Eclipse Magnetics Boilermag XL User manual

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Operating Instructions
Boilermag XL
Filter
High Intensity Magnetic Separator
Technical data is subject to change without
notice due to technical innovation!
Eclipse Magnetics Ltd
Atlas Way, Atlas North, Sheffield, S4-7QQ, England
Tel: ++44 (0)114 225 0600 Fax: ++44 (0)114 2250525
[e-mail]
www.eclipsemagnetics.com
20130531

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Table of contents
1Introduction 3
1.1 Range of application 3
1.2 Used symbols 3
1.3 Legal basis 3
1.4 Overview 4
2Technical data 6
2.1 Performance data 6
2.2 Noise data sheet 6
2.3 Dimensions 7
3Design and method of operation 7
3.1 Method of operation 7
3.2 Constructional design 7
4Safety 8
4.1 Intended use 8
4.2 General preventive measures 8
4.3 Dangers during neglect of the safety notes 8
4.4 Safety notes for operation and maintenance 8
4.5 Notes on residual risks 9
4.6 Consequences with arbitrary change 9
4.7 Prohibited operation 9
5Installation / Operation 9
5.1 Mechanical installation 9
5.2 Connections 10
5.3 Setting of the operating parameter 10
5.4 Cleaning 10
6Maintenance 14
6.1 General notes 14
7Service 14
7.1 Service address 14
8Shipping, preservation, waste disposal, transport, storage 15
8.1 Shipping, preservation, waste disposal 15
8.2 Transport 16
8.3 Storage 16

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1 Introduction
1.1 Range of application
The Boilermag XL follows on from the standard Boilermag family and has all the same incredible
benefits. The unit was developed to suit larger domestic boiler systems and small commercial
systems.
Boilermag XL is designed to be installed on the return line to the boiler and will ensure that even sub
micron magnetic and paramagnetic particles are removed before they can cause any expensive
damage.
For further information relating to the standard benefits and operation please refer to the
downloadable Boilermag brochure on our website –http://www.boilermag.com/.
The filter is not to be used with a corrosive or aggressive medium.
Pressure rating –Standard filter is designed and tested to operate at 6 bar max line pressure.
1.2 Used symbols
1.3 Legal basis
This device corresponds to the machine guideline 206/42/EC.
= Important notes
= Danger notes
= Safety notes

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1.4 Overview of Boilermag XL
Magnet Core Assembly
Filter Body
Details of magnetic circuits
showing open flow path
through bowl even when core
is fully contaminated.

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Magnet Core
Assembly
Filter Body

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2 Technical data
2.1 Performance data
Design Temperature: 5 to 150°C
Maximum Operating Pressure: 6 bar
Vessel Construction Stainless steel
Magnetic Material: NdFeB N42SH
Port size: 1.1/2” BSP
Port size: Optional 1.1/2” NPT
Contamination capacity: 1kg
Vessel Volume 1.4 Litres
Vessel Weight 5.4 kg
2.2 Noise data sheet
Sound pressure level, measurement according to DIN 45635:
Idling < 70 dB(A)
Conveying < 70 dB(A)

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2.3 Dimensions
3 Design and method of operation
3.1 Method of operation
The single magnetic rod is integrated in a stainless steel housing and forms one unit e.g. fitted in
series with the pipe-line. The flow is arranged in such a manner that the material that is to be cleaned
is well distributed and comes intensively into contact with the magnetic field.
3.2 Constructional design
Stainless Steel Construction
Viton O Ring
1/2” Drain Plug
High Intensity magnetic rod

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4 Safety
4.1 Intended use
The inline liquid filter is designed for installation into pressurised pipe lines working at up to 6 bar. All
pipeline connections are to be installed accurately and sealed to prevent the loss of pressure/product.
The lid seal is to be maintained in a good condition.
To ensure that the supplied magnets maintain their high level of performance, attention must be paid
to the following conditions:
1. NO temperatures above the specific operating temperature
2. NO oscillating vibrations
3. NO impacts
4. NO strong external flux fields
5. Pay attention to the cleaning and maintenance of the system
4.2 General preventive measures
The rod is constructed with strong magnets. The handling of ferrous tools (e.g. with maintenance or
cleaning) etc. can cause risk of injury for the personnel due to the magnetic attraction.
Special measures regarding the presence of ferrous items have to be considered when handling
magnetic material.
4.3 Dangers during neglect of the safety notes
Using this equipment in a manner not intended can present safety hazards.
4.4 Safety notes for operation and maintenance
Maintenance work is to be executed only by qualified personnel.
With work on pneumatic, hydraulic, pressurised or electrical services the supply lines are
to be isolated prior to any cleaning or maintenance actions.
Prior to any maintenance work being carried out, the process, equipment used and personnel must be
risk assessed and deemed suitable to conduct that task. All work is to be carried out in accordance
with local and legislative regulations.
WARNING! This system incorporates strong permanent magnetic materials. Please pay attention to
the safety notes in order to avoid personal injury or material-damage:
Operators fitted with heart pace-maker’s shall not come within 1m of the equipment.
Oppositional poles of magnets attract each other with high clamping forces.
Do not use steel/iron tools or other ferrous parts in the flux field of the system.
Data carriers, credit cards, computer drives etc can be erased by the influence of the magnetic
field. Keep electronic and sensitive mechanical units (i. e. watches) away from the magnet.
Please contact our service department before welding or drilling works on the unit.

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4.5 Notes on residual risks
Vent any trapped pressure from the process line prior to working on the unit.
4.6 Consequences with arbitrary change
With arbitrary change or repairs all warranties and assertions delivered by the manufacturer become
void.
Only genuine o.e.m. parts are to be used in any repair to maintain the manufacturer’s warranty.
4.7 Prohibited operation
The unit must not be subjected to any high external loads or induced vibrations.
5 Installation / Operation
5.1 Mechanical installation
For optimum performance the unit is to be installed as follows:
Before installation ensure that all supplies are isolated.
Boilermag XL is to be installed vertically with the bowl pointing downwards; this allows fluid to
drain out of the bowl prior to cleaning.
It is recommended that Boilermag XL is installed on the return line of the heating system just
prior to the boiler.
If the Boilermag XL is to be installed using flexible hoses, please ensure the unit is suitably
supported.
The function of the magnetic core ‘cartridge’ is direction specific. When installing please
ensure the mesh segment is on the outlet side of the pipework.
If the system is subject to pressure surges install a pressure regulator set at 6bar prior to the
Boilermag XL.
oSeal mating piping joints effectively to reduce pressure/product loss
oErect signage in the close proximity warning of hazards presented by permanent
magnets, ie pace makers and the dangers of opening the magnet housing whilst
product is flowing.
oInstall in location with adequate free space to withdraw magnet cartridge from vessel
for cleaning
oConsider manual handling regulations when deciding installation location

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5.2 Connections
No external power sources required for this product
5.3 Setting of the operating parameter
No customer adjustment available to this unit
5.4 Cleaning
If operated and cleaned correctly your Boilermag XL will give many years of trouble free filtration with
no consumable parts. The filter will remove even the smallest particle due to its high magnetic filed
strength. Cleaning should take no more than a few minutes.
Turn off the heating system
Isolate the filter from the system flow
Using Screwdriver, open the air vent in the top of the filter
Remove the Drain Plug using Tool provided.
Fully drain contents into a suitable container.
Using the Tool provided, unscrew and remove M8 Domed nuts / Washers
Lift the Magnet Cartridge Assembly out of the body and move it away to a cleaning station.
Non-magnetic contamination will remain in the bottom of the bowl and requires rinsing out
Remove the Quick release Mesh Plate from the Magnet Core Assembly and rinse clean
Using the cleaning tool provided, scrape the bulk of the ferrous contamination off the magnet core
and into a suitable container –it is not essential to remove all of the collected contamination
Refit the Mesh Plate to the Magnet Core Assembly
Re-assemble the Magnet Cartridge Assembly into the body
Refit and tighten M8 Domed Nuts / Washer
Refit the Drain Plug
Close vent
Remove the Filter isolation
Carefully open the air vent to release any trapped air
Close Vent
Switch on the heating system
Do not use corrosive substances to clean the equipment

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Remove Core from Body
Dismantling Instructions
Loosen Drain Plug
using Tool Provided
Remove Drain Plug

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Rotate Mesh Plate
Counter Clockwise
Remove Mesh Plate
(Before cleaning Magnet Core)
Dismantling & Cleaning Mesh
Instructions

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Cleaning Magnet Core Instructions
Scrape Contamination in
a downwards movement
using Tool Provided

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6 Maintenance
6.1 General notes
Keep the system clean, especially the magnetic rods
Regular check of the seal for defects
Regular check of the housing and the tube surface for wear
Do not clean with aggressive cleaner!
Do not clean the rod with water!
Moisture on the bar magnets leads to corrosion and possible damage to the system.
It is strongly recommended that regular inspections are carried out to check for
moisture and that appropriate action is taken to ensure the bar magnets are dried
thoroughly.
7 Service
7.1 Service address
Manufacturer:
Eclipse Magnetics Ltd
Atlas Way, Atlas North
Sheffield, S4 7QQ
England
Tel.: [phone]
Fax: [phone]
E-mail: [email protected]
Internet: www.boilermag.com
www.eclipsemagnetics.com
Sales/Service: Phone: ++44 (0) 114 2250550
Representative:

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8 Shipping, preservation, waste disposal, transport, storage
8.1 Shipping, preservation, waste disposal
1.
Select a suitable packing depending upon type and range of the transmission (export,
sea air freight, truck national, internationally). The packing must be selected in such a
way that under normal transport prerequisites no damage to the commodity can
occur.
2.
National transmissions are packed exclusively truck-transportable depending upon
scope, weight and condition of the commodity in cardboard, cardboard pallets etc..
When filling and protection material in the packing strengthened cardboard,
cardboard, air cushion foil and shred paper used.
On the packing outside warning labels are additional to attach, e.g.: 'Caution! High-
energy magnet. Do not throw'. The packing is locked with tape and with weights
starting from 50 kg additionally with safety tape.
2a.
International truck transmissions are packed accordingly to point 2, larger and
heavier transmissions depending upon protection neediness also export-fairly in
wooden boxes. To corrosion protection in the packing is to be paid attention.
Easily corrosive sections are to be packed up before the packing in oiled paper or
corrosion protection foil. It is to be made certain that the packed sections in the
packing become secured against slipping.
2b.
International air fright transmissions are to be packed accordingly in wooden boxes or
in export packaging. You have to ensure that the maximum values of magnetic field
strength are not exceeded, when sending by air-freight (IATA Dangerous Medium
Prescript “Cap. 3.9.1.2. Magnetized Material”; ICAO Instructions “Packing Instruction
902”). On charge protection within the packing is absolutely to note (this can be
achieved by screw connections or keying). Corrosion protection with susceptible
sections is to attach (oiled paper, protective plastic film, corrosion spray etc.).
2c.
Seaworthy export supplies are to be packed in seaworthy export crates. The crates
are made particularly and accurate to size, relating to orders by drawer operations.
Crates are to be laid out with oiled paper corrosion resistant and seawater.
Commodity is to be protected from corrosion additionally with spray or protective
plastic film.
It is to be made certain that the transmissions in the crate become secured against
slipping (this can by woods, wood slats and additional screw connections takes
place). After the packing the sea-crates are to be nailed correctly or bolted. The sea-
crates with safety tape become additional secured.
With the loading it is to be guaranteed that the transmissions become correctly and
surely stowed away and secured. The transfer and loading correct of the transmission
on means of transport are by the carrier on the waybill to certify on the load list, etc..
3.
Waste disposal: Observe the national waste disposal regulations.

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8.2 Transport
In order to avoid injury or damage to the unit it must be handled properly. In addition to
following the instructions below, general health and safety good practice and specific
accident prevention guidelines should be observed.
For correct handling and storage comply with the following symbols:
Protect against moisture
Careful: glass
Up
Centre of gravity
Do not compress the side walls of the unit or any attached parts by pulling obliquely on
ropes or chains.
Only remove handling safeguards once all installation work has been completed.
When handling in a loading area make sure the unit cannot topple over or slip.
Damage caused during transportation must always be reported to the manufacturer.
8.3 Storage
If possible the unit should be stored in a closed room until final installation.
If the unit is stored in the open it must be covered over with tarpaulins and open
underneath, to allow condensation to drain off.
If the unit has been packed for transportation by sea the packaging must not be
damaged or opened during transit and storage.
For correct storage comply with all storage and handling symbols:
Protect against moisture
Careful: glass
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