures of 20 C to 80 C Refer to the supplier s documentation in the Appendix for specifications Synthetic roller bearing grease Klüber Barrierta L55 2 for ambient temperatures of 20 C to 100 C Kyodo Y...

Page 27: ...at a defined working distance above a conventional conveyor belt system or are installed above conveyor troughs or chutes To enable an inclined position of the over belt magnetic separator matched to the inclination of the conveyor belts troughs or chutes the machine is flexibly mounted on the suspension points Iron contained in the conveyed material is pulled up by the magnet and thus withdrawn f...

Page 28: ...ed Attach sling gear to the attachment points provided Make sure the sling gear is securely seated G_SL_01_EN US 00 WARNING Center of gravity is off center Risk of injury Pay attention to the markings on the packing units Attach the crane hook so that it is over the marked center of gravity Take care when lifting Watch for load tilting Use a different suspension point if necessary W_AS_01_EN US 00...

Page 29: ...eparator UME C Transport packaging and storage 29 GB_UME 75 135 C 03 US 7 2 Symbols on the packaging Marks the top Keep dry Attachment point packing unit Center of gravity Weight of slung load Industrial trucks prohibited ...

Page 30: ...n as it is detected Damage claims are only valid within the valid claim period I_R_01_EN US 00 7 4 Packaging Re packaging The packing pieces have been packed in accordance with the transport conditions to be expected Only environmentally friendly materials are used for packaging The packaging is to protect the machine against transport damage corrosion and other damage until they are assembled The...

Page 31: ...s Use installed transportation aid Only use suitable lifting accessories Only use suitable hoisting gear W_HL_01_EN US 00 Lifting eyes on the machine Fig 3 Lifting eyes on the machine Dimensions T g h mm mm mm UME 75 115 C 115 22 50 UME 135 C 180 26 100 WARNING Center of gravity is off center Risk of injury Pay attention to the markings on the packing units Attach the crane hook so that it is over...

Page 32: ... Crane and hoist gear must match the weight of the machine The operator must be authorized to operate the crane Slinging 1 Sling ropes belts or multi leg slings according to Fig 7 2 Ensure that the machine is hanging straight allowing for an off center center of gravity if necessary Crane transport of pallets Fig 6 Machines fastened to pallets can be directly transported with a crane under the fol...

Page 33: ...h until they extend on the opposite side 3 Ensure that the pallet cannot topple over if the center or gravity is not central 4 Lift the machine 7 6 Storage Observe the storage conditions below if the machine is not installed immediately after arrival Observe additional notes on the machine if present Protect packing pieces against moisture Protect machine against aggressive media Avoid mechanical ...

Page 34: ... being reactivated All work on the electrical system must be carried out by trained electricians G_ES_01_EN US 00 WARNING Improper installation and commissioning Risk of injury Before starting any work Make sure there is enough clear space During work Wear personal protective equipment Do not place tools on the conveyor belt Protect parts from falling down or tipping Install parts according to the...

Page 35: ...uired when installing outside The machine is not designed for use in areas exposed to explosion hazards 8 1 1 Use of nonmagnetic material The following parts of the plant must be manufactured from nonmagnetic material insofar that they are in the area of the magnetic field Support roller stations in conveyor belts below the magnet Drive drum if the magnet is installed above the discharge end of co...

Page 36: ...t of the upper suspension points taking into consideration the load to be suspended the angle the lifting gear and the overhang length For belt speeds greater than or equal to 1 6 m s an impact wall or protective wall for limiting the discharge width must be fitted The direction of running of the discharge belt of the over belt magnetic separator must match the direction of the arrow applied to th...

Page 37: ...plied to the magnet viewed from below the machine Check the discharge belt for straight running The discharge belt may run at askew as a result of transport and installation especially installation at an inclined angle This is normal is not a quality defect Visually check the gearbox for leaks Make sure protection and safety devices are present correctly installed and functioning Ensure that an im...

Page 38: ...terminals as follows The center pole of the magnet must be directed to North in variants with discharge pole Minus pole to terminal 2 Plus pole to terminal 1 Minus pole to terminal 2 Plus pole to terminal 1 Plus pole to terminal 1 Minus pole to terminal 2 Plus pole to terminal1 Minus pole to terminal 2 The three phase gear motor driving the conveyor belt has to be connected via a standard motor pr...

Page 39: ...3 US 8 5 Inspections After setting up or connection of the machine within the complete plant Test the entire plant in line with applicable local regulations In subsequent running Check the entire plant for technical defects in line with applicable local regulations at specified intervals ...

Page 40: ... of severe injuries or even death Always wear anti fall protection when working at heights of greater than 1 5 m Do not enter any areas without protection G_AH_03_EN US 00 CAUTION Hot surface Burns Avoid contact Wear suitable personal protective equipment Allow hot surfaces to cool to ambient temperature V_HO_01_EN US 00 NOTE Improper fault rectification Material damage Use suitable tools Use only...

Page 41: ... the malfunction Depending on the malfunction have authorized specialists eliminate it or eliminate it yourself Personnel Unless otherwise indicated the work to remedy malfunctions which is described here can be performed by the operator Some work may only be performed by specially trained personnel or only by the manufacturer This is indicated in the description of the individual fault Work on th...

Page 42: ... Motor defective Check motor Authorized electrician Belt running askew Uneven belt tension Reduce the tension of the belt and re tension it evenly on both sides Operator Belt damaged worn on one side Stop plant perform belt change Specialist Bearing noise Insufficient lubrication Replace bearings and lubricate adequately Specialist Defective bearings Belt tension too high Reduce belt tension repla...

Page 43: ... injuries or even death Always wear anti fall protection when working at heights of greater than 1 5 m Do not enter any areas without protection G_AH_03_EN US 00 WARNING Improper maintenance work Risk of injury Before starting any work Switch off and secure against switching back on Make sure there is enough clear space After completion of all work Re install all removed parts Attach all covers W_...

Page 44: ...llowing protective equipment when working on the plant Protective clothing Helmet Safety gloves Protective gloves Hearing protection Eye protection Environmental protection Remove and dispose of escaping waste or superfluous grease in line with locally applicable regulations 10 2 Cleaning NOTE Moisture penetration Material damage Never clean with high pressure cleaners Protect from moisture H_EF_0...

Page 45: ... bodies from the internal surface of the discharge belt Visual inspection Specialist Remove deposits on the cover plate below the magnet Clean Operator Check the wear of the cover plate below the magnet Visual inspection Specialist Transverse suspension With an inclined position at the maximum 25 the true running of the discharge belt should be checked daily and corrected as necessary Visual inspe...

Page 46: ...inspection Operator Six monthly Check suspension points attachment points Visual inspection Specialist Annually Gear oil Check and if necessary top up Specialist Check all screw connections are tight Tighten if necessary Specialist Corrosion and surface inspection General wear Visual inspection Operator Every 18 months or after 2000 RHR Grease in bearing chamber Replace Specialist Every 3 years or...

Page 47: ...orized personnel can switch on the system Make sure there are no persons in the danger area After completion of all work Attach all covers G_UW_01_EN US 00 DANGER Static load Risk to life Only use adequately dimensioned aids Secure the aids against slipping G_DSB_02_EN US 00 DANGER Falls from heights Risk of severe injuries or even death Always wear anti fall protection when working at heights of ...

Page 48: ...e roller To replace the discharge belt always remove the over belt magnetic separator from the customer provided device plant WARNING There is a danger to life if the belt is replaced in situ at the place of use in the plant Set down on smooth ground on wooden supports 1 Remove guards 2 Fig 11 Slackening off the discharge belt Slacken off the discharge belt at the tension bearings 3 of the belt dr...

Page 49: ...ce 5 Fig 15 Positioning the discharge belt Position a new discharge belt 6 on the belt change device 5 Check the running direction of the discharge belt The direction of running of the discharge belt must match the direction of the arrow applied to the magnet viewed from below the machine Fig 16 Suspension Attach the lifting device B to the belt change device 5 Thereafter remove the lifting device...

Page 50: ...n the machine Fig 18 Fit the lifting device A on the machine Thereafter remove the lifting device B from the belt change device 5 Fig 19 Removing the belt changing device 5 Fig 20 Parallel alignment Lower the magnetic separator Set down on the ground on wooden supports 1 Align both support rollers 7 parallel to the drive belt drum 8 A A B B 1 6 7 8 5 ...

Page 51: ...lt magnetic separator is adjusted in the factory so that it runs centrally and is supplied after a test run Slight deviations from central running may occur during transport and installation especially in the event of inclined installation To reset central running of the discharge belt observe the following points Check that both support rollers are parallel to the drive belt drum Align the belt d...

Page 52: ...O 11 01 of 6 25 2006 Fig 22 Belt slack Axis separation A A less than or equal to in mm s min conveyor belt slack mm 1 000 30 2 000 40 2 500 50 3 000 60 4 000 70 The specified slack of the attachment relates to conveyor belts with a total thickness of 12 mm and maximum 4 textile layers Special versions of the discharge belts with additional impact plates have greater slack ...

Page 53: ... 23 UME with 2 support rollers Behavior of the attachment upon adjustment of a bearing side 1 Support roller 3 in direction A Discharge belt in direction C 2 Support roller 3 in direction B Discharge belt in direction D 3 Belt drum 2 in direction A Discharge belt in direction C 4 Belt drum 2 in direction B Discharge belt in direction D Item 1 drive belt Item 2 belt drum tensioning drum Item 3 supp...

Page 54: ...H_F_01_EN US 00 Storage of lubricants Lubricants such as oil and grease store in clean and closed containers protect from dust and moisture store in a cool and dry place 10 5 1 Lubricating the roller bearings The factory fitted maintenance free bearing units are lubricated with corrosion and aging resistant roller bearing grease Designation Unit Grease nipple size R1 8 DIN 71412 B Lubricating poin...

Page 55: ...nned long shutdown period 4 months perform a relubrication Perform another relubrication after a long shutdown just prior to recommissioning Determine the precise lubrication intervals under actual operating conditions check the grease condition during the operating period The relubrication must be performed at running temperature with rotating bearings until a fresh grease collar forms See the ma...

Page 56: ...enerous amount of grease on all sealing lips NOTE Mixing of different grease Material damage Avoid mixing of different grease types H_F_01_EN US 00 NOTE Bearings overfilled Material damage Do not fill more than 30 50 of the bearing H_UPC_01_EN US 00 10 5 2 Lubricating the drives The drives were filled with synthetic oil DIN ISO CLP HC VG 460 in the factory see Consumables and Suppliers documentati...

Page 57: ...k Before starting any work Switch off Secure against being reactivated All work on the electrical system must be carried out by trained electricians G_ES_01_EN US 00 WARNING Improper disassembly Risk of injury Before starting any work Make sure there is enough clear space Consult the manufacturer in case of questions During work Wear personal protective equipment Demount parts according to the ins...

Page 58: ...a in line with local regulations Clean the machine Dismantle the machine according to applicable industrial safety and environment protection regulations 11 2 Disposal NOTE Electric scrap electronic components lead components Environmental damage Have disposal carried out by authorized specialist companies H_EEB_01_EN US 00 When a return or disposal arrangement was not made Recycle dismantled part...

Page 59: ...Over belt magnetic separator UME C Appendix 59 GB_UME 75 135 C 03 US 12 Appendix 12 1 Dimension sheet ...

Page 60: ...Over belt magnetic separator UME C Appendix 60 GB_UME 75 135 C 03 US ...

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Page 63: ...r Type Length a mm Screw thread b mm c mm d mm Bearing capacity total max t Weight per peace approx kg AHG 24 130 1300 M24 30 30 7 5 12 5 AHG 24 170 1700 14 0 AHG 24 210 2100 15 5 AHG 36 160 1600 M36 40 40 20 21 5 AHG 36 200 2000 25 0 AHG 36 240 2400 28 0 DIN 976 A S235JRG2 ...

Page 64: ...2 GB_Aufhängung AHG 02 ...

Page 65: ...Over belt magnetic separator UME C Appendix 61 GB_UME 75 135 C 03 US 12 2 Belt change device Drawing V03 3043 10 00 3 ...

Page 66: ...Over belt magnetic separator UME C Appendix 62 GB_UME 75 135 C 03 US ...

Page 67: ...Ù Ù Ù Ù ...

Page 68: ......

Page 69: ...Over belt magnetic separator UME C Appendix 63 GB_UME 75 135 C 03 US 12 3 3 phase motor ...

Page 70: ...Over belt magnetic separator UME C Appendix 64 GB_UME 75 135 C 03 US ...

Page 71: ...Over belt magnetic separator UME C Appendix 65 GB_UME 75 135 C 03 US 12 4 Gearbox ...

Page 72: ...Over belt magnetic separator UME C Appendix 66 GB_UME 75 135 C 03 US ...

Page 73: ...Over belt magnetic separator UME C Appendix 67 GB_UME 75 135 C 03 US 12 5 STUME operating instructions ...

Page 74: ...Over belt magnetic separator UME C Appendix 68 GB_UME 75 135 C 03 US ...

Page 75: ...Over belt magnetic separator UME C Appendix 69 GB_UME 75 135 C 03 US 12 6 Wiring diagram ...

Page 76: ...Over belt magnetic separator UME C Appendix 70 GB_UME 75 135 C 03 US ...

Page 77: ...Over belt magnetic separator UME C Appendix 71 GB_UME 75 135 C 03 US 12 7 Spare parts list ...

Page 78: ...Over belt magnetic separator UME C Appendix 72 GB_UME 75 135 C 03 US ...

Page 79: ...ection right hand side m p M1A FBP07 01296 VA1180077 00010 in 60 Hz network P 3 0kW n rpm IP55 d 45 mm mounting position M1B These specifications apply only to orders in Germany Observe tension and frequency on type plate FBP 5 1 Torque arm S67 T FBP07 00049 6 1 Discharge belt endless EP 400 3 4 2 mm 800 x 4400 FBP09 00649 800 x 4800 FBP09 00501 1000 x 4800 FBP09 00648 1000 x 5200 FBP09 00503 1200...

Page 80: ...2 GB_Ersatzteil UME 75 115 C 01 ...

Page 81: ...Over belt magnetic separator UME C Appendix 73 GB_UME 75 135 C 03 US 12 8 Declaration of incorporation ...

Page 82: ...Over belt magnetic separator UME C Appendix 74 GB_UME 75 135 C 03 US ...

Page 83: ... at the date of the declaration Furthermore we declare that the special technical documents for this incomplete machine were produced in accordance with Annex VII Part B and we commit to communicate these documents to the authorities on demand Chief designer H Leinen This declaration will be invalidated if any alterations are made to the equipment without prior agreement with our company Applicabl...

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Page 85: ...0 Copyright 10 Customer service 10 D Decals 22 Declaration of incorporation 73 Dimension sheet 59 Disassembly 57 58 Disposal 58 E Emissions 25 Environmental protection 21 F Faults 40 troubleshooting 41 G Gearbox 65 GLR operating instructions 67 Guards 19 I Inspections 39 Installation 36 Installation and commissioning 34 Installation instructions 9 Installation location 35 Instruction 17 Intended u...

Page 86: ...elt tension 52 Signs 22 Spare parts 10 Spare parts list 71 Specialist staff 17 Staff Requirements 17 Storage 33 Storage 28 Symbols 11 Symbols in the danger area 22 Symbols on the packaging 29 T Technical data 24 Technical data UME 75 115 C 24 Transport 28 31 Crane 32 Forklift 33 Transport inspection 30 Transporting packages modules 31 Type plate 25 U Use of nonmagnetic material 35 W Warranty 10 We...

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