Dings Magnetic Group 2 PULLEY EDDY CURRENT SEPARATOR User Manual
IMPORTANT SAFETY INFORMATION
CAUTION: STRONG MAGNET
Rare earth magnets in the magnetic rotor assembly are extremely powerful. They can project magnetism through a considerable distance and exert
strong pulling force on magnetic metals. Use of
iron or steel tools near the magnet could cause
injury to personnel or damage to the separator.
Strong magnetic field may have an affect on
pacemakers and other electrical devices.
Please contact the device manufacture for further
information.
Wear eye protection, such as safety glasses, when
adjusting the splitter or observing the operation of
the separator.
Always stop the separator before cleaning any
component.
Preventing damage to the separator:
When unloading the eddy current separator or
moving it, do not place it near angle iron structures
or truck floors or walls that are steel.
The separator should be handled gently when picking
it up or setting it in position. Although it is ruggedly
designed for heavy-duty operation, the magnets
and shell are brittle and a sudden shock or blow
could damage them.
Clean off any ferrous metal particles which may
have accumulated on the magnetic rotor during
shipment (see page 6).
The rotor is a high inertia load on the rotor motor, so
special consideration must be taken during start-up.
The motor can be started no more than once in a 15
minute period. After shut down, allow the motor to rest
for at least 15 minutes before restarting.
DESCRIPTION
The Dings eddy current system separates nonferrous metals
such as aluminum, die-cast metal, and copper from nonmetallic material.
WARNING: An eddy current separator is designed
to remove nonferrous metals. It is NOT designed
to be a source of magnetic ferrous separation.
Serious damage will occur if magnetic separators such
as pulleys or drums are not used to remove the ferrous metal
from the burden before it reaches the eddy current system.
At least two stages of magnetic separation are recommended
prior to the eddy current separator. Large pieces of steel or
other ferrous can damage or crush the wear cover of the
magnetic rotor. Small ferrous particles can accelerate wear
on the rotor cover and the belt and ultimately cause failure.
A strict maintenance plan to ensure the cleanliness of
the magnetic rotor will extend the life of the shell (see page
6).
PRINCIPLES OF OPERATION
Material is fed onto the conveyor belt of the eddy current
separator, which moves it across the magnetic rotor where
separation occurs (Fig. 1). The two streams of material discharge into a housing. The housing has a splitter to divide
the nonferrous metal from the nonmetallic material, such as
paper, plastic, wood or fluff.
The key component of the eddy current separator is the
magnetic rotor, which has a series of permanent rare earth
magnets mounted on a support plate attached to a shaft.
Bulletin 9000F1 (10/11)
2 PULLEY EDDY CURRENT SEPARATOR
MAINTENANCE AND OPERATING INSTRUCTIONS
Check immediately when the eddy current separator is received for possible shipping damage. Report
damage to the delivering carrier.
Read this bulletin carefully before operating the separator. It is important that a strict maintenance
plan for the magnetic rotor be followed (see page 6) to ensure a long life for the separator.
Figure 1 - Nonferrous Separation
U.S. Patent Nos. 5,626,233 and 5,655,664
The magnetic rotor is surrounded by (but not attached to) a
wear shell which supports the conveyor belt. This allows the
rotor to spin independently and at a much higher speed than
the wear shell and belt.
When a piece of nonferrous metal, such as aluminum,
passes over the separator, the magnets inside the rotor rotate
past the aluminum at high speed. This forms eddy currents
in the aluminum which in turn create a magnetic field
around the piece of aluminum. The polarity of that
magnetic field is the same as the rotating magnet, causing
the aluminum to be repelled away from the magnet.
This repulsion makes the trajectory of the aluminum
greater than that of the nonmetallics, allowing the two
material streams to be separated.
INSTALLATION
The eddy current separation system consists of the separator
and the optional discharge housing. The height at which you
place these two components depends on both the height of
the feeder before the separator and the take-away conveyors
or collection bins beneath the discharge housing.
LOCATION OF THE SEPARATOR
Magnetic performance may be affected by magnetic
material in the field. This includes such items as I-beams,
metal supports, hoppers, or splitters. These and other ferrous
objects need to be kept out of the magnetic zone.
Place the eddy current separator at the discharge end of
a conveyor or vibratory feeder. (“Feeding the Separator” on
page 5 describes the use of a vibratory feeder to control
surges in the burden.)
Mount the separator close enough to the feeder so that
material does not fall between the two conveyors when the
feeder is initially turned on or turned off.
The belt surface of the separator should be below the
feeder conveyor, but not so low as to cause damage to the
separator belt. The greater the gap between the separator
and feeder, the harder the impact will be of sharp metal
pieces in the burden falling onto the belt. Use a 45
o
slide
chute between the end of the feed conveyor and the eddy
current belt. The slide chute will present the material to the
belt without impact or bouncing.
LOCATION OF THE DISCHARGE HOUSING
The roof and walls of the discharge housing protect you and
your machinery from flying metal when the eddy current
separator is running. The housing also contains the
adjustable splitter and two discharge chutes.
Place the discharge housing next to the discharge end
of the eddy current separator as shown on the certified
print. The base of the legs of the separator and the bottom
of the channel frame of the discharge housing should be at
the same height. Clearance must be allowed beneath the
discharge chutes for the take-away conveyors or collection
bins.
SETTING IN POSITION
Bolt both components securely to footings or framework
that can support the weight of the separator and provide a
stable foundation.
Figure 2 - Major Components of the Dings Eddy Current Separator.
2
EDDY CURRENT SEPARATOR
OPERATION
CAUTION: Do not operate the separator with the
access doors open.
The separator has two motor drives (Fig. 3):
(A) fixed high speed drive which rotates the magnetic rotor
assembly;
NOTE: The rotor is a high inertia load on the rotor motor,
so special consideration must be taken during start-up.
The motor can be started no more than once in a 15
minute period. After shut down, allow the motor to rest
for at least 15 minutes before restarting.
(B) fixed speed drive which runs the conveyor belt at about
400 fpm.
Optional motor controls are located in the control panel (C).
Conveyor belt
Nitrile belt with thermowelded PVC “T”
cleats and PVC “C” sidewalls.
Conveyor belt pulley
Pulley is crowned and there is lagging on the
drive pulley.
Gearmotor.
Belt speed adjustment (if equipped)
See “Start-Up” on page 5 for more information
about belt speed.
If equipped with a variable frequency drive:
The conveyor belt speed is preset to 400 fpm.
The speed is adjustable at the drive from 198 to
440 fpm by pushing and holding one of the
arrow keys on the drive until the desired speed
is reached. The unit reads the speed of the belt
directly in fpm. (Eg: 400/MIN = 400 fpm).
For most applications, a belt speed of
approximately 400 fpm will result in the best
separation.
If equipped with a fixed-speed drive:
The belt speed is fixed at approximately
400 fpm.
Figure 3 - Motor Drives and Controls.
Figure 4 - Conveyor Belt and Drive.
Figure 5 - Variable Frequency (VF) Drive for
Conveyor Belt (Optional).
No keys other than speed
adjustment need to be
used, as the main control
panel (Fig. 7) controls the
VF drive. If other changes
to the drive’s programming
are needed, please refer to
the VF manual or consult
Dings. See wiring diagram
for factory settings on
the VF drive.
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