C1000-R3.

Installation, Operations, and Maintenance Manual

Table 4-3: Falcon Concentrator Run Set Points and Status

Run Settings /
Factory
Unit
Range
Description
Status
Setting
High Pressure
230
15
The length of High Pressure time while
Seconds
Time
seconds
seconds
Rinsing
Low Pressure
230
10
The length of Low Pressure time while
Seconds
Time
seconds
seconds
Rinsing
The length of time the Falcon will rinse
Rinse Cycle Time
060
30
for once the rinse speed 1 has been
Seconds
Step 1
seconds
seconds
reached
The length of time the Falcon will rinse
Rinse Cycle Time
0300
60
for once the rinse speed 2 has been
Seconds
Step 2
seconds
seconds
reached
060
10
The length of time before the Falcon
Dry Time
Seconds
seconds
seconds
fully stops after Rinsing
2-10
The length of time before the Falcon
Rinse Delay Time
Seconds
5 seconds
seconds
starts rinsing
Changes the Falcon rinse mode as per
Auto
On / Off
On
the Control Philosophy
Changes the Falcon rinse mode as per
the Control Philosophy. In Manual the
Manual/
On / Off
Off
Falcon will run at rinse speed
Hand
Rinse Mode Select
indefinitely
Changes the Falcon rinse mode as per
the Control Philosophy. In Off, if there
is a stop sequence the Falcon will stop
Off
On / Off
Off
directly without going to the rinse
mode

Sepro Mineral Systems Corp.

Page | 4-13

C1000-R3.1

Installation, Operations, and Maintenance Manual

Drive Settings
The Drive Settings screen allows an operator to adjust and monitor drive settings associated with the run
sequence of the Control Philosophy. See Table 4-4: Falcon Concentrator Run Set points and Status.

Table 4-4: Falcon Concentrator Run Set points and Status

Run Settings /
Factory
Unit
Range
Description
Status
Setting
Run Speed Set
Point

Hertz (Hz)

0 - 60

40

Middle Speed Set

Point

Hertz (Hz)

0 - 60

30

Rinse Speed 1 Set

Point

Hertz (Hz)

0 - 60

1.5

Rinse Speed 2 Set

Point

Hertz (Hz)

0 - 60

20

Sepro Mineral Systems Corp.

Speed Output of the VFD. Determines

the Run speed of the Falcon
Concentrator
Speed Output of the VFD. Determines
the Middle speed of the Falcon
Concentrator
Speed Output of the VFD. Determines
the Rinse speed 1 of the Falcon
Concentrator
Speed Output of the VFD. Determines
the Rinse speed 2 of the Falcon
Concentrator

Page | 4-14

C1000-R3.1

Installation, Operations, and Maintenance Manual

Pressure Setup
The Process EUH (Engineering Unit High) of each instrument can be changed here, though it is imperative it
matches the units and range the instrument is scaled to for the Falcon to operate as intended. See Table 4-6:
Pressure Setting.

Table 4-6: Pressure Setting

Alarm Name

Unit

Range

Factory
Setting

Description

Segment Drop

psi

0-10

Refer to the control philosophy

Segment Jump

psi

0-10

Refer to the control philosophy

Segment Timer

0-999

120

Closed Pressure

psi

200-300 psi

250 psi

High Operating

Pressure

200-300 psi

230 psi

Low Operating

Pressure

50-200 psi

120 psi

Auto

On / Off

On

Manual

On / Off

Off

PSI

0-300 psi

Refer to the control philosophy

The maximum pressure can use at
middle speed
The amount of pressure that the
falcon does not go more than at run
speed
The amount of pressure that the
falcon does not go less than at run
speed
The PID controlling the pressure
according to the control philosophy
The PID setting the pressure for
manual fixed set point
Manual set point for the PID

PID Control
Manual PID SP

Sepro Mineral Systems Corp.

Page | 4-16

C1000-R3.1

Installation, Operations, and Maintenance Manual

Caution: Do not change HMI parameter settings outside given ranges without factory
authorization. Changing some settings may adversely affect machine operation and void warranty.

Resets
Emergency stop button is pressed
Maintenance interval has been reached
Drive Fault
Pressure Low shutdown alarm
Vibration High shutdown alarm

Pull E-Stop button then press the Control Power

Reset button to clear
Reset counter from Maintenance Screen.
Reset the Drive from Drive Screen. If it does not
reset check the fault on the drive keypad.
Reset the Alarm from the Pressure Alarms Screen.
Reset the Alarm from the Vibration Alarms
Screen.

4.5. Rinse and Throttle Functions

Rinse Selection
The rinse function is started during normal shut down or if a pre-set vibration level is detected or if a Rinse
Cycle Time is selected. The rinse cycle is programmable and consists of stopping the feed, running at a slower
speed, injecting water into the rotor and allowing the rotor bowl to clear of material. See 4.10 Control
Philosophy for more detail.

Rinse ON (manual rinse)

The machine will initiate a rinse cycle. From a stop, when the START button is pressed, the VFD accelerates
the rotor to the rinse speed with no feed entering the machine. If at run speed, the VFD decelerates the rotor.
Once at rinse speed the rinse water comes on.
Timers are activated to switch between Rinse Maximum Pressure and Rinse Minimum Pressure, but no run
timers are activated meaning the machine will remain in this state until the operator selects a different
operating mode or stops the machine.

Rinse OFF
When the START button is pressed, the VFD accelerates the rotor to the run speed and feed is introduced. The
Concentrator will process feed continuously. Pressing normal STOP, or if a vibration danger limit shut down
or other fault occurs in the Rinse OFF mode, the machine will stop with no rinsing.
The machine will remain in this state until the operator selects a different operating mode, stops the machine,
or if a shutdown fault is initiated.

Rinse AUTO
When the START button is pressed, the VFD accelerates the rotor to the Middle speed and feed is introduced.
After the Feed U/F delay time is done it accelerates to the Run speed.
Sepro Mineral Systems Corp.

Page | 4-20

C1000-R3.1
Basket
Belt
Grease Motor

Installation, Operations, and Maintenance Manual

Maintenance

0 - 15000 hours

2500 hours

Maintenance
Maintenance

0 - 15000 hours
0 - 15000 hours

2500 hours
2500 hours

The above tables are to guide the supervisor in making changes to the operating parameters, but these should
not be changed unless the user is aware of the purpose of each and what may result.
Note: The upcoming screens can be opened by any level.

Trending Screens
There are 2 Trending Screens, The Real time Trend logs process data as it happens, and only captures a
snapshot of the previous minute of operation.

The Trended Variables:

Drive speed
Pressure
Vibration
Sentronic

Alarms Screens
Alarm Button
Press the Alarm button in the lower left hand corner of each screen to display all the active alarms on the
machine.

Sepro Mineral Systems Corp.

Page | 4-19

C1000-R3.1

Installation, Operations, and Maintenance Manual

Maintenance
The Falcon Concentrator has been programmed to log runtime hours and report critical maintenance intervals.
Both the current hour set points and the time remaining to the next service are displayed here. When a
maintenance service is due, an alarm message will be displayed across the bottom of the current screen and in
the Alarm History Table.
These alarms will not shut down the machine and are resettable once the maintenance service is done. See also
suggested maintenance frequency schedules and instructions in section 6. Maintenance. See Table 4-8:
Maintenance Alarm Settings and Table 4-9: Maintenance Alarm Settings.

Maintenance
Menu
Each hour
counter can be
set for a
scheduled
maintenance
interval

Table 4-8: Maintenance Alarm Settings

Alarm Name

Description

Save Commissioning Setting

Saves all machine parameters and

set points

Restore Commissioning Defaults

Restores saved machine

parameters and set points

Table 4-9: Maintenance Alarm Settings

Maintenance
Menu
Timers
Lubrication
Maintenance
Feed Pipe
Maintenance
Bowl Lining
Maintenance
Lid Lining
Maintenance
Impeller/Baffle
Maintenance

Sepro Mineral Systems Corp.

Range

Factory Setting

0 - 15000 hours
0 - 15000 hours
0 - 15000 hours
0 - 15000 hours
0 - 15000 hours

500 hours
2500 hours
2500 hours
2500 hours
2500 hours

Page | 4-18

C1000-R3.1

Installation, Operations, and Maintenance Manual

Pressure Alarm
The Pressure Setup screen is used to change the alarm Set Points and enable or disable alarms associated
with each instrument. See Table 4-7: Pressure Alarm Set Points.

Table 4-7: Pressure Alarm Set Points

Alarm Name

Unit

Range

Factory
Setting

Description

Low Warning

Psi

100

Self-Reset

Warns that the bowl pressure is lower

than usual

Low Shutdown

n/a

90

Latch

Deadband

Psi

10

n/a

Delay

Seconds

30 sec

n/a

Out of Range

n/a

ON

Self-Reset

Enable / Disable

n/a

ON

n/a

Sepro Mineral Systems Corp.

The bowl pressure is too low for the

Falcon to operate. This will trigger an
auto rinse and the machine will not
restart
An offset added, or subtracted from the
alarm set point to create a reset point
for self-resetting alarms.
The amount of time the pressure needs
to exceed the set point before the alarm
trips
Checks that the pressure signal is
correct. If not all other alarms are
ignored and the Falcon will auto rinse
and stop
Enables or disables an alarm point.

Page | 4-17

C1000-R3.1

Installation, Operations, and Maintenance Manual

Vibration Setup
The Vibration Setup Screens allow an operator to change the alarm set points and enable or disable alarms
associated with the Vibration Sensor. The EUH of the instrument can also be changed here, though it is
imperative it matches the units and range the instrument is scaled to for the Falcon to operate as intended. See
Table 4-5: Vibration Alarm Set Points.

Table 4-5: Vibration Alarm Set Points

Run Settings /
Factory
Unit
Status
Setting

Type

Description
Vibration has exceeded the set point. The
Falcon will adjust pressure to go to under
flow and attempt another run cycle
After a 1st Vibration Warning, Pressure
stabilization delay time
If the vibration has reached critical levels
very quickly the Falcon will auto rinse and
stop

1st Vibration
Warning

Percentage

70%

Latch

2nd Vibration
Warning

Seconds

30sec

Latch

High Vibration
Shutdown

Seconds

90%

N/A

Delay

Seconds

10sec

n/a

The amount of time the vibration needs to

exceed the set point before the alarm trips

Out of Range

n/a

ON

n/a

Checks that the vibration signal is correct.

If not all other alarms are ignored and the
Falcon will auto rinse and stop

Enable

n/a

ON

n/a

Enables or disables an alarm point

Sepro Mineral Systems Corp.

Page | 4-15