TECNOMAGNETE MaxX 125, MaxX 300E, MaxX 250, MaxX Series, MaxX 1500 Use And Maintenance Manual

...

PERMANENT – ELECTRO MAGNETIC SYSTEMS

USSEE

LLiigghhtt DDuuttyy LLiiffttiinngg DDiivviissiioonn

hhaanndd ccoonnttrroolllleedd lliifftteerrss -- M

Lainate (MI) - Italy Edition: May 2019

TRANSLATION OF THE ORIGINAL INSTRUCTIONS

according to LEGISLATION 2006/42/EC concerning machinery

AII

NTTEE

ALL

CEE

MaaxxXX

code 09MAXX001 version EN revisione 01

CONTENTS

1 GENERAL NOTES ..................................................................................................................................................... 4

1.1

1.2

1.3

1.4

1.5

1.6

1.7

1.8

1.9

1.10 E

1.11 U

1.12 N

2 TRANSPORT AND HANDLING.................................................................................................................................. 7

2.1

2.2

2.3

2.4

RESENTATION

IMPORTANCE OF THE MANUAL .................................................................................................................. 4

ETENTION OF THE MANUAL

ONVENTIONS

C D

EFINITION OF SYMBOLS

ERSONNEL ASSIGNED TO OPERATIONS

RAINED PERSONNEL

ERSONAL PROTECTIVE EQUIPMENT

ENERAL SAFETY WARNINGS

MERGENCY DRILL

NINTENDED OR IMPROPER USE AMEPLATE DATA

ECEIPT

ANDLING

RANSPORT

NACTIVITY

...................................................................................................................................... 4

.................................................................................................................... 4

....................................................................................................................................... 4

......................................................................................................................... 5

....................................................................................................... 5

.............................................................................................................................. 5

(PPE) ................................................................................................. 6

.................................................................................................................... 6

.................................................................................................................................. 6

............................................................................................................... 6

.................................................................................................................................. 7

............................................................................................................................................... 7

............................................................................................................................................ 7

.......................................................................................................................................... 8

............................................................................................................................................ 8

3 DESCRITPION OF THE SYSTEM ................................................................................................................................ 8

3.1 A

3.2

3.2.1. A

3.2.2 C

3.2.3 T

3.2.4 M

3.3

4 MODELS AVAILABLE ............................................................................................................................................. 11

4.1

5 TECHNICAL CHARACTERISTICS .............................................................................................................................. 12

5.1

5.2

6 GENERAL DESCRIPTION OF THE SUPPLY ............................................................................................................... 14

6.1

7 INSTALLATION ...................................................................................................................................................... 14

7.1

8.1 RISKS RELATED TO MAXX LIFTERS ............................................................................................................ 16

8.2 P

8.3 E

8.4 A

DVANTAGES ASIC PRINCIPLES OF MAGNETIC CLAMPING WITH MAX

IR GAP AND ROUGHNESS ONTACT SURFACE YPE OF MATERIAL

ATERIAL THICKNESS AGNETIC FORCE

MAXX ........................................................................................... E

MAXX TECHNICAL CHARACTERISTICS .............................................................................................. 12

MAXX

ENERIC INSTALLATION

ERSONAL PROTECTIVE EQUIPMENT XPOSURE TO MAGNETIC FIELD CTION LEVELS

........................................................................................................................................ 8

X ............................................................................... 9

..................................................................................................................... 10

............................................................................................................................... 10

........................................................................................................................... 10

................................................................................................................................ 11

RRORE. IL SEGNALIBRO NON È DEFINITO

DIMENSIONS AND WEIGHTS

DESCRIPTION OF THE SUPPLY

......................................................................................................................... 14

(LA)

OF THE STATIC MAGNETIC FIELD

.......................................................................................................... 13

........................................................................................................ 14

......................................................................................................... 16

............................................................................................................... 16

.................................................................................. 17

Use and Maintenance Manual

MaxX

codice 09MAXX001 versione EN revisione 01

THE FOLLOWING IS THE BASIC OPERATING PROCEDURE FOR USING THE MAXX .......................................................... 18

9.1

9.2

10 CHECKS AND MAINTENANCE ................................................................................................................................ 19

10.1 C

10.2 C

10.3 D

10.4 F

10.5 P

10.6 M

10.7 D

10.8 F

10.9 P

10.10 S

11 PROBLEMS AND RELATED SOLUTION ................................................................................................................... 22

11.1 P

12.1 D

12.2 D

PERATING PROCEDURE - MAGNETIZING AND HANDLING

PERATING PROCEDURE - DEMAGNETISATION

ONTROLS – STANDARDS HECKS - METHOD

AILY CHECK REQUENT CHECK ERIODICAL CHECK

AINTENACE - WARNINGS AILY MAINTENACE REQUENT MAINTENANCE

ERIODICAL MAINTENANCE UMMARY TABLE MAINTENANCE/CHECKS

ROBLEMS

ECOMMISSIONING ISPOSAL

....................................................................................................................................... 20

......................................................................................................................................... 22

........................................................................................................................................... 22

...................................................................................................................... 19

............................................................................................................................... 19

................................................................................................................................ 20

............................................................................................................................... 20

.................................................................................................................... 20

............................................................................................................................. 20

..................................................................................................................... 20

.................................................................................................................... 20

............................................................................................................................. 22

............................................................................ 18

........................................................................................... 19

................................................................................................ 21

13 SPARE PARTS ........................................................................................................................................................ 22

13.1 S

14 WARRANTY AND SERVICE .................................................................................................................................... 23

14.1 WARRANTY CONDITIONS ................................................................................................................ 23

14.2 WARRANTY EXPIRATION ................................................................................................................. 23

15 TECNOMAGNETE SERVICE NETWORK ................................................................................................................... 24

16 ANNEXES .............................................................................................................................................................. 24

16.1 D

PARE PARTS

ECLARATION OF CONFORMITY

....................................................................................................................................... 22

.............................................................................................................. 24

Use and Maintenance Manual

MaxX

codice 09MAXX001 versione EN revisione 01

1 GENERAL NOTES

Congratulations on choosing a TECNOMAGNETE product. This publication will help you find out more about your new product and we recommend that you carefully read these pages and always follow the instructions. The descriptions and illustrations contained in this publication are not difficult, given the basic features of the product described. TECNOMAGNETE reserves the right to make changes at any time to components and accessories in order to improve the product or due to manufacturing or commercial requirements. Updates of this manual will be provided as required as Annexes or on the website

ww.tecnomagnete.com

of this manual and its reproduction, even partial, is prohibited, as is disclosure to third parties, without its written permission. In the event of changes and/or updates to the product, which will be agreed exclusively with TECNOMAGNETE, additional content concerning the use and any residual risks arising from the changes shall be provided to supplement the manual.

1.1

Presentation

TECNOMAGNETE was founded in 1974 and has attained a position of leadership position in world markets as a manufacturer of powerful, flexible permanent-electro magnetic systems that operate in total safety, due to its innovative technology and numerous patents filed over the years. Permanent-electro magnetic systems produced by TECNOMAGNETE are able to generate sufficient magnetic force both for clamping and lifting workpieces, only consuming electricity when turned on and off. The main fields of operation include:

MACHINE TOOLS CLAMPING SECTOR

Grinding series Milling series Turning series Rail machining series

MOULDING SECTOR Systems for clamping press molds

LIGHT LIFTING SECTOR

Manually-controlled lifters Battery-powered lifters

HEAVY LIFTING SECTOR

Magnetic lifters Fixed beam magnetic module beam

. TECNOMAGNETE retains ownership

 Telescopic beam magnetic module beam

Importance of the manual

1.2

A copy of this manual must be distributed and kept available to operators assigned to the installation, operation and maintenance of MaxX, enabling them to operate in accableance with the instructions given in this document. A careful reading of the manual will enable MaxX to be used in the correct way and safeguard the security and safety and operators and others. This manual is an integral part of the MaxX, and all reproduction and dissemination rights of the manual and its attachments are reserved. Pass this manual on to any other user or subsequent owner.

1.3

Retention of the manual

Making changes to and removing parts of this manual are prohibited. When using the manual, take care not to damage it. Keep the CD-R or USB key away from impact, heat and magnetic sources and make it easily accessible to operators for further reference.

Conventions

1.4

For ease of consultation, the manual is divided into the following hierarchical order so that each phase is described in detail:

1. Chapter 1 of the manual

1.1. section 1 of Chapter 1 of the manual

1.1.1. sub-section 1 of section 1 of Chapter 1 of the manual

Some sections and/or chapters are presented with numbered sequences in order to illustrate the operation step by step. Symbols are given in sections requiring greater attention. Units of measurement, including the decimal point, are displayed with the international system (SI).

Use and Maintenance Manual

MaxX

codice 09MAXX001 versione EN revisione 01

Definition of symbols

1.5

All parts concerning safety are highlighted in bold. All warning notes that alert the personnel concerned that the described operation involves exposure to residual risk, with possible damage to health or injury, if not carried out in compliance with the instructions, are shown in bold and identified with the following symbol :

All warning notes that indicate that the described operation must be performed by trained and qualified personnel are shown in bold and indicated with the following symbol:

In turn, the trained / specialized personnel, depending on the specific tasks, can be indicated by the following symbols: (see details in paragraph 1.7)

Personnel assigned to

1.6

operations

As indicated in this manual, certain procedures must be carried out only by qualified or trained personnel. The level of qualification is described using standard terms:

1. qualified personnel have technical knowledge and/or sufficient experience to enable them to avoid thepotential dangers from electricity and/or mechanical movements (operation and maintenance personnel) trained personnel are appropriately advised and/or supervised by qualified persons to enable them to avoid the potential dangers from electricity and/or mechanical movements (operation and maintenance personnel)

2. the User is obliged to obtain confirmation of the following from all designated persons, before they are allowed to work to work with MaxX the personnel have received the instruction

2.1. the personnel have received the instruction manual, and have read and understood it

2.2. the personnel shall work in the manner described..

Trained personnel

1.7

The qualifications are given below of the personnel allowed to use the MaxX:

OPERATOR: a person or persons who, following appropriate and indispensable training, is/are assignedand authorized by the owner of the MaxX to run operations. The occupier of this post must be completely aware of and understand the contents of this manual

HANDLER: this post requires specific skill (possibly acquired by attending mandatory courses, if required by law, in hoists the methods and features of harnesses handling and safe handling procedures. This position also requires complete awareness and understanding of the contents of this manual, in particular paragraph 2.2

MECHANICAL MAINTENANCE OPERATOR:

this post requires specific skills in the installation, adjustment, maintenance, cleaning and/or repair of systems. The occupier of this post must be completely aware of and understand the contents of this manual.

requires specific skills in carrying out installation, adjustments, maintenance cleaning and/or repair. For his preparation and experience he has skills and knowledge in the lifting sector as well as a sufficient familiarity with the main regulations in order to be able to determine any deviations from the expected conditions. The occupier of this post must be completely aware of and understand the contents of this manual.

SPECIALIZED TECHNICIAN:

this post

Use and Maintenance Manual

MaxX

codice 09MAXX001 versione EN revisione 01

1.8

Personal protective equipment (PPE)

The staff referred to in the previous paragraph must wear an adequate safety distance from the parts clamped on the magnetic equipment, with special attention when in vertical or suspended (this distance must be suggested by the plant operator in accordance with the regulations). The staff must also wear appropriate safety clothing. Protective footwear is mandatory, while the need for headsets, helmets and goggles must be assessed by the User. Loose fitting clothes or articles that could be trapped by moving parts are prohibited. (see chapter 8)

General safety warnings

1.9

The rules and recommendations below are in compliance with the current safety regulations, on which they are based. TECNOMAGNETE S.p.A. declines all responsibility for any damage caused to persons or things deriving from failure to observe the safety regulations in force and the instructions given below. Machine safety systems must be selected and installed on the basis of the following requirements:

 be under the technical responsibility of qualified

personnel

 be integrated with technical compliance and with

appropriate control systems

 installations must be made in such a way that they can

not be neutralized or tampered with

All designated operators must respect and implement the following and scrupulously adhere to the regulations on accident prevention in force in the country of installation and on the use of the MaxX. All ordinary and extraordinary maintenance must be performed with stationary system and with structure not hooked to the crane etc. To avoid the danger of accidental connections during maintenance operations, attach a warning sign on the control panel with the words:

MAINTENANCE IS UNDERWAY

All operations of transport, installation, use, ordinary and extraordinary maintenance on the MaxX must only be carried out by the personnel identified in section 6 of chapter 1. The permanent-electro magnetic system can only be used for the applications indicated in the manual and only in combination with devices and components recommended and authorized by TECNOMAGNETE S.p.A.

1.10

In an emergency, it is recommended to follow the procedures given in the operation and maintenance manual of the machine on which the MaxX is installed. In the event of fire, use the devices provided to extinguish the fire, taking care never to use water on electrical parts (considering however that MaxX is not made up of electrical parts).

1.11 Unintended or improper use

Emergency drill

MaxX is not designed or constructed for operation in explosive atmospheres.

Unintended use may:

 cause injury to personnel  damage the system or other equipment  diminish reliability and performance.

MaxX cannot be used for purposes other than those recommended and in compliance with the intended use, avoiding the following in particular:

 unsuitable parameters of use  defective or lack of maintenance  use of inappropriate materials  failure to follow instructions  uncertain or insecure clamping of MaxX system or parts

thereof

In the events of doubts over the appropriate usage, contact TECNOMAGNETE S.p.A. to determine whether it is use for which the system was intended or otherwise.

Use and Maintenance Manual

MaxX

codice 09MAXX001 versione EN revisione 01

1.12

Two plates are applied on the MaxX:

1) Logo and data referring to the identification of the

2) Load / force curves, data referring to the performances and

3) The plates are indelible and must not be removed for any

Example of a nameplate on MaxX500:

Fig.1.12A

Nameplate data

manufacturer, serial number, production date, weight of the MaxX, symbology in compliance with the laws in force (example Fig.1.12A).

dimensions and types of load to be magnetically anchored (example Fig.1.12B).

reason even should the MaxX be sold. In the event the plate has been damaged or lost after coming away from its housing, contact TECNOMAGNETE S.p.A. to obtain a replacement. When communicating with TECNOMAGNETE S.p.A., always quote the model on the plate. Failure to comply with these provisions exempts TECNOMAGNETE S.p.A. from any liability for damage or injury to persons or property that may arise, which shall remain the sole responsibility of the user with regard to the competent bodies.

2.2

MaxX 125 – MaxX 250 – MaxX 300E – MaxX 500 – MaxX 600E MaxX TG 150 – MaxX TG 300

Handling

Each of the above models is placed inside cardboard boxes, protected by a sheet and wrapped in a layer of polyurethane foam that guarantees the absolute mechanical integrity in case of shocks or incidents of the packaging.

Fig.2.2A

MaxX 1000 – MaxX 1500 – MaxX 2000

Each of the above models is placed inside the cardboard box (see above) and fixed to a wooden pallet to allow easy handling.

Fig.2.2B

Fig.1.12B

2 TRANSPORT AND

HANDLING

2.1

Receipt

MaxX are thoroughly checked before shipment. On receipt, the integrity of the package and the material contained therein must be checked (unless other instructions are issued by TECNOMAGNETE S.p.A.), in order to confirm that no damage occurred during transport and that the consignment complies with the order specifications. Otherwise, report any irregularities to TECNOMAGNETE S.p.A. and the Carrier responsible for any damage during transport. Notification of damage or defects must be given within ten days from receipt of the supply. After that period, TECNOMAGNETE S.p.A. will consider the provision free of defects.

All personnel handling loads must operate with protective gloves and safety shoes. It is the responsibility of the user to ensure that handling is conducted in compliance with current safety regulations. The following table identifies the packaging size and its weight according to the models:

Fig.2.2C

Model

MaxX 125 MaxX 250

MaxX 300E

MaxX 500 MaxX 600E MaxX 1000 MaxX 1500 MaxX 2000

MaxX TG150 MaxX TG300

Dimensions

[mm]

130x130x200 0.3 4

195x145x200 0.5 7

255x190x245 1 16

350x230x250 3.5 36

400x300x300 5 66

460x300x300 6 82

195x145x200 0.5 7

255x190x245 1 16

Packing

mass

(Tare) [kg]

Complete

packing

(Gross) [kg]

Use and Maintenance Manual

MaxX

codice 09MAXX001 versione EN revisione 01

Inactivity

2.4

When hoisting or handling MaxX, clear the operations area of obstructions and keep it clear, also consider providing a sufficient safety zone to prevent harm to persons, animals or objects that might be in maneuvering range. MaxX are designed to be hoisted and handled with suitable hoisting devices, the type and scope of which must be selected in accableance with the weight. (see table Fig.2.2C). It must be handled with extreme care, avoiding impacts that could damage delicate parts, compromising normal operation When moved with forklift trucks, comply with the permitted speed and inclination. Never leave load suspended on hoists. (also refer to paragraph 1.8).

The permanent-electro magnetic system must be disconnected from power sources and its moving parts appropriately locked during transport, handling and storage.

The instructions on the package must be read and digested before opening.

Keep the original packaging for later handling.

2.3

Transport

Some parts may have to be dismantled for transport, to be reassembled and reconnected during installation by TECNOMAGNETE S.p.A. technicians, or by the User on TECNOMAGNETE S.p.A.’s recommendations. The system must be transported in observance of the following environmental limits: a temperature range of -5 °C to +55 °C, rising to a maximum of +70 °C for a period no longer than 24 hours. Should it be necessary to transport the MaxX by sea or by air, suitable packaging and protection systems must be provided to avoid any damage caused by impact. To protect against weathering, use anti-rust lubricants and bags of hygroscopic salts inside the packages. All moving parts must be properly anchored and removed from their housing, where possible.

In the event of long-term storage or inactivity, the MaxX must be thoroughly cleaned of any residues and its uncovered metallic parts must be protected with oil or grease in order to avoid oxidation. It is recommended to cover the MaxX with a tarpaulin and keep them in a dry, sheltered place The room temperature should be between -5 ° C (23 ° F) and + 55 ° C (131 ° F). The relative non-ondensing humidity should be between 30% and 90%, The atmosphere should be clean, free of acids, corrosive gases, salts, etc. If restoring to operation, follow the instructions contained in this manual.

3 DESCRITPION OF THE

SYSTEM

Advantages

3.1

MaxX consists of a very small number of details. Rotor and stator, in steel with high magnetic permeability, are obtained by machining from solid, using CNC machines; this grants uniformity and robleness of the product and the quality control necessary for a magnetic hoist built in large series. The material used (steel, aluminum, plastic) is easily disposable and recyclable when the tool is dismantled. The magnetic material used, with a high specific energy, made it possible to reduce to the maximum weight and volume. To allow a high uniformity of performance, given the large series, the MaxX lifter is magnetized in a single stroke after assembly, using the largest magnetizer built in Europe. MaxX is able to handle the load, which is always anchored and lifted from above, without any deformation or damage with an optimal use of the available work areas. Some of the most recognized areas with the use of MaxX are the following:

- servicing of machine tools

- wholesalers of ferrous material

- cutting plants

- carpentry

- shipyards

- foundries

- steel industries

- mold handling

Use and Maintenance Manual

MaxX

codice 09MAXX001 versione EN revisione 01

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TECNOMAGNETE MaxX 125, MaxX 300E, MaxX 250, MaxX Series, MaxX 1500 Use And Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual