ELEKTROMAG SEPARATORS & SUSPENSION MAGNETS Page 1 of 6

Overband Magnetic Separators

and Suspension Magnets

RANGE OF APPLICATION

In many branches of industry

ELEKTROMAG Overband Magnetic Separators and Suspension
Magnets have become indispensable for decades. They are used for
removing magentics parts from non-magnetic material in order to protect
crushers, mills, procescing plants etc. against too much wear and
damage. They serve for cleaning non-magnetic bulk goods with iron
contamination, for instance cleaning of foundry sand, fodder and the
like. They are used for recovering magnetic material from ore, steel mill
slag etc. Generally, overband magnetic separators and suspension
magnets are installed above conveyor belts, vibratory feeders or chutes.
They pick up ferrous metal parts from bulk goods. In most cases, the
magnets can also be installed in an existing installation without much
expense.

When using overband magnetic separators and suspension magnets,

many factors must be considered for the various applications, and it is
impossible to list them all in a brochure. Each application, each material
and each kind of conveying involves different problems.

Owing to the shape ( demagnetization factor), long, barshaped and large

iron parts can be better separated than short, cube-shaped bulbous and
small iron parts.

The efficiency of the overband magnetic separator or suspension magnet

depends on the pole size, pole distance field intensity in the conveyor
burden, lines of the magnetic flux conveying speed and properties of the
material to be separated.

http://www.emagindia.com/suspen.htm 3/22/2012
ELEKTROMAG SEPARATORS & SUSPENSION MAGNETS Page 2 of 6

Large burden depths, large lump sizes, sticky or humid material render
the separation more difficult.

METHOD OF OPERATION

ELEKTROMAG Suspension magnets are used when only small

contamination levels are encountered. The material accumulated on the
pole face must be removed at regular intervals. When stopping the plant
to the material and/or long and bulky pieces are contained in the
conveyor burden. This material is attached by the magnet and is
transported out of the magnetic field and ejected by the discharge belt
running around the magnet.

DESIGN

ELEKTROMAG Suspension magnets consist of a magnet body and

exciter coil. Cross sections, shape and size of the magnet body are
specially designed for magnet coil and power input. Thus despite
compact construction, low weight and low power input, high efficiency
is reached.

The magnet body is a welded steel construction of high permeability.

The standard exciter coil consists of an aluminium conductor and it is
manufactured by using insulating material of class `H' and mounted into
the magnet body. If specially requested we can also supply coils wound
with copper conductor. The coil is covered by a non-magnetic plate.

Suspension lugs and one set of turn buckles and suspension rod with bull
ring are normally supplied.

Electric connection is by a terminal box. The entrance for cable fixing is

fitted with a suitable cable gland.

ELEKTROMAG Overband magnetic separators consist of suspension

magnet, supporting structure for the discharge belt with drive drum, tail
drum and 2 additional idlers where necessary. The drums, idlers are
mounted on suitable self aligning bearings. A suitable geared-motor or
motor coupled to gear box is used to drive the discharge belt.

The discharge belt is a rubber/canvas or rubber/nylon belt with several

plies and cleats. For re-tightening the discharge belt, the fixed axle of the
tail drum is fitted with a tensioning device.

SELECTION

For making out an offer, we need the answer to the following questions:

http://www.emagindia.com/suspen.htm 3/22/2012
ELEKTROMAG SEPARATORS & SUSPENSION MAGNETS Page 3 of 6

1. Kind of material :
{ wet or dry
{ easy-flowing or tending to lump.
2. Bulk weight in t/m3.
3. Chemically aggressive or neutral.
4. Lump size- if possible distribution.
5. Throughput per hour in cbm or tons:
{ is feed continuous or in batches.
{ maximum and average burden depth measured on belt.
6. Size of tramp iron to be separated :
{ dimensions and weight of largest pieces.
{ dimensions and weight of tramp iron presenting no threat to
subsequent processing installations.
7. Technical data of conveyor :
{ width
{ troughing angle.
{ inclination
{ speed.
8. Purpose of separation:
{ protection of crushers, mills, machines and other parts.
{ cleaning foundry sand, fodder, wood chips etc. from
contaminating iron parts.
{ recovery of ferrous material from slag, refuse etc.
9. Available supply:
{ three phase current, voltage frequency, power.

MOUNTING

The suspension magnet can be suspended with height adjustment above

the conveyor from a suitable supporting structure, by means or ropes,
chains or fastening devices.

Suspension
can be
made
over the
conveyor
or over
the discharge end of the conveyor. The parts of the conveyor in the stated
area of the magnetic field (idlers, belt head drums, troughs, sieves etc.)
must be made of non-magnetic material.

Overband
magnetic
separators
are
either
suspended
across

http://www.emagindia.com/suspen.htm 3/22/2012
ELEKTROMAG SEPARATORS & SUSPENSION MAGNETS Page 4 of 6

the conveyor or in line above the discharge end of the conveyor. Also
here suspension should be adjustable in height by means of ropes, chains
or fastening devices above the conveyor from a suitable supporting
structure.

In the case of mounting in line above the discharge end of the conveyor ,
it should also be possible to adjust the suspension height and angle to the
conveying direction. The figures above show where non-magnetic
material must be used.

For instance, the head pulley of a conveyor belt, the spout of a feeder or
a sieve, the plate dividing magnetic and non-magnetic material must be
non-magnetic.

Mounting the overband magnetic separator in the line above the

discharge end of the conveyor increases the efficiency of the magnet and
facilitates the iron discharge because tramp iron leaps out toward magnet
face as material looses and fans out. It is ideal where long pieces, rods,
etc. are likely to be encounted as inline belt moves faster than main belt.

ELECTRICAL CONNECTION

D. C. supply is required of the coils. A suitable rectifier is necessary for

each magnet. Switching ON/OFF is done on the three phase / A.C. side
of the rectifier.

By this kind of connection no additional protective measures against

voltage peaks are required which arise by the high inductivity of the
magnet when switching off.

The rectifiers and the three phase current motors are dimensioned for
415V/50Hz. The units can also be supplied for other voltages and
frequencies.

MAINTENANCE

Maintenance is confined to regular checks of oil level in the gear box, to

checks of the discharge belt and to normal.

GENERAL REMARKS

ELEKTROMAG Overband magnetic separators and suspension

magnets comply with the `Regulations for elektromagnetic equipment'
VDE 0580. All technical data listed in this brochure apply to normal
operating conditions. The magnets can be used in a temperature range

http://www.emagindia.com/suspen.htm 3/22/2012
ELEKTROMAG SEPARATORS & SUSPENSION MAGNETS Page 5 of 6

between -20 degree Centigrade and + 40 degree Centigrade.

Where extraordinary operating conditions prevail - such as high ambient

temperature (over 40 degree Centigrade) high air humidity, chemically
aggressive atmosphere, severe dust pollution, handling of wet and sticky
material, very large tramp iron, hot material, marked voltage fluctuation
in the supply network, special magnets are required.

Many such special magnets are already in operation and are technical
developed according to the requirement of our customers.

We reserve the right to carry out alterations in line with further technical
development without prior notice.

COMBINATION UNITS

z for extra protection from tramp iron.

z for increased clearing.
z for heavy duty separation applications.

SYSTEM 1:

ELEKTROMAG Suspended or
overband magnetic separator for
initial tramp iron removal followed
by :

ELEKTROMAG Magnetic head

pulley for removing remaining
iron. This ensures double protection removing even very small particles.

SYSTEM 2:

ELEKTROMAG Suspended
or overband magnet for
removal of ferrous
contamination followed by :

ELEKTROMAG-EAB
Electronic metal detector with
a highly sensitive search coil which can sound alarm and stop the
conveyor when any non-ferrous contamination passes through the field
of the search coil. Sensitivity of search coil can be easily adjusted so that
it acts only for objects large enough to be damaging. This combination
unit is particularly useful where damaging non-magnetic tramp metals
(e.g. manganese steel, stainless steel, brass etc. ) are likely to be

http://www.emagindia.com/suspen.htm 3/22/2012
ELEKTROMAG SEPARATORS & SUSPENSION MAGNETS Page 6 of 6

encountered in addition to tramp iron.

SYSTEM 3:

ELEKTROMAG -EAB
Electronic metal detector followed
by :

ELEKTROMAG Suspended or
overband magnet running with a
low basic excitation.

Particularly useful where burden depths and belt speeds are excessively
high. When the search coil detects the presence of tramp iron the metal
detector actuates a circuit that overexcites the magnet coil briefly thereby
creating a powerful magnetic field to ensure tramp iron extraction. After
extraction, the excitation automatically drops back to the original level
which is sufficient to hold the attracted tramp iron.

Magnetic Separators/Lifting Magnets

http://www.emagindia.com/suspen.htm 3/22/2012