Spear & Jackson BoilerMagXL User guide

Installation
and servicing
instructions
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1 Introduction 3
1.1 Range of application 3
1.2 Used symbols 3
1.3 Legal basis 3
1.4 Overview 4
2 Technical data 6
2.1 Performance data 6
2.2 Noise data sheet 6
2.3 Dimensions 7
3 Design and method of operation 7
3.1 Method of operation 7
3.2 Constructional design 7
4 Safety 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
5 Installation / Operation 9
5.1 Mechanical installation 9
5.2 Connections 10
5.3 Setting of the operating parameter 10
5.4 Cleaning 10
6 Maintenance 14
6.1 General notes 14
7 Service 14
7.1 Service address 14
8 Shipping, preservation, waste disposal, transport, storage 15
8.1 Shipping, preservation, waste disposal 15
8.2 Transport & Storage 15
Contents
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3
1.1 Range of application
The BoilermagXL 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.
BoilermagXL 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 – 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 12 bar max line
pressure. (10 bar max line pressure if using the automatic air vent option)
Temperature rating – Standard filter is designed and tested to operate between 5°C to
150°C (If using automatic air vent option the maximum operating temperature is 110°C).
Warranty – To qualify for a 10 year warranty complete and return the card enclosed.
1.3 Legal basis
This device corresponds to the machine guideline 206/42/EC.
1.2 Used symbols
Important notes
Danger notes
Safety notes
1 Introduction
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1.4 Overview of BoilermagXL
Magnet Core AssemblyFilter Body
Details of magnetic circuits
showing open flow path through
bowl even when core is fully
contaminated.
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Domed Nuts &
Washers
Lid
Handle
Baffles
Vent
Magnet Core
Removable
Mesh Plate
ORing
Body
Drain Plug
Lid
Handle
Baffles
Vent
Magnet Core
Drain Plug
5
Magnet Core
Assembly
Filter Body
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2.1 Performance data
Design Temperature: 5 to 150°C (Max 110ºC if using automatic air vent)
Maximum Operating Pressure: 12 bar (Max 10 bar if using automatic air vent)
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)
2 Technical data
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Ø150
155
Ø102
291
Ø150
155
Ø102
291
1 1/2” BSP
female ports
7
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.
tted in series with the pipe-line. The ow 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 eld.
3.2 Constructional design
• Stainless Steel Construction
• Viton O Ring
• 1/2” Drain Plug
• High Intensity magnetic rod
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4.1 Intended use
The BoilermagXL filter is designed for installation into systems working at up to 12 bar (10
bar if using automatic air vent). All 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 preventative 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.
4 Safety
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9
4.5 Notes on residual risks
Vent any trapped pressure from the process line prior to working on the unit.
BoilermagXL is fitted with a manual vent, however, an additional automatic air vent is
supplied in the box. If using the automatic air vent the pressure rating is 10 bar and
maximum operating temperature is 110ºC.
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.
• BoilermagXL 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 BoilermagXL is installed on the return line of the heating system just
prior to the boiler.
• If the BoilermagXL 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 12 bar (10 bar if
using automatic air vent) prior to the BoilermagXL
• Seal mating piping joints effectively to reduce pressure/product loss
• Erect 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.
• Install in location with adequate free space to withdraw magnet cartridge from vessel for cleaning
• Consider 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 BoilermagXL 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 (see Fig 1 page 11)
• Fully drain contents into a suitable container
• Using the Tool provided, unscrew and remove M8 Domed nuts / Washers
(see Fig 2 page 11)
• Lift the Magnet Cartridge Assembly out of the body and move it away to a cleaning
station (see Fig 3 page 12)
• 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
(see Fig 4 page 12)
• 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 (see Fig 5 page 13)
• 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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11
Dismantling Instructions
(Fig 1)
(Fig 2)
Loosen Drain Plug
using Tool Provided Remove Drain Plug
Unscrew and Remove
Domed Nuts / Washers Remove Core from Body
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Dismantling & Cleaning Mesh
(Fig 3)
(Fig 4)
Rotate Mesh Plate
Counter Clockwise
Remove Mesh Plate
(Before cleaning Magnet Core)
Rotate Mesh Plate
Counter Clockwise
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13
Cleaning Magnet Core Instructions
(Fig 5)
Scrape contamination in
a downwards movement
using tool provided
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:
Spear & Jackson
Atlas Way, Atlas North
Sheffield, S4 7QQ
England
Tel: [phone]
Fax: [phone]
E-mail: [email protected]
Internet: www.boilermag.com
Representative:
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15
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.
8.2. Transport and Storage
1 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.
2 For correct handling and storage comply with the following symbols:
Protect against moisture Careful: glass Up Centre of gravity
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While every effort has been made to ensure the accuracy of the information in this
publication please note that specifications may change without notice.
(To suit 2", 3", 4", 6"
8"12"port sizes)
Boilermag
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(22mm/28mm)
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try our range of treatment products
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T: [phone]
F: [phone]
[email protected]