Summary
Detailed instructions are provided with each unit. Here we outline general rules for safe installation of the Magnom units.
The following instructions are generic and are intended to give an indication of what is required to safely install and operate Magom™ products.
1 General Safety Information
Safe operation of any Magnom™ product can only be guaranteed if it is properly installed, commissioned and maintained by a qualified person in compliance with the operating instructions. General installation and safety instructions for pipeline and plant construction / on-vehicle piping, as well as the proper use of tools and safety equipment, must be complied with.
1.1 Tools and Consumables
Before starting work ensure that you have suitable tools and /or consumables available. Use only genuine Magnom™ replacement products supplied by FCS Limited.
1.2 Protective Clothing
Consider whether you and other personnel in the vicinity require any protective clothing to protect against potential hazards, for example chemicals, high/low temperature, noise, and dangers to eyes and face.
1.3 Permits to Work
All work must be carried out or be supervised by a suitably competent person. Installation and operations personnel should be trained in the correct use of a Magnom™ product according to our installation and maintenance instructions.
Where a formal permit to work system is in force it must be complied with. Where there is no such system, it is recommended that a responsible person should know what work is going on and where necessary arrange to have an assistant whose primary responsibility is safety. Post “warning notices” if necessary.
1.4 Handling
Manual handling of large and or heavy products may present a risk of injury.
Lifting, pushing, pulling, carrying or supporting a load by bodily force can cause injury particularly to the back. You are advised to assess the risk taking into account the task, the individual, the load and the working environment and use the appropriate handling method depending on the circumstances of the work being done.
1.5 Isolation
Consider whether closing isolation valves will put any other part of the pipework system or personnel at risk. Dangers might include isolation of vents and protective devices or alarms. Ensure that isolation valves are turned off in a gradual way to avoid pipework system shocks.
1.6 Pressure
Before attempting any maintenance consider what is or may have been in the pipeline. Ensure that any pipeline pressure is isolated and safely vented to atmospheric pressure before attempting to maintain a Magnom™ product. Do not assume that the pipework system is depressurised even when a pressure gauge indicates zero.
1.7 Temperature
Allow time for temperature to normalise after isolation to avoid the danger of burns and consider whether protective clothing (including safety glasses) is required.
1.8 Residual Hazards
Many pipework products are not self draining. Take care when dismantling or removing a Magnom™ product from an installation.
1.9 Rubber O-ring
If parts made from rubber are subjected to temperatures around 260ºC or higher they will give off toxic fumes which if inhaled are likely to cause temporary discomfort. All Magnom™ products contain rubber o-rings. It is essential for a no-smoking rule to be in force when installing or maintaining any Magnom™ products.
2 Disposal
All Magnom™ products are partially recyclable. No ecological hazard is anticipated with the disposal of any Magnom™ product. Magnom™ products are made of metal, plastic and rubber. All metallic parts are recyclable. Rubber o-rings and plastic components can only be disposed of by approved methods and not by incineration. Hence keep rubber and plastic parts in a separate container, do not mix with other rubbish and consign it to a landfill site or as directed by Government regulations.
3 Returning Products
Customers and distributors are reminded that under EC Health, Safety and Environmental Law when returning Magnom™ products to FCS Limited (or any one of our distributors) they must provide information on any hazards and the precautions to be taken due to contamination residues or mechanical damage which may present a health, safety or environment risk. This information must be provided in writing including Health and Safety data sheets relating to any substances identified as hazardous or potentially hazardous.
4 General Product Information
4.1 Description
All Magnom™ units are high quality, high efficiency magnetic filters used to remove ferrous contaminate particles from a variety of hydraulic oil fluids and aqueous solutions.
The use of Magnom™ units on other fluids may be possible but if this is contemplated FCS Limited (or any one of our distributors) should be contacted to confirm the suitability of a Magnom™ unit for the application being considered.
It may be necessary to check material suitability, pressure and temperature and their maximum and minimum values. If the maximum operating limits of the product are lower than those of the system in which it is being fitted or if malfunction of the product could result in a dangerous over pressure or over temperature occurrence then it is vital to ensure that a suitable safety device is included in the pipework system to prevent such over limit situations.
Prior to piping a Magnom™ unit into the pipework system determine the correct installation situation and direction of fluid flow. It is usual for a Magnom™ unit to be pipework supported in a metal piping system. It is usual that the pipework around the Magnom™ unit would be fitted with unions / quick connect fittings so that the Magnom™ magnetic core can be removed easily and quickly.
All Magnom™ units are not intended to withstand external pipework stresses that may be induced by any pipework system to which they are fitted. It is the responsibility of the installer to consider these pipework stresses and take adequate precautions to minimise them by use of appropriate pipework supports and expansion devices.
End connections may be fitted with metal or plastic covers to protect from ingress of debris during shipping. If fitted these shall be removed prior to installation.
It should be noted that one particular feature of the Magnom™ product is it has a minimal pressure drop through it and therefore is particularly suitable for installing upstream of pumps where it can offer additional protection for the pump.
4.2 Operation
All Magnom™ units are high quality, high efficiency magnetic filters that use patented flux plates and a magnet. It removes ferrous particles from a variety of hydraulic oil fluids and aqueous solutions. It is not dependant on flow direction, unless clearly indicated otherwise.
It should be noted that one particular feature of the Magnom™ product is it has a minimal pressure drop through it and therefore is particularly suitable for installing upstream of pumps where it can offer additional protection for the pump.
4.3 Supply
All Magnom™ units are supplied assembled ready for use and installation.
The following optional extras are available:
- A cleaning cabinet.
- An insulation jacket
5 Installation
5.1 General
Consideration should be given to the use of isolation valves, check valves, air bleed valves and drain valves when considering the design of the interconnecting pipework. It is the installer’s responsibility to decide what is appropriate for their installation.
Once the Magnom™ product has been unpacked they should be inspected to ensure that no transit damage has occurred.
The interconnecting pipework should now be installed using appropriate fittings. It is the installer’s responsibility to determine the most appropriate use of components for their situation. Once the interconnecting pipework has been installed check that the o-ring is fitted between the the two body halves and then hand tighten. Once hand tight use a spanner to tighten until the two body halves are joined.
There are 3 main criteria which need to be met in order to ensure that the Magnom™ unit will work effectively and for a long trouble free life.
1 The two body halves must be tightened using a spanner to ensure an even load is applied to the o-ring.
2 Provision must be made to protect products which are not self draining against frost damage in environments where they may be exposed to temperatures below freezing point. For customer convenience an insulation jacket is available as an optional extra.
3 Use only genuine Magnom™ products supplied by FCS Limited.
If these steps are followed then any Magnom™ unit will give years of trouble free life.
5.2 On-vehicle Applications
For on-vehicle applications a Magnom™ unit should be installed on the low pressure side of the vehicle hydraulic system. Do not install a Magnom™ unit directly into the vehicle reservoir or pump but instead use two short pieces of flexible hose to suspend the Magnom™ unit between two fixed points within the vehicle system. Once installed turn on the engine and inspect all connections to ensure that there are no leaks.
6 Commissioning
Once the pipework installation has been completed the following steps should be taken in sequence to commission a Magnom™ unit.
All isolating valves should be gradually opened to allow fluid into the housing at a controlled rate. Any air bleed valves fitted to the pipework system will need to be opened and closed as necessary. During this time all connections should be inspected for leaks. If leaks are observed then any isolating valves should be closed and any joints should be appropriately retightened. It may be necessary to drain down the system prior to retightening joints and it is the installer’s responsibility to determine this.
Once all joints are tight then the Magnom™ unit can be filled.
After the Magnom™ unit has been in use for some time (determined by experience) the magnetic core assembly should be checked for contaminant and removed for cleaning or replacement as necessary.
We offer a range of optional cleaning cabinets.