C1000-R3.

Installation, Operations, and Maintenance Manual

The concentrator will process feed continuously until the normal STOP is pressed or if a vibration danger limit
shut down occurs a rinse cycle will also be initiated before the machine stops.

Rinse AUTO is the standard operating mode for most applications.

Throttle Selector Switch
The throttle control functions regulate the throttle valves which meter out pre-determined amounts of
underflow or heavies.
With normal operation this is all done automatically throughout the many operating sequences such as start-up,
rinsing, vibration, etc. The throttle selector switch set to open or close can be used for maintenance purposes or
to run the machine manually for a test or and so forth.

Throttle OPEN
When this is selected, the Pneumatic Proportional Valve, or PPV, exhausts air from the system until the
throttling valves are at OPEN pressure. This can be used to flush the machine or to manually purge the rotor
contents during operation.

Throttle CLOSE
When this is selected, the PPV increases throttling pressure to CLOSED pressure. This is used to establish or
re-establish a consistent rotor bed (to eliminate vibration), test the
System, and clean the machine.

Throttle AUTO
When selected, the PPV controls pressure directed to the throttling nozzles according to program logic. This
includes operating pressure, shut down pressure, rinsing pressure, and so forth. This setting must be selected to
allow the PURGE function to activate.

Normal STOP
The normal STOP should be used for normal shutdowns. This will initiate a rinse cycle
(Except in Rinse OFF) before stopping the machine.

EMERGENCY STOP
The EMERGENCY STOP should only be used only in emergencies. The deceleration time is very short, and
no rinse cycle will be initiated. Also, there will be no delay to allow feed material to empty from the feed
piping, possibly causing a large amount of material to remain in the rotor bowl after the machine is stopped.

Control Power Reset

Once an EMERGENCY STOP condition has been rectified, press the CONTROL POWER RESET button
to reset the machine.

Maintenance Timer (general)

The PLC contains an internal Maintenance Timer that measures the Concentrators running time. When the
Maintenance Timer reaches a programmed time, the maintenance description is displayed on the HMI. This
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C1000-R3.1

Installation, Operations, and Maintenance Manual

can be set up according to site- specific priorities.

4.6. Control Logic

See Control Philosophy and PLC Ladder Logic (if available). The PLC and HMI programs are only available
upon request and accompanying operating software must also be purchased.

4.7. Start-Up Procedure (see also 5. Start-Up and Operation)

This is a procedure for the machine only and must be integrated with plant procedures.
1.
2.
3.
4.
5.
6.
7.
8.
9.

Be familiar with the circuit.

Make sure the machine and AutoPac are properly fastened or mounted.
Check all piping connections and slopes (if gravity fed).
Check that air pressure requirements are met.
Energize the AutoPac and set the parameters (including the VFD).
Select Rinse AUTO and Select Throttle AUTO.
Go to main display screen.
Press Control Power Reset.
Monitor the pressure settings during ramp up, feed introduction, etc. as per the
Control Philosophy.

Caution: Press the EMERGENCY STOP button if there is any problem.

4.8. Common Faults

Caution: Read entire AutoPac section before troubleshooting. See schematic drawings and
consult a qualified electrical technician if there are any problems.

Accel / Decel (VFD trip)

The Braking Resistors control the deceleration of the concentrator to a stop or a slower speed of the rotor (for
rinsing). If the VFD should trip during acceleration or deceleration, reset the VFD and extend the
corresponding ramp times.

Vibration Shutdown
The vibration switch monitors vibration levels, and the AutoPac attempts to correct the vibration and if unable
to do so shuts the concentrator down. If a Vibration Shutdown has occurred, the machine will be stopped and
the related HMI display will register this fault and will display VIBRATION HIGH SHUT DOWN in the
Alarm line Press the RESET, then investigate the cause of the vibration shutdown.
There are two settings in the Vibration Menu; Warning level and Danger level. If a vibration warning level is
detected a START U/F DELAY is initiated and the Pressure setpoint increase by the Segment Jump. If a
Vibration Danger level is detected the concentrator will also shut down with a normal STOP and a display on
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C1000-R3.1

Installation, Operations, and Maintenance Manual

the HMI will indicate that it has shut down due to vibration.

Does not start

The START command will not begin if the normal STOP or EMERGENCY STOP buttons are depressed, if
the CONTROL POWER RESET button is not pressed after an EMERGENCY STOP reset, if a Low
Pressure or Vibration Shutdown has occurred, or if there is a VFD fault. Check the HMI screen.
These faults must first be corrected and/or RESET. If the Machine Not Ready, this indicates a VFD, brake,
or other internal fault. Open the AutoPac cabinet door and investigate.

Low Pressure
If the concentrator has shut down on low pressure this should be displayed on the screen.
The machine may start momentarily in Throttle OFF, but will most likely shut down before it reaches
operating speed. This normally indicates either the low pressure limit being is set too low (0-5 psi), or the
supply pressure is lower than the throttle CLOSE PSI setting.

4.9. External Communication

Sepro Mineral Systems guarantees each AutoPac being fully capable of complete stand-alone operation, and
will commission each installation as such.
The PLC and HMI Ladder Logic Programs can only be accessed using the correct programming cable
connected between the HMI and a laptop, PC, or compatible hand- held device. Software must be loaded into
the computer first, which is available at Sepro Mineral Systems. Call for current price.
Different types of communication/control links between the AutoPac and plant control systems are possible,
the most common being Profibus, Profinet, and Ethernet.
For quotations on further control requirements please contact Sepro Mineral Systems.

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C1000-R3.1

Installation, Operations, and Maintenance Manual

EMERGENCY STOP SEQUENCE (with THROTTLE AUTO and any RINSE option selected)
Max Pressure - Unless power is lost, in which case the machine will coast
to a stop and air pressure would default to zero immediately.
Feed will shut off in the case of a power loss.

SPEED (Hz.) and AIR PRESSURE

Push EMERGENCY STOP Button

or Remote Shutdown Device Tripped.

Machine will not automatically restart.

Run or Rinse Speed
Current Operating Pressure

Output Frequency Detection

Feed

Feed Off

On

Decel time absolute minimum without tripping VFD

Zero
Pressure

1 VIBRATION WARNING LIMIT in RINSE AUTO (with THROTTLE AUTO selected)

st

SPEED (Hz.) and AIR PRESSURE

1st Vibration Warning Limit

(If Vibration Danger Limit is reached, a normal
Shut Down is initiated)

Segment Time

Run
Speed

Segment Jump

Current Operating
Pressure
Output Frequency Detection

Feed On

Vibration Mask Time starts

(ignores vibration

nd

VIBRATION WARNING LIMIT (continued from previous)

Vibration Shut down Limit Reached.

Dry Time - rinse water off and zero

pressure at end of rinse cycle.

There is no rinse cycle in RINSE OFF

Closed Pressure
Run Speed

Decel
Time

Timed Rinse Cycle Step 1 and Step 2

Current Operating Pressure

Rinse Water On
Output Frequency Detection

Feed

Feed Off

On
Rinse Cycle Delay Time

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Rinse Speed Step 2

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C1000-R3.1

Installation, Operations, and Maintenance Manual

continued from previous

RINSE ON RINSE AUTO or OFF (with THROTTLE AUTO selected)

Closed Pressure

Select RINSE
AUTO or OFF

Segment Time
Middle Speed Timer

Feed Start
U/F Delay

Run Speed
Pressure decreases one step
(Segment Pressure Drop)

SPEED (Hz.) and AIR PRESSURE

Maximum Operating Pressure

Rinse Water On
Middle Speed

Feed Off
U/F Produced When at Operating Pressure

Rinse Speed
Step 2

Zero Pressure

START SEQUENCE in RINSE ON Go to RINSE AUTO (THROTTLE AUTO selected)

Select RINSE
AUTO or OFF

Push START button

with RINSE ON
selected

Closed Pressure

Segment Time
Middle Speed Timer

SPEED (Hz.) and AIR PRESSURE

Feed Start
U/F Delay

Run Speed

Maximum Operating Pressure

Rinse Water On
Middle Speed
Output Frequency Detection
Feed Off

Feed On (solenoid energized)

Rinse Speed

U/F Produced When At Operating Pressure

Zero Pressure

Zero Pressure

NORMAL STOP WITH RINSE PURGE SEQUENCE (RINSE AUTO and THROTTLE AUTO selected)
Normal STOP button Pushed,
2nd Vibration Warning Limit reached,
1st Vibration Danger Limit reached, or
Low Pressure Alarm.

Dry Time - rinse water off and zero

pressure at end of rinse cycle.

There is no rinse cycle in RINSE OFF

SPEED (Hz.) and AIR PRESSURE

Closed Pressure
Run Speed

Decel
Time

Timed Rinse Cycle Step 1 and Step 2

Current Operating Pressure

Rinse Water On
Output Frequency Detection

Feed

Speed Step 2

Zero Pressure

On

Rinse Cycle Delay

Time Feed Off
Rinse

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C1000-R3.1

Installation, Operations, and Maintenance Manual

4.10. Control Philosophy

START SEQUENCE (with RINSE AUTO, THROTTLE AUTO and AUTO PURGE YES selected)

SPEED (Hz.) and AIR PRESSURE

Push START
Button

Segment
Time

Closed Pressure
Middle Speed Timer
Feed Start
U/F Delay

Run Speed
Pressure decreases one step
(Segment Pressure Drop)

Maximum Operating Pressure

Rinse Water On
Middle Speed
Output Frequency
Detection
Feed On (solenoid
energized)
U/F Produced When At Operating Pressure
Purge Cycle
Time
Zero Pressure

SPEED (Hz.) and AIR PRESSURE

continued from previous (segments are shorted for display purposes)

Segment
Timer

Vibration Warning
Level reached

Run Speed

Stepped Operating Pressure

Segment Jump
Output Frequency Detection
Minimum Operating Pressure
Feed On
No adjustments are made once
minimum operating pressure has
been achieved.

Vibration Mask Time starts

(ignores vibration level)

Purge Cycle
Time

Purge Time

Zero Pressure

SPEED (Hz.) and AIR PRESSURE

TO INITIATE MANUAL RINSE from RINSE AUTO or OFF (with THROTTLE AUTO selected)
Select RINSE ON
Closed Pressure
Run Speed

Decel
Time

Current Operating Pressure

Rinse Water On
Output Frequency Detection

Feed On

Feed Off

Rinse Cycle Delay Time

Rinse Speed Step 2

Zero Pressure

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Rinse Purge
Sequence

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