C1000-R3.

Installation, Operations, and Maintenance Manual

Contents
5

START-UP AND OPERATING ......................................................................................................................... 5-1

5.1 SLURRY FEED ..................................................................................................................................................... 5-1
5.1.1
Oversize Particles/Excess Density ......................................................................................................... 5-2
5.1.2
High and Low S.G. Gangues ................................................................................................................. 5-2
5.1.3
Solids Throughput................................................................................................................................. 5-2
5.1.4
Table 5.1.1 Tonnes per Hour ................................................................................................................ 5-3
5.2 PRE-START CHECKS ............................................................................................................................................. 5-3
5.3 STARTING THE CONCENTRATOR (SEE ALSO 4.10 CONTROL PHILOSOPHY) ....................................................................... 5-4
5.4 OPTIMIZATION ................................................................................................................................................... 5-4
5.5 RINSING / FLUSHING ........................................................................................................................................... 5-5
5.6 SHUT DOWN...................................................................................................................................................... 5-6
5.7 VIBRATION ........................................................................................................................................................ 5-6
5.8 CENTRIFUGAL FORCE ........................................................................................................................................... 5-7
5.8.1
Figure 5.8.1 RPM vs. Gs ....................................................................................................................... 5-8

Sepro Mineral Systems Corp.

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C1000-R3.1

Installation, Operations, and Maintenance Manual

Start-up and Operating

With the Falcon AutoPac, operating functions will be performed automatically after start-up. Refer to the
AutoPac portion of the manual for additional programming and operational instructions.
Although this manual provides general operating guidelines, it is important that qualified factory
personnel commission the equipment. Incorrect installation and/or operating causing failure will not
be covered under warranty. The following operating instructions assume that equipment has been
correctly installed and commissioned.

WARNING: Use safety precautions when working with, on or around rotating machinery and
electrical equipment.
Each installation is unique, therefore it is not possible to specify exact procedures for start up, operating,
rinsing and shut downs. The procedures mentioned in the following sections are only meant to give the
operating personnel general guidelines to help optimize the performance of the machine and minimize
downtime.

G Force
Bed

5.1

In the following pages the terms bed and breakthrough will be used
frequently. The term bed describes the operating condition whereas the
slurry forms a de-watered bed of solids around the inside perimeter of the
concentrator bowl (this area is also known as the retention zone). The term
breakthrough describes the operating condition whereas the bed is lost,
and all the material entering the bowl is forced out through the heavy
fraction discharge assembly. This must be avoided as it causes severe wear
and compromises the concentrate grade significantly.

Slurry Feed

With a standard AutoPac the feed material will only be introduced when the bowl has reached operating or
run speed. If feed is allowed to enter before this the unit may flood. The throttling nozzles will be closed,
and sufficient time must be allowed to enable the slurry to form a bed (see above) before opening the
throttling nozzles or a breakthrough condition will result (this is start underflow delay).
There is no minimum density for the concentrator feed but the maximum density should not exceed 50%
solids by weight. Clear water may be added to reduce the density. For low-density feed the throughput may
be governed by the maximum slurry capacity of about 325 USgpm (1230 l/m).
When no solids are fed into the unit, this will most likely result in a breakthrough condition when feed
resumes and it will be necessary to re-establish the bed to resume normal operation.

Sepro Mineral Systems Corp.

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C1000-R3.1

Installation, Operations, and Maintenance Manual

The following takes place during an automatic rinse (as initiated by a vibration warning):
1.
2.
3.
4.
5.
6.
7.
8.
9.

Feed valve stops feed to the machine.

Throttling nozzles close to full pressure.
Machine brakes to rinse speed and rinse water comes on.
Throttling nozzles open fully.
Rotor contents drain out through the heavy fraction discharge head.
Rinse function times out, rinse water turns off and machine accelerates to middle speed.
Throttling nozzles close to full pressure and feed is re-introduced.
Start underflow delay times out, then throttling nozzles adjust to operating pressure.
Middle speed timer begins, times out, then machine accelerates to operating speed.

5.6

Shut Down

It is important to note if the feed valve is working correctly, stopping the flow of material before the
concentrator begins to decelerate. If not, adjust the underflow delay set-points as described in 4.4
Programming.
Pressing the normal STOP button initiates the following procedure:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

Feed valve stops feed to the machine.

Throttling nozzles close to full pressure.
A rinse delay cycle begins, times out.
Machine decelerates to rinse speed and rinse water comes on.
Throttling nozzles open fully (zero pressure).
Throttling nozzles cycle open and closed according to set-points.
Rotor contents drain out through the throttling nozzles.
Rinse cycle times out.
Rinse water stops and machine runs at rinse speed for dry time.
Machine comes to a stop.

Pressing the red EMERGENCY STOP button initiates the following procedure:
1. Feed valve stops feed to the machine.
2. Throttling nozzles close to full pressure.
3. Machine decelerates quickly until stopped.
4. Throttling nozzles open fully (zero pressure).
The machine cannot be started again until the EMERGENCY STOP button is cleared or pulled out.

5.7

Vibration

Prior to leaving the factory all machines are started and balanced at the anticipated running speed for the
application. Upon installation some vibration of the unit during operation is normal and safe as the feed
material may cause varying degrees of imbalance in the rotor.

Caution: Vibration means that there is something out of balance. Rectify before
recommencing operation.

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C1000-R3.1

Installation, Operations, and Maintenance Manual

Common causes for vibration are listed below. Excessive vibration may be the result of improper operation
or handling during shipping and may require repair, re-balancing or replacement of rotating components.
The following causes should be thoroughly investigated before contacting a service representative:
1. Improper feed conditions causing excessive heavy fraction retention. Adjusting the feed characteristics
(density, particle size, etc.) to specifications should eliminate the problem.
2. Improper AutoPac settings, such as rotation speed too high for application.
3. Foreign matter in the rotor such as grinding balls, oversize, dropped tools, etc.
4. Structural damage to the bowl, rotor, shaft, discharge head, etc.
5. Plugged or blocked throttling nozzle orifices and/or flow channels.
6. Worn rotor and/or throttling valve components causing improper operation.
7. Damage to the frame due to improper lifting of handling.
8. Improper maintenance practices. During maintenance every effort should be taken to maintain the
balance of the machine.
9. Worn, damaged or mis-aligned bearings.
10. Improper mounting of the equipment (load not distributed evenly, etc.).
In many cases vibration can be decreased by changing feed and/or operating conditions such as increasing
feed, decreasing feed density and/or reducing speed.
If the above causes are investigated and vibration is still present, it may be necessary to field balance the
unit. This is a relatively simple operation, and various companies throughout the world are can perform
this. Sepro Mineral Systems is prepared to send a factory representative to site at a minimal cost to perform
a field balance if requested.

Caution: Do not add any weight to the rotating mass without having a field balance done by a
qualified technician.

5.8

Centrifugal Force

The rotational speed of the rotor bowl determines the G forces impacted on the material moving through
the machine. This is calculated by the formula:
G-FORCE = Rotor (inches) x r.p.m.2
70471
Generally, the fine streams (< 50 microns) require higher Gs for optimal recovery and coarser streams
lower Gs. The rotational speed can be set in Hz. See also Table 5.8.2 RPM vs. Gs.

Sepro Mineral Systems Corp.

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C1000-R3.1

Installation, Operations, and Maintenance Manual

5.1.1 Oversize Particles/Excess Density

Optimum feed volumetric flow rate and pulp density will vary slightly with different materials. For
estimating and set up purposes, begin with the nominal values given in section 2. Specifications /
Requirements.
It is highly recommended that a trash screen or strainer be installed in the feed system just prior to the
concentrator. Any oversize (+ 3mm) material will cause the nozzle orifices to plug. The recommended
aperture of the trash screen is 1.0 mm, and the screen should be placed where it does not interfere with
maintenance functions such as removing the lid.

Caution: Only qualified personnel should perform maintenance or repair.

Generally, heavier particles require lower solids density in the feed, thus higher specific gravity gangues or
larger maximum particle size will require higher water flows for a given total solids throughput. See
Tonnes per Hour Table on next page.

5.1.2 High and Low S.G. Gangues

In some instances where a high specific gravity gangue is present (such as magnetite) it may be necessary
to reduce the feed density (more water in feed) and/or feed throughput.
Where a low specific gravity gangue is present (such as talc) it may also be necessary to reduce feed
throughput. The correct operating conditions for each given material is usually determined and established
during a commissioning visit by a qualified representative.

5.1.3 Solids Throughput

Solids throughput is sensitive to particle size and particle weight distributions. Generally, finer and lighter
particle streams allow higher maximum throughput and less water in the feed. If the throughput is
approaching the nominal maximum capacity as listed in section 2.1 Specifications / Requirements it is
recommended that tests with different operating conditions are performed. These tests should include
sampling of the tails in order to determine which conditions influence maximum recovery.
A good indication that the machine is functioning correctly is when the film of slurry moving up the
migration zone is relatively smooth and the retention zone looks uniformly distributed. Further, the
impeller and the bottom portion of the rotor should be partially visible during operation.
The following table is provided to aid in determining operating solids throughput limitations. An average
S.G. of 2.65 was used here, an S.G. higher or lower than this will change the flow limits slightly at a given
pulp density.

Sepro Mineral Systems Corp.

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C1000-R3.1

Installation, Operations, and Maintenance Manual

below 40% of the feed weight, meaning for every 1 t/h of solids fed to the machine no more than 0.4 t/h
should be drawn out as a heavy fraction. This is to insure consistent operation, which will maximize heavy
fraction grade by eliminating breakthrough occurring from lack of feed.
To reduce the likelihood of this an on stream analyzer or flow meter can be installed on the heavy fraction
discharge and monitored along with the feed.
In some near capacity situations and when processing some types of feed, depending on its characteristics,
it may be beneficial and convenient to increase the heavy fraction production rate and re-process this
rougher in a clean-up cycle.
A smaller Falcon concentrator, or the original concentrator, when off line, can be used for this clean-up
operation to produce a primary high-grade concentrate when lower volumes can allow optimum feed
parameters. The light fraction from the clean-up operation should be reprocessed through the rougher
cycle. This is usually the best way to achieve higher-grade final concentrates without sacrificing high
recovery.
Contact the manufacturer for specific operating ranges in varying applications.
The following procedure can be used as a guide to determine the optimum heavy fraction volume for any
particular material.
1. Operate the concentrator for 20 minutes at approximately constant feed rate and pulp density,
establishing a constant heavy fraction rate and density.
2. Measure feed, tailings and concentrate rate and density.
3. Calculate the percentage of feed weight reporting to heavy fraction.
4. Collect feed, tailings and concentrate samples simultaneously. The samples can be collected by taking
3 second cuts every 30 seconds or by a similar sampling system.
5. Analyze these samples to determine optimum concentrate amount.
For example:
Increasing heavy fraction volume may lower grade of lighter fraction and increase
recovery but also lower the grade of the heavy fraction.
Decreasing heavy fraction volume may increase grade of lighter fraction and lower
recovery but also increase the grade of heavy fraction.
6. Using this information and by monitoring other operating conditions such as rotor speed, feed rate and
density, and particle size analysis, optimum operating conditions can then be established.

5.5

Rinsing / Flushing

A standard AutoPac will have been programmed for automatic rinsing of the rotor contents if a vibration
shutdown or normal stop has been initiated.
A rinse can also be initiated manually by setting the RINSE switch to the ON position. Different
applications will require varied rinse times and/or speeds, and these will be determined during the
commissioning visit.

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C1000-R3.1

5.3

Installation, Operations, and Maintenance Manual

Starting the Concentrator (see also 4.10 Control Philosophy)

Before starting the concentrator, be familiar with the operating parameters such as run speed, rinse speed,
acceleration time, deceleration time, and so forth as found in the AutoPac portion of this manual. It is
recommended that a qualified representative be present during start up.
Once you are sure the operating parameters are set correctly, press the START button with the RINSE
switch in the ON position. The machine should rotate counter clockwise (CCW). After making sure the
rotor is clear of material, turn the switch to the AUTO position. This will bring the machine to operating
speed.
If the machine does not reach operating speed within the set acceleration ramp time shut the machine down
and determine the cause. If no mechanical problem is apparent and the rotor spins freely, an electrical or
programming problem is likely.
Check the machine before the introduction of any feed material for any substantial vibration. If a vibration
switch has not already instigated a shutdown, immediately shut off the concentrator.

Caution: Vibration means that there is something out of balance. Rectify before
recommencing operation.

Common causes for vibration are listed in section 5.7 Vibration.

The following sequence takes place during a routine start up:
1. RINSE and THROTTLE switch should be in AUTO position.
2. Press START button, machine accelerates to middle speed with throttling nozzles fully open (zero
pressure).
3. Once at middle speed throttling nozzles close (full pressure).
4. Feed is introduced into the rotor bowl.
5. After start underflow delay times out, throttling nozzles adjust to operating pressure.
6. Middle speed timer begins.
7. After middle speed timer times out, machine accelerates to operating speed.
8. Auto Purge cycle begins to time.
9. After purge cycle times out, throttling nozzles purge at zero pressure for set purge time.
10. Run operation will continue until rinse function is activated and/or a shut down occurs either
automatically or manually.
11. To initiate a rinse cycle, switch the RINSE to ON position.
12. For normal shutdowns press the normal STOP button.
The red EMERGENCY STOP button should only be pressed in emergencies.

5.4

Optimization

To determine the optimum heavy fraction production rate for the desired grade(s) and/or recovery, some
experimentation may be required. Sepro recommends that the heavy fraction discharge weight is kept
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C1000-R3.1

Installation, Operations, and Maintenance Manual

5.1.4 Table 5.1.1

S.G. SOLIDS

Tonnes per Hour

2.65

PULP

PULP FLOW IN USGPM

DENSITY
(% SOLIDS)

125

150

175

200

225

250

275

300

325

350

375

400

5
10
15
20
25
30
35
40
45
50

1.6
3.3
5.2
7.1
9.3
11.5
14.0
16.6
19.5
22.7

1.9
4.0
6.2
8.6
11.1
13.8
16.8
20.0
23.4
27.2

2.3
4.7
7.2
10.0
13.0
16.1
19.6
23.3
27.4
31.8

2.6
5.3
8.3
11.4
14.8
18.4
22.4
26.6
31.3
36.3

2.9
6.0
9.3
12.9
16.7
20.8
25.2
30.0
35.2
40.8

3.2
6.7
10.3
14.3
18.5
23.1
28.0
33.3
39.1
45.4

3.5
7.3
11.4
15.7
20.4
25.4
30.8
36.6
43.0
49.9

3.9
8.0
12.4
17.1
22.2
27.7
33.6
39.9
46.9
54.5

4.2
8.7
13.4
18.6
24.1
30.0
36.4
43.3
50.8
59.0

4.5
9.3
14.5
20.0
25.9
32.3
39.2
46.6
54.7
63.5

4.8
10.0
15.5
21.4
27.8
34.6
42.0
49.9
58.6
68.1

5.2
10.7
16.5
22.8
29.6
36.9
44.8
53.3
62.5
72.6

IMPORTANTE: Shaded area represents solids throughputs exceeding the recommended

limits. Operating at or above these limits may adversely affect performance and will increase wear.

5.2

Pre-start Checks

Before starting the machine, checks the following:

1.
2.
3.
4.
5.
6.
7.
8.

Voltage to the AutoPac is correct and constant.

All electrical connections comply with local standards.
Feed stream is within recommended limits.
Feed valve has been tested and is operating correctly.
The compressed air supply is 300 psi @ 14 scfm to machine.
Air system does not leak.
Machine rotor is free of debris, and the rotor turns freely.
The machine is water tested for leaks.

WARNING: Do not operate or energize the machine without all guards in place. Doing so
could result in injury.

Sepro Mineral Systems Corp.

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