14 Longstaff Rd

Bayswater VIC 3153

Ph. +61 (0) 3 8720 0800
Fax. +61 (0) 3 8720 0888
Email. sales@steinert.com.au
Web. www.steinert.com.au

Installation, Operation and

Maintenance Manual
For
Model 77S HE
Electro Overhead Suspension Magnet
Customer: Pt Jaya Mandiri Rekabuana
Contract: 002/PO/V/2010

Serial No: 500042-1

Date: September 2010

Supplier: Steinert Australia Pty Ltd

14 Longstaff Rd
Bayswater VIC 3153
Ph. +61 (0) 3 8720 0800
Fax. +61 (0) 3 8720 0888

Manufacturer: Steinert Australia Pty Ltd

14 Longstaff Rd
Bayswater VIC 3153
Ph. +61 (0) 3 8720 0800
Fax. +61 (0) 3 8720 0888

Equipment: 500042-1-1 Model 77S HE Electro Overhead Suspension Magnet

500042-1-2 Model 77S HE Transformer Rectifier
500042-1-3 10 Tonne Single Rail Suspension Trolley
500042-1-4 Cable Catenary System

P a g e | ii

SERIAL NO| 500042-1

This symbol appears in the manual in connection with those recommendations preventing
danger to the safety of persons operating near the equipment.

These directions should be observed carefully. It must be ensured that any personnel
working at or near this equipment have previously read and understood these operating
instructions before starting any work.

All the requirements of local, state and national regulatory authorities should also be
followed in operating this equipment.

P a g e | iii

SERIAL NO| 500042-1

 Danger: Strong Magnetic Field

As the Model 77S HE is a powerful Electro Magnet which will emit a powerful magnetic field.
The following parameters should be followed when installing and operating the magnet.
Appropriate signage and exclusion zones should be installed depending on the magnets
position, based on these recommendations.

• The maximum permitted limit value for persons with an implanted pacemaker is 1
mT (equal to 10 gauss).

• This value is not exceeded at a distance ≥ 5 m to the strongest magnet.

• With limited exposure, the maximum permitted value for persons without implants is
2 T (20000 gauss).

• The permitted average value for prolonged exposure (approx. 8 hours) is 212 mT.

• The maximum measured values at a distance of approx. 1 m to a magnet with

maximum magnetic field intensity and power of 70 kW were less than 100 mT.

P a g e | iv

SERIAL NO| 500042-1

Table of Contents
PART A  INSTALLATION AND COMMISSIONING INSTRUCTIONS .................. A-1 
A.1  PACKING AND HANDLING DETAILS ..................................................................A-1 
A.1.1  Magnet ..........................................................................................A-1 
A.1.2  Transformer Rectifier .......................................................................A-2 
A.1.3  Trolley...........................................................................................A-3 
A.1.4  Catenary .......................................................................................A-3 
A.2  INSTALLATION INSTRUCTIONS .......................................................................A-4 
A.2.1  Installing the Trolley........................................................................A-4 
A.2.2  Installing the Magnet .......................................................................A-5 
A.2.3  Installing the Transformer Rectifier Cubicle .........................................A-6 
A.2.4  Installing the Catenary System .........................................................A-6 
A.2.5  Installing the Cabling.......................................................................A-7 
A.3  COMMISSIONING INSTRUCTIONS ....................................................................A-9 
A.3.1  Initial Checks .................................................................................A-9 
A.3.2  Trolley...........................................................................................A-9 
A.3.3  Magnet ..........................................................................................A-9 
A.3.4  Heat Exchanger ..............................................................................A-9 
PART B  OPERATION INSTRUCTIONS ........................................................... B-1 
B.1  TECHNICAL INFORMATION ............................................................................B-1 
B.1.1  Magnet ..........................................................................................B-1 
B.1.2  Heat Exchanger ..............................................................................B-1 
B.1.3  Transformer Rectifier .......................................................................B-2 
B.1.4  Trolley...........................................................................................B-2 
B.2  FUNCTIONAL DESCRIPTION...........................................................................B-3 
B.2.1  Heat Exchanger (HE) (if applicable) ...................................................B-4 
B.3  OPERATOR INSTRUCTIONS ...........................................................................B-5 
B.3.1  Local Mode.....................................................................................B-5 
PART C  MAINTENANCE INSTRUCTIONS ....................................................... C-1 
C.1  PRECAUTIONS......................................................................................... C-1 
C.1.1  Restriction of Access ...................................................................... C-1 
C.1.2  Warning to Other Personnel ............................................................. C-1 
C.1.3  Isolations...................................................................................... C-1 
C.1.4  Safety Harnesses. .......................................................................... C-1 
C.2  MAINTENANCE SCHEDULE ........................................................................... C-2 
C.3  TROUBLESHOOTING .................................................................................. C-3 
C.4  MAINTENANCE PROCEDURES ........................................................................ C-4 
C.4.1  Special Tools ................................................................................. C-4 
C.4.2  Magnet Insulation and Resistance Testing.......................................... C-4 
C.4.3  Checking Magnet Oil Level............................................................... C-4 
C.4.4  Replacing Magnet Oil ...................................................................... C-5 
C.4.5  Checking Pressure Relief Valve......................................................... C-5 
PART D  SPARE PARTS LISTINGS .................................................................. D-1 
D.1  COMMISSIONING SPARES ........................................................................... D-1 
D.2  OPERATING SPARES.................................................................................. D-2 
D.3  CRITICAL INSURANCE SPARES ...................................................................... D-3 

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SERIAL NO| 500042-1

PART E  APPENDICES .................................................................................... E-1 
E.1  MATERIAL SAFETY DATA SHEETS .................................................................... E-1 
E.1.1  XL Electrical Insulation Oil ................................................................ E-1 
E.2  DRAWINGS ............................................................................................. E-1 
E.2.1  Magnet GA ..................................................................................... E-1 
E.2.2  Suspension Layout .......................................................................... E-1 
E.2.3  Trolley GA...................................................................................... E-1 
E.2.4  Control Cubicle GA .......................................................................... E-1 
E.2.5  Control Button Layout..................................................................... E-1 
E.2.6  Electrical Schematic Key .................................................................. E-1 
E.2.7  Electrical Schematic ........................................................................ E-1 
E.2.8  Catenary Mechanical Layout ............................................................. E-1 

List of Tables
Table 1 - Local Pushbutton Controls .................................................................................... B-5 
Table 2 - Local Indicators ..................................................................................................... B-6 
Table 3 - Maintenance Cross Reference .............................................................................C-2 
Table 4 - Troubleshooting Table ..........................................................................................C-3 
Table 5 - Commissioning Spares .........................................................................................D-1 
Table 6 - Operating Spares..................................................................................................D-2 
Table 7 - Critical Insurance Spares ......................................................................................D-3 

List of Figures
Figure 1 - Catenary Cabling ................................................................................................. A-7 

P a g e | vi

SERIAL NO| 500042-1

 Part A
Installation and Commissioning Instructions

Part A Installation and Commissioning Instructions

A.1 Packing and Handling Details

A.1.1 Magnet
The magnet is wrapped in a heavy duty plastic wrap to prevent damage to the paintwork
during shipping.

A.1.1.1 Mass
500042-1 Model 77S HE Electro Overhead Suspension Magnet 7800kg

A.1.1.2 Handling Instructions

Warning: A forklift should not be used to unload the magnet. The magnet should never be shipped
on its side or back as damage may occur to the internal coils and oil may leak from the
pressure relief valve.

The magnet is supplied complete with two (2) sets of four (4) lifting lugs, located on the top
surface of the magnet body. The magnet should be loaded and unloaded by lifting from the
set of four (4) inner lifting lugs.

A.1.1.3 Storage Instructions

The Model 77S HE magnet may be stored either inside or outside. Protective packing
around the heat exchanger motors should be left in position until installation. (HE models
only.)

SERIAL NO| 500042-1 P a g e | A-1

 Part A
Installation and Commissioning Instructions

A.1.2 Transformer Rectifier

The transformer rectifier is shipped fully wrapped in heavy duty plastic wrap inside a wooden
crate.

A.1.2.1 Mass
500042-2 Model 77S HE Transformer Rectifier 450kg

A.1.2.2 Handling Instructions

Warning: The Transformer Rectifier is a fragile piece of electrical equipment and should be handled
with care. It should always be kept in an upright position.

The crate containing the transformer rectifier can be moved using a forklift. Once unpacked
from the crate, the cubicle should always be lifted by the bottom plinth, as lifting from any
other points may damage the cubicle.

A.1.2.3 Storage Instructions

Warning: Continuously varying temperatures will cause condensation to build up inside the cubicle.
This moisture may cause damage to internal components due to oxidation.

The transformer rectifier should always be stored under cover, preferably in a dry (non-
humid) environment. This will prevent the buildup of moisture within the cabinet whilst it is in
storage.

During operation, heat from the operating components within the cabinet prevents this
buildup of moisture. In areas with high humidity, a heater within the cabinet should be used.
Contact your supplier for details.

SERIAL NO| 500042-1 P a g e | A-2

 Part A
Installation and Commissioning Instructions

A.1.3 Trolley
The trolley is shipped on a custom made pallet. The trolley is wrapped in heavy duty plastic
wrap to prevent damage to the paintwork during shipping.

A.1.3.1 Mass
500042-3 10 Tonne Single Rail Suspension Trolley 350kg

A.1.3.2 Handling Instructions

The base of the pallet has been constructed to allow movement by forklift.

A.1.3.3 Storage Instructions

The trolley may be stored either inside or outside. Protective packing around the trolley
motor should be left in position until installation.

A.1.4 Catenary
The catenary system is shipped in two packages. The first consists of two (2) 30mm square
rails packed tightly together with packing tape. The second consists of a wooden crate
wrapped in heavy duty plastic wrap.

A.1.4.1 Mass
500042-1-4 (1) Cable Catenary System - Crate 400kg
500042-1-4 (2) Cable Catenary System – Rails 20kg

A.1.4.2 Handling Instructions

The base of the crate has been constructed to allow movement by forklift.

A.1.4.3 Storage Instructions

The catenary system may be stored either inside or outside. Protective packing around the
wooden crate should be left in position until installation.

SERIAL NO| 500042-1 P a g e | A-3

 Part A
Installation and Commissioning Instructions

A.2 Installation Instructions

The individual components supplied need to be assembled in the correct order. The basic
order of installation for the supplied components is as follows:

1. Trolley
2. Magnet
3. Transformer Rectifier
4. Catenary System
5. Cabling

More detailed information is available in the following sections.

A.2.1 Installing the Trolley

When installing the trolley, reference should be made to the trolley GA drawing (500042-3-
TRO-001) and the suspension layout drawing (500042-1-MAG-SPE-001).

The trolley is constructed with removable channels. These channels are disassembled from
the main trolley frame. The main trolley frame may now be lifted into place using soft slings.

Note: Care should be taken when positioning the trolley. Special notice should be given to the
position of the motor and any junction boxes relative to where you intend the supply
cabling to run.

The trolley may now be reassembled around the supporting structure. The main trolley
frame should be supported throughout this process.

Note: When refitting the channels ensure all connecting bolts are tightened to a minimum of 90
Nm.

SERIAL NO| 500042-1 P a g e | A-4

 Part A
Installation and Commissioning Instructions

A.2.2 Installing the Magnet

When installing the magnet, reference should be made to the magnet GA drawing (500042-
1-MAG-77S-HE) and the suspension layout drawing (500042-1-MAG-SPE-001).

Note: The oil level in the magnet should be checked prior to installation. See Section C.4.3 -
Checking Magnet Oil Level for details.

The magnet is supplied complete with two (2) sets of four (4) lifting lugs, located on the top
surface of the magnet body. Using appropriate lifting equipment, the magnet should be lifted
into position using the set of four (4) outer lifting lugs.

Note: Care should be taken when positioning the magnet. Special notice should be given to the
position of the pressure relief valve, terminal box and heat exchanger (if applicable). In all
cases, the pressure relief valve must be located at the high point of the magnet.

With the magnet suspended in position, the permanent suspension slings may now be
attached to the set of four (4) inner lifting lugs and to the trolley.

The suspension slings provided with the magnet are adjustable in order to get the correct
suspension height. If necessary, the magnet position should be adjusted before removing
the lifting equipment.

SERIAL NO| 500042-1 P a g e | A-5

 Part A
Installation and Commissioning Instructions

A.2.3 Installing the Transformer Rectifier Cubicle

The transformer rectifier cubicle should be mounted as close as practicable to the magnet.
For details on the transformer rectifier cubicle, refer to drawings (500042-2-TRA-77S-M-01,
500042-2-TRA-77S-M-02, 500042-2-TRA-77S-M-03, & 500042-2-TRA-77S-M-04.

For information on handling the cubicle, refer to Section A.1 - Packing and Handling Details.

A.2.4 Installing the Catenary System

When installing the catenary system, reference should be made to the catenary GA drawing
No. 500042-4-CAT-30-SPE

30mm heavy duty track is supplied in 4 metre lengths. The track may be cut to length to suit
the application. Joining of the track using the track coupler will require the use of the drilling
jig (provided) for location of the mounting holes.

The track support arms are attached to the support structure using the girder clips provided.
The track is suspended from the track support arms via track support brackets. The drilling
jig will again be provided when attaching the track to the track support brackets.

The track must also be drilled to accommodate the end stop, and end clamp.

The towing trolley, cable trolleys, end clamp and end stops may now be positioned on the
track. The towing arm may be fixed to the trolley in a suitable location.

Warning: The end of the towing arms must pass through the towing trolley such that the towing arm
initiates movement of the catenaries’ trolleys. Not doing so may cause damage to the
cables due to over tensioning.

SERIAL NO| 500042-1 P a g e | A-6

 Part A
Installation and Commissioning Instructions

A.2.5 Installing the Cabling

When installing the cabling system, reference should be made to the termination diagram
500042-4-CAT-30-SPE.This diagram shows which junction boxes, cables, glands and
sensors (where applicable) have been provided as part of Steinert Australia scope of
supply, and those to be supplied by others.

The flat cables(s) are positioned on the catenary trolleys as shown in Figure 1 - Catenary
Cabling.

Figure 1 - Catenary Cabling

SERIAL NO| 500042-1 P a g e | A-7

 Part A
Installation and Commissioning Instructions

Warning: Where cabling is to be provided by others, care should be taken to ensure that the cable is
suitable for the electrical current being carried. Reference should be made to the supplied
drawings and B.1 - Technical Information for details on the electrical requirements for each
item of equipment.

A.2.5.1 Connection to magnet

Cable entry to the terminal box on the side of the magnet is by side entry. A gland plate has
been provided for drilling on site.

Warning: The terminals housed within the magnet terminal box are a permanent seal between
the magnet coils and the atmosphere. Over tightening of the lock nuts can cause the
epoxy seal within the terminal to displace and allow oil to leak from the magnet.
Please ensure that two spanners are used and the lock nut is not pulled down on the
ceramic top.

Warning: Damage to cabling may occur if the cabling is allowed to protrude below the bottom
face of the magnet. Ensure that cabling is routed such that this cannot occur.

SERIAL NO| 500042-1 P a g e | A-8

 Part A
Installation and Commissioning Instructions

A.3 Commissioning Instructions

A.3.1 Initial Checks
Before commissioning, ensure the magnet has been set up in accordance with the
instructions set out in Part A - Installation and Commissioning Instructions.

The following checks should also be made:

1. Confirm that all electrical connections have been completed and approved.
2. Confirm the supply voltage to the transformer rectifier cubicle is correct.

A.3.2 Trolley
The following procedure should be carried out when commissioning the trolley:

1. Bump test each motor to ensure correct direction of rotation.

2. Confirm the operation of the trolley proximity switches and limit switches (if
applicable).

A.3.3 Magnet
The following procedure should be carried out when commissioning the magnet:

1. Remove the DC Fuses

2. Turn the magnet on. The voltmeter on the front of the cabinet should read
approximately 230VDC. The ammeter should remain at zero current.
3. Replace the DC Fuses
4. Turn the magnet back on. The voltmeter on the front of the cabinet should read
approximately 230VDC and the ammeter approximately 90 Amps.

A.3.4 Heat Exchanger

• Bump test each motor to ensure correct direction of rotation. The correct direction
of rotation is indicated on the cowling of the heat exchanger fan and the body of the
pump unit.

Warning: The heat exchanger (where applicable) is covered to protect it from damage during
transport. Ensure this cover is removed before operating the heat exchanger.

SERIAL NO| 500042-1 P a g e | A-9

 Part B
Operation Instructions

Part B Operation Instructions

B.1 Technical Information
B.1.1 Magnet
Model No: Model 77S HE

Serial No: 500042-1

The serial no. is located below the terminal box

Magnet Dimensions: As per Drawing No. 500042-1-MAG-77S-HE

Mass: 7800kg

Operating Current (DC): 90 A cold

75 A hot

Operating Voltage (DC): 230 V

Resistance: 2.6 ohms

Power: 20,700 W

Coolant: XL Electrical Insulation Oil

Oil Quantity: 1300 L

Operating Temperature: 125°C at Core

110°C at Core with Heat Exchanger (if applicable)
90º C on outside face
70ºC on outside face with Heat Exchanger (if applicable)

B.1.2 Heat Exchanger

Pump Motor Power: 0.75kW

Pump Motor Voltage: 380 V

Fan Motor Power: 0.75kW

Fan Motor Voltage: 380 V

Motor Power: 0.75 kW

Motor Voltage: 380 V

SERIAL NO| 500042-1 P a g e | B-1

 Part B
Operation Instructions

B.1.3 Transformer Rectifier

Model No: Model 77S HE

Serial No: 500042-2

The serial no. is located on the front door of the cabinet

Cubicle Dimensions: As per Drawing No. 500042-2-TRA-77S-M-01

Mass: 450kg

Input Current: 50 A

Input Voltage: 380 VAC

IP Rating: IP56

Cable Entry: via Gland Plate on bottom of Cabinet

B.1.4 Trolley
Model No: 10 Tonne Single Rail

Serial No: 500042-3

Dimensions: As per Drawing No. 500042-3-TRO-001

Mass: 350kg

Motor Power: 0.75kW

Motor Voltage: 280 V

Gearbox Oil: Mobil Gear Oil 630 or equivalent

Oil Quantity: 0.5 L

SERIAL NO| 500042-1 P a g e | B-2

 Part B
Operation Instructions

B.2 Functional Description

The tramp magnet system is used to remove tramp metal from the burden of a conveyor.

Under normal operation the magnet is turned on and placed over the conveyor as described
in Part A - Installation and Commissioning Instructions and turned on. When a DC voltage is
supplied to the electromagnet, a strong magnetic field is generated. Tramp metal removed
from the burden will accumulate on the face of the magnet.

At regular intervals the magnet must be manually cleaned of this tramp metal to ensure the
best possible magnetic performance.

Warning: Over time, a buildup of tramp metal will occur on the magnet face. Tramp metal attached
to the magnet face acts to short circuit the magnet. This means that the magnetic field
generated will not be as deep into the burden, thereby decreasing the magnets
performance.

The magnet is supplied with a suspension trolley. It is recommended that the tramp metal
be deposited into a tramp metal bin located beside the conveyor. The trolley allows the
magnet to be moved from its normal location over the conveyor to a position over the dump
bin. The magnet may then be switched off. When power is removed from the
electromagnet, the magnetic field collapses, and any attached tramp metal will dislodge from
the face of the magnet into the tramp metal bin.

Warning: The magnet should not be switched on for at least 60 seconds after it has been switched
off. Doing so may result in damage to the rectifier unit.

SERIAL NO| 500042-1 P a g e | B-3

 Part B
Operation Instructions

B.2.1 Heat Exchanger (HE) (if applicable)

The magnet is supplied with a heat exchanger. The magnet is filled with inhibited
transformer oil. Heat is removed from the magnet by circulating the oil through an external
heat exchanger. The heat exchanger consists of both a pump and a cooling fan. When
running, the heat exchanger system increases the magnetic strength of the magnet by
approximately 15%.

Note: The magnet may operate without the heat exchanger operational. The only effect is to
reduce the magnetic performance by 15%..

SERIAL NO| 500042-1 P a g e | B-4

 Part B
Operation Instructions

B.3 Operator Instructions

B.3.1 Local Mode
The following pushbuttons allow operation of the magnet system in Local Mode. It should be
noted that the Transformer Rectifier unit can only be placed in local mode from the main
control room. These buttons are inactive whilst the transformer rectifier is set to remote
mode.

B.3.1.1 Local Pushbutton Controls

The following buttons are located on the front door of the transformer rectifier cubicle. Refer
to drawing 500042-2-TRA-77S-M-01 for location of these buttons.

Name Type Colour Description

Magnet Start Push Button Black Energizes the magnet.

Magnet Stop Push Button Black De-Energizes the magnet.

Heat Exchanger On Push Button Black Turns the Heat Exchanger On.

Heat Exchanger Off Push Button Black Turns the Heat Exchanger Off.

Moves the Trolley to the Operating Position.

The button does not need to be continuously held in. The

trolley will continue moving to the operating position
Trolley Forward Push Button Black
unless the Trolley Stop button is depressed.

This button will not work if the trolley is already in the

operating position.

Moves the Trolley to the Dump Position.

The button does not need to be continuously held in. The

trolley will continue moving to the dump position unless
Trolley Reverse Push Button Black
the Trolley Stop button is depressed.

This button will not work if the trolley is already in the

dump position.

Trolley Stop Push Button Black Stops the trolley.

Table 1 - Local Pushbutton Controls

SERIAL NO| 500042-1 P a g e | B-5

 Part B
Operation Instructions

B.3.1.2 Local Indicators

The following indicator lamps are located on the front door of the transformer rectifier
cubicle. Refer to drawing 500042-2-TRA-77S-M-02 for location of these lamps.

Name Colour Description

Magnet Green Lamp illuminates when the magnet is energised

Heat Exchanger Green Lamp illuminates when Heat Exchanger is operating

Table 2 - Local Indicators

SERIAL NO| 500042-1 P a g e | B-6

 Part C
Maintenance Instructions

Part C Maintenance Instructions

C.1 Precautions
This section outlines procedures that will ensure an optimum level of safety for personnel
engaged in the maintenance of hoists the magnet system.

Warning: The operation of the magnet system is inherently dangerous failure to understand
and observe the following operational requirements could create a dangerous
situation causing injury or death.

C.1.1 Restriction of Access

Personnel shall not gain access to the suspension magnet, except where such access is
necessary for them to perform their duties.

Personnel requiring access to the magnet shall, prior to gaining access, obtain authorization
from the person responsible for safety within the area in which the magnet is located.

C.1.2 Warning to Other Personnel

The person responsible for safety within the area in which the magnet is located shall ensure
that all personnel within the area, or could enter the area, are warned of any potential
hazards involved.

If there is a danger of falling objects to personnel working below the trolley, the area below
shall be isolated from surrounding areas and a hazard warning sign displayed.

C.1.3 Isolations
All isolations necessary should be carried out before any maintenance work to the magnet
system.

C.1.4 Safety Harnesses.

The installation of the magnet may require working at heights above ground level. An
approved safety harness must be worn in accordance with site specific requirements in
relevant Australian Standards on an open walkway and working away from an enclosed
walkway.

SERIAL NO| 500042-1 P a g e | C-1

 Part C
Maintenance Instructions

C.2 Maintenance Schedule

The following table is a recommended maintenance schedule for the magnet system.

FREQUENCY OF MAINTENANCE.

MONTHS

MONTHS

MONTHS

MONTHS
MONTH
OPERATION TO BE PERFORMED.

12

24

36
1

3
MAGNET

TEST INSULATION AND RESISTANCE. X

CHECK MAGNET BODY FOR OIL LEAKS X
CHECK OPERATION OF PRESSURE RELIEF VALVE X
CHECK OIL LEVEL X
CHANGE OIL X

HEAT EXCHANGER

CHECK PUMP AND RADIATOR FOR LEAKS X

CHECK PUMP COUPLING FOR WEAR X
TEST INSULATION RESISTANCE OF MOTORS X

TROLLEY

TEST INSULATION RESISTANCE OF MOTOR X

CHECK PERFORMANCE OF MOTOR BRAKE, ADJUST IF

X
NECESSARY.
CHECK OIL LEVEL IN MOTOR GEARBOX, ADJUST IF
X
NECESSARY
CHANGE OIL IN MOTOR GEARBOX X
GREASE PILLOW BLOCK BEARINGS X
CHECK SEALS ON PILLOW BLOCK BEARINGS X
CHECK CONDITION OF TROLLEY WHEELS X
Table 3 - Maintenance Cross Reference

SERIAL NO| 500042-1 P a g e | C-2

 Part C
Maintenance Instructions

C.3 Troubleshooting

Trouble What To Inspect Action

Check that all 3 phases are

Complete or Partial Loss of Magnet active
Transformer Rectifier AC Supply
Power
Check AC Circuit Breakers

Check DC fuses and replace as

required.
Transformer Rectifier DC Power
Source Check resistance and insulation on
magnet. See C.4.2 - Magnet
Insulation and Resistance Testing

Inspect rectifier inside transformer

Replace Stack
rectifier unit for possible failure

Belt Slip Motor Drive Check for Sheared Key

Check circuit breakers

Over temperature alarm Check pump and fan are running Check isolation valves are open
Check magnet current and voltage.
Table 4 - Troubleshooting Table

SERIAL NO| 500042-1 P a g e | C-3

 Part C
Maintenance Instructions

C.4 Maintenance Procedures

C.4.1 Special Tools
None Required.

C.4.2 Magnet Insulation and Resistance Testing

Warning: The measured resistance of the magnet is affected by temperature. The magnet
should be tested in the cold condition. Please allow magnet to cool down before
testing.

C.4.2.1 Insulation Test

A breakdown in the insulation of the magnet coils, or the inhibited transformer oil will cause
the magnet to short out.

Dielectric tests, carried out using a 500V megameter may indicate a ground or short inside
the magnet. A reading of five (5) or less may indicates an insulation breakdown. If this
occurs, please contact your supplier.

C.4.2.2 Resistance Test

The resistance of the magnet may be measured using an appropriate Wheatstone bridge
type resistance meter. The resistance of the magnet should be as specified in B.1.1 -
Magnet.

C.4.3 Checking Magnet Oil Level

The magnet oil level may only be checked whilst the magnet is horizontal and in a cold
condition. An oil level plug is located on the side of the magnet. A show of oil should be
present when this plug is removed.

The oil should remain clear and free of contaminants. If oil is turbid or cloudy it should be
replaced. See C.4.4 - Replacing Magnet Oil.
.

SERIAL NO| 500042-1 P a g e | C-4

 Part C
Maintenance Instructions

C.4.4 Replacing Magnet Oil

To replace the oil, the magnet must be lowered to a level surface.

1. Allow magnet to cool (minimum 6 hours)

2. Ensure isolation valves on Heat exchanger are open (if applicable)
3. Remove 1” BSP Fill Plug. This will prevent an air lock from occurring.
4. Remove 1” BSP drain plug and drain oil to waste. Ensure that oil is disposed of
properly.

Note: To assist in draining the old oil into a suitable container, the magnet may be
suspended above the ground using its suspension lugs.

5. Replace 1” BSP Drain Plug and seal with Dow Corning RTV 732 Silicon sealant or
equivalent
6. Remove ¼” BSP oil level plug.
7. Fill magnet with Inhibited Transformer Oil. The magnet is full when oil just dribbles
from ¼” BSP oil level hole. Refer to B.1 - Technical Information for more details on oil
volume and type.
8. Replace all and seal all plugs as previously described.

C.4.5 Checking Pressure Relief Valve

The pressure relief valve is located on top of the magnet body. Over time this valve may
become sticky due to a buildup of oil and dirt.

Warning: When manually operating the pressure relief valve, air may escape at up to 90
degrees Celsius if the magnet has been operating. All necessary precautions to
prevent injury should be taken.

The valve may be operated manually by lifting the spring loaded cap. If the valve feels tight
to operate, lubricate with WD40 or equivalent. If the valve operation continues to feel tight, it
will require replacement.

SERIAL NO| 500042-1 P a g e | C-5

 Part D
Spare Parts Listings

Part D Spare Parts Listings

D.1 Commissioning Spares
Original Contractor’s
Expected Delivery Proposed Holding
Short Item Supplier Equip OEM / Supplier
Item Annual Lead time of Spares
Description Name Name Manufacturer Part No. *
Usage (weeks)
(OEM) Ex Stock

1 FUSE 100 A Fuse Steinert GEC NOS100M100 1 2 0

Table 5 - Commissioning Spares

SERIAL NO| 500042-1 P a g e | D-1

 Part D
Spare Parts Listings

D.2 Operating Spares

Original Contractor’s
Expected Delivery Proposed Holding
Short Item Supplier Equip OEM / Supplier
Item Annual lead time of Spares
Description Name Name Manufacturer Part No. *
Usage (weeks)
(OEM) Ex Stock

1 RECTIFIER Rectifier Steinert Fastron ST6109 0 4 0

2 CONTACTOR MC Steinert Sprecher CA7-60 0 4 0

3 CONTACTOR PC Steinert Sprecher CA7-30 0 4 0

4 PUMP Oil Pump Steinert Regent 25-171-T413 0 2 0

Oil Pump R19.Alu.92.1.16.

5 COUPLING Steinert Regent 0 1 0
Coupling 1.16
0.75kW,
6 MOTOR Pump Motor Steinert WEG 0 3 0
380V,IP65
Heat Fluid
7 RADIATOR Steinert Maxi 60 Special 0 2 0
Exchanger Dynamics
0.75kW,
8 MOTOR Fan Motor Steinert WEG 0 3 0
380V,IP65
0.75kW, 380V,
9 MOTOR Trolley Drive Steinert SEW Output Speed = 0 3 0
42RPM
Table 6 - Operating Spares

SERIAL NO| 500042-1 P a g e | D-2

 Part D
Spare Parts Listings

D.3 Critical Insurance Spares

Expect Contractor’s
Original
ed Delivery Proposed Holding
Short Item Supplier Equip OEM / Supplier
Item Annua lead time of Spares
Description Name Name Manufacturer Part No. *
l (weeks)
(OEM) Ex Stock
Usage

1 TRANSFORMER Transformer Steinert Voller Model 77S 0 6 0

3 SENSOR Oil Flow Sensor Steinert Effector IFM SF-5300 0 2 0

FLOW Effector IFM SR-0102 0 2 0

4 Flow Controller Steinert
CONTROLLER

¼”BSP Pressure Generant VRV-250B-B-5 0 1 0

5 VALVE Steinert
Relief Valve

9 GEAR WHEEL Gear Wheel Steinert Steinert SW150G 0 2 0

TROLLEY Steinert SW150P 0 2 0

10 Trolley Wheels Steinert
WHEELS
Table 7 - Critical Insurance Spares

SERIAL NO| 500042-1 P a g e | D-3

 Part E
Appendices

Part E Appendices

E.1 Material Safety Data Sheets

E.1.1 XL Electrical Insulation Oil

E.2 Drawings
E.2.1 Magnet GA

E.2.2 Suspension Layout

E.2.3 Trolley GA

E.2.4 Control Cubicle GA

E.2.5 Control Button Layout

E.2.6 Electrical Schematic Key

E.2.7 Electrical Schematic

E.2.8 Catenary Mechanical Layout

SERIAL NO| 500042-1 P a g e | E-1

 XL Lubricants Pty Ltd
ABN84 131 080 790

10 Longstaff Rd, Bayswater, Victoria, 3153

Ph: 03 9729 5819 Fax: 03 9738 1382
E: sales@xllubricants.com.au

23rd February 2010

MATERIAL SAFETY DATA SHEET

Not Classified as Hazardous according to criteria of NOHSC Australia

IDENTIFICATION:

XL ELECTRICAL INSULATING OIL

USES: Electrical Insulating Oil.

Product Name: XL Electrical Insulating Oil

Other Names: Transformer Oil
Manufacturer's code: None allocated
UN Number: N/A
Shipping Name: Light Liquid Petroleum Hydrocarbon
Hazchem Code: N/A
Poisons Schedule No: S5

PHYSICAL DESCRIPTION / PROPERTIES:

Appearance: Clear, light amber liquid with a slight characteristic odour

Boiling Point: > I.B.P. 260°C
Vapour Pressure: N/Av
Specific Gravity: 0.88 @ 20°C (Typical)
Flashpoint: >140°C(COC)
Autolgnition Temp: 242°C
Flamm. Limit LEL: N/Av
Flamm. Limit UEL: N/Av
Solubility in Water: Insoluble.

OTHER PROPERTIES:

Viscosity: 2.75 cSt@ 100° C (Typical)

Stability Hazard: Thermally unstable but stable under normal conditions of
storage and handling.
Polymerization: Will not occur.
Materials to Avoid: Oxidising agents.

CHEMICAL COMPOSITION:

Ingredients / Chemicals CAS Proportion

Re-refined mineral oils (C16 -C40) 69029-75-0 >99%
2,6-Ditertiary butyl-4-meth yl phenol 128-37-0 <0.5%
Information on Composition:
Testing for other analyte concentrations has determined results to be below level of
detection as determined by testing conducted by NATA Accredited Laboratory.

HEALTH HAZARD INFORMATION

HEALTH EFFECTS:

Acute-Swallowed: This material is a Scheduled Poison: S5. If swallowed

seek urgent medical treatment. May also cause mild
irritation of the gastrointestinal tract that may include
nausea, vomiting and diarrhoea.

Acute- Eye: Irritation expected with stinging, blurring and tearing.

Acute- Skin: May result in mild skin irritation. In any other event seek
medical assistance.

Acute- Inhaled: Inhalation of vapours or mists in confined, poorly ventilated

areas or at elevated temperatures may cause respiratory
system irritation or other pulmonary effects.

Chronic: No chronic effects expected with this product.

FIRST AID MEASURES:

If poisoning occurs, contact a doctor or Poisons Information Centre (Australia Phone: 131 126,
or in New Zealand 0800 764 766).

Ingestion: This material is a Scheduled Poison: S5. If swallowed seek

urgent medical treatment. If swallowed, do NOT induce
vomiting as aspiration of vomited material may cause pneumonitis.
Rinse mouth with water and give water to drink. If vomiting occurs
give further water. Never give anything by mouth to an
unconscious patient.

Eye: If contact with the eye(s) occur, wash with copious amounts of
water for approximately 15 minutes holding the eyelid(s) open.
Take care not to rinse contaminated water into the non-affected
eye. In all cases of eye contamination it is a sensible precaution to
seek medical advice.

Skin: Remove all contaminated clothing. Wash gently and thoroughly

with water and non-abrasive soap. Ensure contaminated clothing is
washed before re-use or discard. If irritation develops and persists,
seek medical attention.

Inhalation: If affected, remove victim from exposure - avoid becoming a

casualty. Ensure airways are clear and have qualified person give
oxygen through a facemask if breathing is difficult. Keep at rest until
fully recovered. Seek medical advice if effects persist.

Advice to Doctor: Treat Symptomatically.

 FIRE FIGHTING MEASURES

FIRE / EXPLOSION HAZARD:

Fire/ Explos. Haz: Classified as a Cl (COMBUSTIBLE LIQUID). This product will

burn if exposed to fire.

Haz. Combustion Expect Carbon Monoxide, Carbon Dioxide, smoke and fumes.
Products: For fires involving this material, do not enter any enclosed or
confined space without approved self-contained breathing
apparatus (S.C.B.A.) to protect against the hazardous effects of
combustion products or oxygen deficiency.

Extinguishing Use water fog, dry chemical foam, or carbon dioxide. Water
Media: or foam may cause frothing. Use water to cool fire exposed
containers. If a leak or spill has not ignited, use water spray to
disperse the vapours and to provide protection for persons stopping
the leak.

Hazchem Code: None allocated.

SAFE HANDLING INFORMATION

STORAGE AND TRANSPORT:

Storage Store in a cool, dry well-ventilated area away from sources of

Precautions: ignition, any incompatible materials such as oxidizing agents and
out of direct sunlight. Water contamination should be avoided.
Keep containers closed when not in use - check regularly for leaks.
This material is a Scheduled Poison (S5) and must be stored,
maintained and used in accordance with the relevant regulations.

Fire Hazard: Classified as a Class Cl Combustible Liquid for the purpose of

storage and handling, in accordance with the requirements of
AS 1940. Refer to State Regulations for storage and transport
requirements.

Fire / Explosion Hazard Data:

FlashPoint: >140°C(COC)
Flammability Class: N/A
Auto Ignition Temperature: 242°C
Flammability Limits: LEL: N/D % UEL: N/D %
Extinguishing Agents: CO2, dry chemical, foam.
Protective Gear: Wear breathing apparatus.

Transport: Not classified as Dangerous Goods according to the Australian

Code for the Transport of Dangerous Goods by Road and Rail.
SPILLS AND DISPOSAL:

Spills and Leaks: Remove all sources of ignition. Increase ventilation. Evacuate all
unnecessary personnel. Wear full protective equipment and
clothing to minimise exposure. If possible contain the spill. Place
inert absorbent material such as vermiculite, sand or dirt onto
spillage. Use clean non-sparking tools to collect the material and
place into a suitable labelled container. Do not dilute material.
Prevent run-off into drains and waterways. If quantities of this
material enter the waterways contact the Environmental Protection
Authority or your local Waste Management Authority.

Disposal: This material may present environmental risk common to all oil
spills. Dispose of according to Federal, E.P.A., State and local
regulations.

EXPOSURE CONTROLS / PERSONAL PROTECTION

PRECAUTIONS FOR USE:

Exposure Limits: No value assigned for this specific material by the National
Occupational Health and Safety Commission (NOHSC Australia).
However, exposure standards for oil mist are listed below:
SUBSTANCE TWA (8 hr) STEL (15 min)
ppm mg/m3 ppm mg/m3
Oil mist, mineral 5

These Exposure Standards are guides to be used in the control of occupational health
hazards. All atmospheric contamination should be kept to as low a level as is workable.
These exposure standards should not be used as a fine dividing line between safe and
dangerous concentrations of chemicals. They are not a measure of relative toxicity.

Biological Limits: As per the "National Model Regulations for the Control of
Workplace Hazardous Substances [NOHSC: 1005 (1994)]" the
ingredients in this material do not have a Biological Limit
allocated.

Engineer' Controls: Ensure ventilation is adequate to maintain air concentrations below

Exposure Standards. Use with local exhaust ventilation or while
wearing appropriate respirator. Keep containers closed when not in
use.

PERSONAL PROTECTION:

Respirator Type: Type (AS 1716) Where vapours, mists or spray is generated and
risk of inhalation exists, select and use approved respirators with
organic vapour/particulate filters in accordance with AS/'NZS
1715/1716. Filter capacity and respiratory type depends on
exposure levels for each individual circumstance.
Eye Protection: Use safety glasses or face shield as appropriate, especially where
splashing or misting is expected. Reference should be made to the
Australian standard AS/NZS - Eye Protectors for Industrial
Applications.

Protective Wear overalls, safety footwear and impervious gloves, such as those
Clothing: made from nitrile rubber. Work clothes should be kept clean.
Always wash hands before smoking, eating, drinking or using the
toilet.

OTHER INFORMATION:

Conditions to avoid: Elevated temperatures and sources of ignition.

Emergency Contact:

XL Lubricants Pty Ltd

Gerry Richens (after hours contact): 03 9748 2442 or 0417 504 503

This MSDS summarizes at the date of issue our best knowledge of the health and safety hazard information
of the product and how to safely handle and use the product in the workplace. We have no knowledge or
control over the user's working conditions however. The user is responsible for the observance of all
required statutory provisions. Each user should read this MSDS and consider the information in the context
of how the product will be handled and used in the workplace including in conjunction with other products.

These data are based on our present knowledge. However, they shall not constitute a guarantee for any
specific product features and shall not establish a legally valid contractual relationship.