PNEUMATIC HUMP SEPARATOR

USER MANUAL

ENGLISH
Pneumatic Hump Separator-User Manual

Contents
0. Foreword ........................................................................................................................................................................................ 3 

1. Introduction ................................................................................................................................................................................... 4 

1.1. Features .............................................................................................................................................................................. 4 

1.2. Main Application & Scope ............................................................................................................................................ 4 

1.3. Model Definition .............................................................................................................................................................. 4 

1.4. Service Environment ....................................................................................................................................................... 4 

1.5. Working Condition.......................................................................................................................................................... 5 

1.6. Safety .................................................................................................................................................................................. 5 

1.7. Quality Guarantee ........................................................................................................................................................... 5 

2. Working Principle ........................................................................................................................................................................ 6 

2.1. Structure............................................................................................................................................................................. 6 

2.2 Function Description ....................................................................................................................................................... 6 

4. Installation ...................................................................................................................................................................................... 9 

4.1. Installation Condition ..................................................................................................................................................... 9 

4.2. Installation Method ......................................................................................................................................................... 9 

4.3. Control System’s mounting and connection........................................................................................................ 10 

5. Operation .................................................................................................................................................................................... 12 

5.1. Adjustment of Air Pressure and Discharge Condensate .................................................................................. 12 

5.2. Air Flow Adjustment .................................................................................................................................................... 12 

5.3. Control Logic ................................................................................................................................................................. 13 

5.4. HMI Operation .............................................................................................................................................................. 15 

6. Trouble Shooting ...................................................................................................................................................................... 19 

7. Maintenance............................................................................................................................................................................... 20 

7.1 Attentions before Maintaining .................................................................................................................................. 20 

7.2 Maintenance ................................................................................................................................................................... 20 

8. Lifting、Transit & Storage ..................................................................................................................................................... 21 

8.1. Lifting and Transit Note .............................................................................................................................................. 21 

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Pneumatic Hump Separator-User Manual

8.2. Storage Conditions, Period and Note .................................................................................................................... 22 

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Pneumatic Hump Separator-User Manual

0. Foreword

Dear user, thank you for choosing our company's products. Before using this product, please read the in-

struction manual in detail, and operate strictly according to the instruction manual to ensure the reliable, effective

and safe performance of the product. This manual fully described the product technical information and the correct

procedure of installation, operation and maintenance. If you have any questions, comments and suggestions to

the manual, please contact o. to acquire the professional assistance to prevent fortuitous accident from happening.

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1. Introduction

1.1. Features

1. The control system is built with PLC+HMI, and the automatic cycle can be well fulfilled, Easily operated

and worked 24 hours without interruption.

2. Wide input range of supply power voltage.

3. Low power consumption, energy saving and environmental protection to save operating costs.

4. Minimal loss rate of materials and free-pollution.

5. Symmetrical structure allows no stop of material flow when cleaning the scrap materials.

1.2. Main Application & Scope

This product is kind of primary iron filtration equipment which is suitable for automatic separation of

magnetic impurities from granular materials and widely used not only in food industry, but also in non-metallic

plastic ceramics, chemical industry, pharmacy, building materials, electronic battery and other industries. It is

not suitable for materials with poor fluidity.

1.3. Model Definition

Model Flow （m³/h） Width NW (kg) About

mb165 165 250 292

mb250 250 400 395

mb390 390 600 533

mb550 550 800 671

mb800 800 1000 809

1.4. Service Environment

1. The altitude is below 2000meters.

2. The ambient temperature is below 40℃ or above 0℃.

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3. There is no explosion risk, liquid splashed, significant dust powder and corrosion gas.

4. Used indoor or outdoor shed.

1.5. Working Condition

1. Power Supply： AC100-240V，2Phase， 50/60Hz，range：±10%

2. Air Supply： Pressure：0.4MPa~0.7MPa

1.6. Safety

 Magnetic Field Warning

People who wear medical pacemakers or similar electronic devices should not be close to the equipment,

unless at least 3 meters away.

People who wear electronic equipment such as mobile phone, mechanical watches, IC card, memory

disk and similar items which are easily influenced by magnetic field should be kept away from equipment.

If needed, man-machine distance should be at least 1 meter.

 Electric Shock Warning

Do not open the control box when it is energized in case the personal injury caused by electric shock

 Warning of Magnetic Plates Movement

Magnetic plates move when the control system is working.

1.7. Quality Guarantee

We strictly fulfill the legal and contractual quality guarantee for the electro-magnetic separator except

following conditions:

1. After delivery, the equipment bears a strong impact from the user’s operation, vibration or sharp tilt

during storage, handling and installation which are likely to cause the equipment damage.

2. After delivery, the user disassembles the equipment without manufacturer’s authorization.

3. After delivery, the user changes the wiring of control cabinet or the pneumatic connection without the

manufacturer’s authorization.

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2. Working Principle

2.1. Structure

P2.1-1，Structure

2.2 Function Description

The pneumatic hump separator has 2 parts -body and a control system.

There are 2 channels in the separator body, left channel and right channel. These 2 channels have a common

inlet and an alternative working style. The selector built in the inlet part is used to choose which channel to work

on. Each channel has 2 magnetic plates, 1 filtration outlet and 1 discharge outlet. When a channel works, the

magnetic plates should be close to the channel and the outlet is at the filtration side. Raw materials flow past the

inlet and channel, and then clean materials flow out from the filtration outlet. When the channel discharges, the

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selector should move to another side, turn the outlet to the discharge side and separate the magnetic plates, then

the magnetic scrap materials will drop out from the discharge outlet.

The control cabinet is wall- mounting which contains PLC+HMI. The operation worker could send commands

to the PLC and PLC to control the equipment through the HMI .

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3. Technical Specification

[Table 3-1 Tecn. Specification]

Equipment Parameter
Body Size (mm) 2036x1520x650(HxWxD)
Body Weight 550Kg
Surface Magnetism Of Magnets (Max. Approx.) 4500GS
Magnets Work Temperature ≤80℃
Control Cabinet Size (mm) 785 x 310 x 207(WxHxD)
Control Cabinet Weight 22 Kg
Control Cabinet mounting Dimension (mm) 735x340(WxH) mounting hole 4xφ12
Power Supply 100V-240V AC，2Phase(L+N+PE)， 50/60H,
Power Consumption 0.04KW/H
Power cable Cable Outer Diameter 8mm~14mm, Single Wire≤2.5mm²。
Air Supply 0.4MPa~0.7MPa Tubing Outer Diameter 8mm
IP Grade IP65
Service Environment
Ambinet Temperature 0℃~40℃
Humidity ≤95%
Altitude 0~2000m

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4. Installation

4.1. Installation Condition

Space should be sufficient for the installation to ensure there is more than 800mm from the top of the equip-

ment to the ceiling (or above obstacles); and 1000mm away from the walls（or other obstacles）under the con-

sideration of convenient operation and maintenance.

4.2. Installation Method

The pneumatic hump separator should be fixed and supported by the user’s pipeline which needs to meet

followings

1. The pipeline is required to support the weight of the equipment. The safety factor is not less than 2.0.

2. Certain vibration will be produced when cylinders are working. Therefore, the impact of vibration should be

fully considered during the installing.

3. The discharge outlet connectors should not be used as a support for the equipment.

4. Tilt angle should not be more than 2 degrees during the installation.

5. Remove the Magnetic plate fasteners after installation.

P4.2-1，Flanges dimensions Of Inlet and Outlet (mm)

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4.3. Control System’s mounting and connection

The control system should be mounted vertically and fixed on the wall by 4 mounting holes. More detailed

dimensions please find P4.3-1

1. Power Connection

Power requirement: two-phase L+N+PE，Voltage: 100VAC-240VAC, Frequency: 50HZ/60HZ, Current: Less

than 1A

Power cable requirement：3 cores，1.0mm²≤ wire diameter ≤2.5 mm², 8mm≤ Cable diameter ≤14mm

Pass the cable through the cable gland at the right side of the control box’s bottom, connect the power cable

to terminal 2 and 4 of F1 breaker, and connect the ground wire to the grounding screw of the mounting plate.

Lock the cable gland to ensure IP grade.

2. Air Supply Connection

Air supply requirement：Pressure 0.4-0.7mPa. Tubing OD 8mm

Connect the tubing between the control cabinet, equipment body and air supply tubing according to P4.3-2

Tubing Connection drawing.

P4.3-1，Dimensions Of Control System (mm)

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P4.3-2，Tubing Connection

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5. Operation

The user should make sure that there are not any obstacles or binding materials near to the magnetic plates

before the control cabinet is on power

5.1. Adjustment of Air Pressure and Discharge Condensate

Open the solenoid actuated on-off valve with HMI, then pull up the rotating head of the pressure regulating

valve, increase the output pressure by clockwise rotation and reduce the pressure counterclockwise. The air pres-

sure should be adjusted between 0.5MPa and 0.6MPa and could be detected by a pressure meter. When the

adjustment is completed, press the rotating head of the pressure regulating valve, and then press the blue lock

key to lock the rotating head. The lock key resetting is needed if next adjustment is going on.

When the condensed water in the plastic bowl is greater than 1/3, it needs to be discharged. Firstly shut off

the air source when discharging the condensate water. Secondly turn the condensate discharge valve counter-

clockwise and tighten the valve clockwise after the water is drained.

P5.1-1，Service Unit Combinations (SUC)

5.2. Air Flow Adjustment

There are two one-way flow control valves for each cylinder. The control valve is air- exhausted which can

be adjusted by rotating the adjustment screw on the top side. The air flow will increase if rotating the adjustment

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screw clockwise. On the contrary, the air flow will decrease. Cylinder’s running speed can be adjusted by adjusting

air flow.

See the P5.2-2 picture, the cylinder axis will move out more slowly if decrease the air flow at left side while

the axis will move back more slowly when adjust the air flow at right side. So, if we increase the air flow, the axis

will move more quickly. The adjustment of air flow is not needed as it’s already completed before delivery.

P5.2-1，One-way flow control valve P5.2-2，Cylinder

5.3. Control Logic

The electric control system consists of manual control and automatic control. Default manual control mode

happens when the control system is on power again.

In manual mode, the operator can control the equipment by pressing buttons on “Manual Operation Panel”.

In auto mode, the control system will work automatically according to the filtration and discharge setting time.

For each channel, there are 3 automatic work status--- filtration, discharge and ready which will be shown in

the control window. More details about auto control logic please find the follow picture P5.3-1，Control Logic.

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P5.3-1，Control Logic

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5.4. HMI Operation

Control window will be shown on the HMI like P5.4-1 when power is on.

P5.4-1，Control Window

1，System Working Status

P5.4-2，System Working Status Panel

System working status panel is in the upper part of the control window which is used to show the equipment

working status. Please find following comments. Mat. Inlet/，Mag. Plates and Mat. Outlet will not be shown if air

supply is off.

Mat. Inlet (materials inlet): Open - the inlet is open

Closed- the inlet is closed

Mag. plates (magnetic plates):
Mat. Outlet (materials outlet):
Available - Magnetic field is formed in the channel due to magnetic plates
are close to the channel. Dis-
abled - Magnetic field disappears in the channel due to
magnetic plates are separated from the channel.
Filtration – the outlet filtration side is open, discharge side is closed

Discharge – the outlet discharge side is open, filtration side is closed.

Filtering: On – the channel is working in automatic filtering mode

OFF - the channel isn’t working in automatic filtering mode

Discharging: On – the channel is working in automatic discharging mode

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OFF - the channel isn’t working in automatic discharging mode

Ready: On – the channel is ready

OFF - the channel isn’t ready

Operating mode: Manual mode – the system is working in manual mode

Auto made – the system is working in automatic mode

Air supply: On – the air supply valve is open

Off - the air supply valve is closed

2，Process Time Setting And Running

The time setting and running panel is in the middle of the control window, please find the picture P5.4-3，

Process Time Setting & Running. This panel is used to set and show the process time – filtration time and

discharge time.

Filtration is timed by minute. Right dialog is for setting time and the left is for running time. The maximum

setting time is 1440 and the minimum is 5.

Discharging is timed by is second. Right dialog is for setting time and the left is for running time. The maximum

setting time is 120 and the minimum is 20.

P5.4-3，Process Time Setting & Running

How to set the setting time? For example, click the dialog of filtration time setting, then the keypad panel will

be shown as picture P5.4-4，Keypad Panel. Input 600 and push “Enter” button, and the filtration setting time will

be changed to 600. The same practice for setting discharge time.

P5.4-4，Keypad Panel

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3，System Operation

There are 4 buttons in the system operation panel.

Manual button: Click manual push button ,the system operating mode will be changed to manual

Auto button: Click auto push button, the system operating mode will be changed to automatic control

Exchange button: Used for exchanging when the system in automatic mode. This button will be out of work

when the system in manual mode or the standby channel is not ready

Man. Panel button: The manual operation panel will be shown if click this button

P5.4-5，System Operation Panel

4，Manual Operation

Click “Man. Panel” button, and picture P5.4-6 will be shown on the manual operation panel which is used to

control the system in manual mode. Click the ”x” on the right top of the panel to stop the operation

Mat. Inlet buttons: “Left on” button is used to change the inlet to the left side. ”right on” button is for right

side .

Left mag. plates buttons: “Mag. On” and “Mag off” buttons are used to control left magnetic plates to

keep close or stay away from the left channel.

Left outlet buttons: Filtration and discharge buttons are used to select the left outlet at filtration side or dis-

charge side.

Right mag. plates buttons: “Mag. On” and “Mag off “buttons are used to control right magnetic plates to

keep close or stay away from the right channel.

Right outlet buttons: Filtration and discharge buttons are used to select the right outlet at filtration side or

discharge side.

Air supply buttons: “On button” is used to open air supply valve and “off button” is used to close the air

supply valve.

P5.4-6，Manual Operation Panel

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5，System Time Setting

Click the clock at the left bottom of the control window, the panel of time setting will be shown which is used

to set system date and time. The setting way is same as process time. The panel will be closed if Click the ”x” on

the right top

P5.4-7，System Time Setting Panel

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6. Trouble Shooting

[Table 6-1 Trouble Shooting]

Serial Abnormal
Analysis Handling
No. Status
Used over the design temperature,
Replace the magnetic plate
magnetic plates have degaussed
The filtering
6.1 The magnetic plate and the pipe are
effect get worse See 6.3
not close, low magnets in the pipe
Poor outlet seal Replace the outlet selector
There is too Clean the inlet or replace the inlet
The inlet selector is not in position
6.2 much material in selector
the discharge The inlet selector is not in position Replace the outlet selector
The magnetic Air supply issue See 6.4 and 6.5
plate can not Magnetic plate mechanical issue Fix the mechanical issue
6.3
close to the There are something between the
Clean the magnetic plate
pipe magnetic plate and pipe
There isn't are Air source faults Check the air soure
6.4 pressure of air Tubing clogging Unchoke the clogging
supply The air supply unit valve is not closed Close the valve
The adjustment of air supply unit is Adjust the adjustment of air supply
Air pressure is
6.5 too low unit
too low
Tubing leakage Replace the damaged tubing
Magnetic can Cylinder issue See 6.7
6.6
not move Magnetic plate mechanical issue Fix the mechanical issue
Cylinder does Air supply issue See 6.4 and 6.5
6.7
not work Solenoid valve fault Replace solenoid valve
Check the power supply or protect
Power off
breaker in the control canbinet
HMI doesn't
6.8 The power plug of HMI is loose Tighten the power plug
work
The emergency stop button is not
Reset the emergency stop button
reset
PLC doesn't work well Replace the PLC
communication
6.9 Tighten the patch cable between
failure Patch cable is loose
PLC and HMI

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7. Maintenance

7.1 Attentions before Maintaining

Please pay attention to follow matters before maintaining:

1. Stop the equipment working, disconnect air and power supply.

2. Read the 1.6 Safety section of this manual carefully and pay attention to the relevant reminder.

3. Don’t open the door of the control cabinet in case of the dust or dripping water.

7.2 Maintenance

1. Check the air tubing connection and connecting parts quarterly and fix problems timely. Check the air

tightness of each connection regularly.

2. Check regularly whether the magnetic plates attract iron or not.

3. Check the control system every six months and check whether the wiring terminals are loose or not.

4. Check regularly whether the air pressure is within the required range.

5. Inspect the SUC part once a day. If the condensed water in the plastic bowl is more than 1/3 of the capacity,

manual draining is required.

6. Check regularly whether the magnetic plates run normally or not.

7. Check the coating of tungsten carbide on plate quarterly.

8. Check the working condition of the plate in the inlet selector and check whether plates run in place or not.

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8. Lifting、Transit & Storage

8.1. Lifting and Transit Note

1. The equipment should be in a vertical state and move slowly in the lifting process.

2. Lifting should take the lifting bracket as the stress point, see picture P8.1-1.

P8.1-1，Lifting Bracket

3. In the transit, the package should be tied securely and vertically seated. Do not have it laid down and or tilt,

and take measures of anti-vibration, anti-collision, anti-skid, anti-collapse.

4. Important Note：On receiving the goods, the consignee must check if there are no defect and or damage

deriving from the transport and or the incompleteness of supply. And the defects, damage and incomplete-

ness must be notified to the manufacturer in written and countersigned by the haulage contractor within

48 hours after receipt of goods.

5. How to lift? Disassemble the protective frame from the equipment first, then lift the equipment like picture

P8.1-2 Lifting.

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P8.1-2，Lifting

8.2. Storage Conditions, Period and Note

When the equipment is not installed immediately, it shall be stored in a dry and ventilated indoor space, and

to avoid the sharp change of ambient temperature.

When it must be stored for an extended period (≥ 3 months,＜2 years at most), ensure the ambient tem-

perature is not less than +5℃ and relative humidity is not more than 60% .

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