C1000-R3.

Installation, Operations, and Maintenance Manual

6.13 Service Record

DATE

SERVICE MAINTENANCE PERFORMED

COMMENTS

Photocopy additional pages if required.

Sepro Mineral Systems Corp.

Page | 6-12

C1000-R3.1

Installation, Operations, and Maintenance Manual

6.14 Maintenance Schedule

FUNCTION

SECTION

FREQUENCY

Check Air System

3.6

Daily

Check For Plugged Heavy Fraction Throttling Nozzles

6.3

Weekly

Inspect Throttling Valves / Nozzles For Wear Or Damage

6.3

Weekly

Inspect Throttling Valve Operation

4.10, 5.3

Weekly

Inspect Heavy Fraction Discharge Launder

6.4

Weekly

Check Rotating Union

6.5

Weekly

Grease Rotor Bearings

6.2

Weekly

Inspect Drive Belt Tension and Condition

6.6

Monthly

Clean/Replace AutoPAC Air Filter

Monthly

Inspect Impeller, Rotor And Linings For Wear Or Damage

Monthly

Remove Top Section Of Discharge Head And Check For Wear

6.4

Semi-Annually

Grease Motor Bearings

6.1

Annually

Inspect Motor Bearings And Wiring

Inspect Rotor Bearings For Wear And Contamination
Check All Fasteners Are Tight (Particularly Rotor Shaft/Bowl)

Annually
6.8

Annually
Annually

Clean Entire Machine Of Grease And Dirt

Annually
Touch Up Paint To Avoid Rust
The above is a recommendation, and based on a projected operation of 24 hours a day and 7 days a week.
The maintenance frequencies should be adjusted accordingly depending on equipment usage.

Sepro Mineral Systems Corp.

Page | 6-13

C1000-R3.1

Installation, Operations, and Maintenance Manual

Contents
7

TROUBLESHOOTING .................................................................................................................................... 7-1

7.1 CONCENTRATOR ................................................................................................................................................. 7-1
7.1.1
Operation ............................................................................................................................................. 7-1
7.1.2
Metallurgy ............................................................................................................................................ 7-2
7.1.3
Table 7.1.1 Heavy Fraction Pull vs. Stability (50 t/h solids) .................................................................. 7-2
7.2 AUTOPAC.......................................................................................................................................................... 7-2

Sepro Mineral Systems Corp.

Page | i

C1000-R3.1

Installation, Operations, and Maintenance Manual

7.1.2 Metallurgy
Changing certain operating conditions may make a small or a significant difference in metallurgical
performance. It is recommended that a test program be implemented upon installation of the machine in
order to find the optimum conditions.
However, keeping all other operating conditions constant, it is generally simple to estimate which pull of
the heavy fraction will achieve the desired metallurgical performance.
For example: (differences may be exaggerated)

7.1.3 Table 7.1.1

HEAVY
FRACTION
2.5 TPH
5.0 TPH
7.5 TPH
10 TPH

Heavy Fraction Pull vs. Stability (50 t/h solids)

%
PULL
10
20
30
40

OPERATING
STABILITY
Stable
Stable
Stable
Unstable

METALLURGICAL PERFORMANCE /
HEAVY FRACTION CHARACTERISTICS
Very high grade, low recovery
High grade, medium recover
Medium grade, higher recovery
Low grade, highest recovery

To change the amount of heavy fraction discharge, it is usually only a matter of adjusting the operating
pressure of the throttling valves.

7.2

AutoPac

Please consult 4. AutoPac section for troubleshooting information. If a problem is suspected, please follow
the following procedure before contacting the factory or representative:
1.
2.
3.
4.
5.
6.
7.

Check that rotor spins freely by hand.

Read and understand AutoPac section, including Control Philosophy.
Check all VFD parameters for correct settings.
Check all operating settings.
Check all voltages.
Check brake resistors.
Check supplied air pressure.

After following the above procedure, please fax or email a complete description of the problem(s) to the
factory or representative prior to contacting. This will help reduce the time needed to reply with specifics
to the problem(s).

Sepro Mineral Systems Corp.

Page | 7-2

C1000-R3.1

Troubleshooting

7.1

Concentrator

Installation, Operations, and Maintenance Manual

The Falcon continuous concentrator was developed to achieve a continuous discharge of the heavy fraction
of a particular feed stream. It does this by retaining the heavy fraction against the smooth rotor wall behind
a single top lip, and discharging the heaviest layer(s) continuously at a controlled variable rate through a
series of plane mass flow hoppers with variable diameter orifice throttling valves. No feed interruptions are
required and no process water is added. The heavy fraction is effectively de-slimed and partially
dewatered.
In any given application, there will be numerous variables working to produce conditions specific to that
application. The main constant operating characteristic of the machine is a steady stream of high pulp
density heavy fraction being discharged.
In a short period of time the machine operators will gain an understanding of the operating characteristics
which indicate optimum performance, in addition to feed, tails and concentrate laboratory analyses.

7.1.1 Operation
Most of the production Falcon continuous concentrators are installed following a procedure of establishing
performance through test work. Usually before installation, there is an expected performance targeted
based on this test work.
The natural ability of the machine to achieve a steady and consistent flow of the heavy fraction is the main
objective, with optimum metallurgical results investigated by changing certain operating conditions. Some
of these are:
1.
2.
3.
4.
5.

Feed rate and/or pulp density.

Thickness of the bed.
Rotational speed of the rotor.
Throttling nozzle operating pressure.
Throttling nozzle purge cycle/time.

A description of these can be found in section 5. Start-up and Operation. During the commissioning visit,
it is the purpose of the representative to thoroughly train the operator(s), transferring operational
knowledge. The effect(s) of changing one or more of the above operating conditions can be observed quite
easily, giving the operator(s) a more thorough understanding of the operational principles.
If the machine is not producing a steady, consistent flow of the heavy fraction, most likely there is a
problem with inconsistent feed or inadequate air pressure to the throttling nozzles.

Sepro Mineral Systems Corp.

Page | 7-1