ISP30 - User Instructions Operations, Maintenance

ISP30 InLine Spinner Bowl
User Instructions: Operations, Maintenance
Operations & Maintenance Manual

Automatic InLine Spinner Bowl
ISP30
Revision 1.1
i Revision 1.1
CLIENT NAME
EQUIPMENT LOCATION
SITE
SERIAL No.
CLIENT NOTES
ii Revision 1.1
CHANGE RECORD
Sections/Pages
Revision Date Author Remarks
Affected
J.Adriaans,
0.1 01/08/11 All Draft
L.Arciaga
0.2 Dec 2011 S. Waters All Draft manual for review
1.0 Jan 2012 S. Waters All Release
1.1 Feb 2014 Kur. Pamarthi Sections 2 & 3 HMI update
iii Revision 1.1

FOREWORD
Gekko Systems specialises in the design, development and distribution of innovative mineral processing equipment
and systems with a particular focus on gravity separation. Long-term relationships based on trust and mutual
benefit, as well as an emphasis on innovation are the cornerstones of our philosophy.
Gekko is the world leader in modular pre-concentration and gravity gold recovery circuits. Manufacture and
assembly of the modular components can be managed in-house utilizing both skilled engineering staff and our
network of key suppliers. One of the significant step-change in mineral processing systems is the development of
the In-line Spinner. The InLine Spinner provides up to 90% recovery. As well, it has the capacity to process up to 6
mm feed. As an automated process, it is highly reliable and cost effective.
Gekko also offers a range of proprietary equipment including:

• The InLine Pressure Jig
• The InLine Leach Reactor
• Electrowinning cell
• G-Rex Resin Column
• Python Underground Processing System
iv Revision 1.1
Table of Contents
1.0 GENERAL INFORMATION.......................................................................................................................... 7
1.1 About this Manual ............................................................................................................................. 8
1.1.1 Manual Purpose .................................................................................................................. 8
1.1.2 Manual Scope...................................................................................................................... 8
1.1.3 Manual Use and On-site Application ................................................................................... 8
1.1.4 Disclaimer ............................................................................................................................ 9
1.1.5 Warnings, Cautions and Notes ............................................................................................ 9
1.2 Safe Work Procedures..................................................................................................................... 10
1.2.1 General .............................................................................................................................. 10
1.2.2 Guarding ............................................................................................................................ 10
1.2.3 Isolation Procedures .......................................................................................................... 10
1.2.4 Stored Energy.................................................................................................................... 11
1.2.5 Working at Heights ............................................................................................................ 11
1.2.6 Housekeeping Standards .................................................................................................. 12
1.2.7 Personnel Qualification & Training .................................................................................... 12
1.2.8 Noise Levels ...................................................................................................................... 12
1.2.9 Recycling and End of Product Life .................................................................................... 12
2.0 EQUIPMENT INFORMATION ................................................................................................................... 13

2.1 InLine Spinner Bowl ........................................................................................................................ 14
2.2 Theory of Operation ........................................................................................................................ 15
2.2.1 Spinner Features ............................................................................................................... 16
2.2.2 Electrical Cabinet............................................................................................................... 18
2.2.3 Pneumatic Control ............................................................................................................. 19
2.2.4 HMI Control Panel ............................................................................................................. 20
2.2.5 Control Philosophy ............................................................................................................ 23
2.3 Handling and Storage ...................................................................................................................... 24
2.3.1 Lifting .................................................................................................................................. 24
2.3.2 Storage ............................................................................................................................... 24
3.0 OPERATIONAL GUIDELINES................................................................................................................... 25

3.1 On First Start ................................................................................................................................... 26
3.2 Pre-checks ....................................................................................................................................... 26
3.3 Standard Start Up Procedure .......................................................................................................... 26
3.4 Standard Stop Procedure (Sequence Stop) .................................................................................... 26
3.5 ISP30 Optimisation .......................................................................................................................... 27
3.5.1 Optimising Cycle Time ...................................................................................................... 27
3.5.2 Optimising Scraper Bar Position ....................................................................................... 28
3.6 Hazard control ................................................................................................................................ 29
3.7 Isolation .......................................................................................................................................... 29
3.8 Unscheduled stops ......................................................................................................................... 29
3.9 Emergency ...................................................................................................................................... 29
4.0 MAINTENANCE ......................................................................................................................................... 30

4.1 Maintenance Management System ................................................................................................. 31
4.2 Maintenance Alert ............................................................................................................................ 31
4.3 ISP30 Schedule ............................................................................................................................... 32
4.3.1 Procedures ........................................................................................................................ 33
5.0 TROUBLESHOOTING ............................................................................................................................... 39

5.1 ISP30 Troubleshooting .................................................................................................................... 40
6.0 OPERATOR TRAINING SIGN OFF SHEET ............................................................................................. 41
7.0 OTHER RELEVANT DOCUMENTATION AND INFORMATION .............................................................. 43

7.1 Certification and Supplementary Manuals ....................................................................................... 44
7.2 Change Notes .................................................................................................................................. 44
v Revision 1.1
8.0 GEKKO SYSTEMS PTY LTD WARRANTY ...............................................................................................45

8.1 Warranty And Defects Liability Period ..............................................................................................46
8.1.1 Defects Liability Period .......................................................................................................46
8.1.2 Extent of Warranty .............................................................................................................46
8.2 Defects After Taking Over ................................................................................................................47
8.2.1 Defects Liability Period .......................................................................................................47
8.2.2 Making Good Defects .........................................................................................................47
8.2.3 Notice of Defects ................................................................................................................47
8.2.4 Extension of Defects Liability Period ..................................................................................47
8.2.5 Failure to Remedy Defects.................................................................................................47
8.2.6 Removal of Defective Work ................................................................................................48
8.2.7 Further Tests on Completion..............................................................................................48
8.2.8 Right of Access ..................................................................................................................48
8.2.9 Joint Occupancy .................................................................................................................48
8.2.10 Defects in Company’s Designs ........................................................................................48
8.2.11 Gekko to Search for the cause of the Defect ...................................................................48
8.2.12 Schedule of Defects .........................................................................................................48
8.2.13 Limitation of liability for Defects:.......................................................................................49
9.0 APPENDICES ............................................................................................................................................50

APPENDIX A: TECHNICAL SPECIFICATIONS ...................................................................................51
APPENDIX B: SPARE PARTS LIST .....................................................................................................52
APPENDIX C: OEM MANUALS LISTING .............................................................................................54
APPENDIX D: TORQUE GUIDE FOR BOLT TIGHTENING ................................................................56
10.0 FURTHER ASSISTANCE .........................................................................................................................57
6 Revision 1.1
1.0 GENERAL INFORMATION
7 Revision 1.1
1.1 About this Manual
This Gekko Instruction Manual contains important information for the successful operation and maintenance of the
Gekko Automatic InLine Spinner Bowl (ISP30). Please read and understand its contents prior to operation.
1.1.1 Manual Purpose
The purpose of this manual is to provide clear instructions for the safe operation and maintenance of the Gekko
ISP30 InLine Spinner Bowl.
1.1.2 Manual Scope
This manual is intended to assist users in the operation and maintenance of the Gekko ISP30 InLine Spinner Bowl.
This manual assumes installation and commissioning of the ISP30 has been fully and correctly undertaken using
Gekko installation guidelines. Accordingly, this manual provides:
• Safety warnings and guidelines associated with ISP30

• Comprehensive operations and maintenance procedures
• Maintenance scheduling guidelines
• A comprehensive troubleshooting guide
• Reference guide to associated OEM manuals
• Specification and Spares Listings
• Contact details for further Gekko Systems Pty Ltd in-field support.
1.1.3 Manual Use and On-site Application
This manual must be read prior to operating and maintaining this product. This product must not be
operated until all conditions relating to safety noted in this manual have been met.
This manual is intended to familiarise operators with the Gekko ISP30 Automatic InLine Spinner Bowl and its
permitted use. Operating the product in accordance with manual instructions will help achieve a safer working
environment, increased efficiency of operation and yield, increased durability of individual components and overall
plant, and reduced likelihood of down time due to improperly installed or adjusted components.
Please note that these instructions may not take into account local operational and/or health and safety regulations:
It is the responsibility of the owner to ensure such regulations are observed by all.
This manual must always be kept in close proximity to the equipment’s operating site or directly with
the product.
8 Revision 1.1
1.1.4 Disclaimer
Information contained in this manual is believed to be reliable. In spite of the efforts of Gekko Systems Pty
Ltd to provide reliable and comprehensive information, the content of this manual is not guaranteed by
Gekko as to its completeness or accuracy.
Gekko Systems Pty Ltd manufactures products to exacting standards and genuine parts have been designed and
tested to ensure continued product quality and performance in use. As Gekko cannot test parts and accessories
sourced from other vendors, the incorrect incorporation of such parts and accessories may adversely affect the
performance and safety features of this product. The failure to properly select, install or use authorised Gekko
parts and accessories is considered to be misuse. Damage or failure caused by misuse is not covered by Gekko’s
warranty. In addition, any modification of Gekko’s products or removal of original components may impair the
safety of these products in use.
1.1.5 Warnings, Cautions and Notes
Three levels of reader alert are used in this manual and appear in full width boxes. Non-observation of reader
alerts would cause hazards.
Electrical and warning level alerts appear as shown below. Failure to heed ELECTRICAL HAZARD and WARNING
alerts can result in serious injury or death.
ELECTRICAL HAZARD
WARNING
Caution level alerts appear as shown below. Failure to heed CAUTION alerts can result in damage to the plant,
associated equipment or equipment used to install the plant.
CAUTION
Note alerts appear as shown below. NOTE alerts are provided to assist and guide installation personnel with
helpful additional information.
NOTE
9 Revision 1.1
1.2 Safe Work Procedures
1.2.1 General
It is a requirement of owners of the Gekko ISP30 InLine Spinner Bowl to develop safe work procedures for the
operation of their equipment. The following guidelines are the minimum requirements to assist owners in
developing such procedures. Owners should also carry out appropriate risk assessments to establish the safe
work practices for activities associated with ISPs under the owner’s control.
1.2.2 Guarding
Guarding has been provided for operators’ safety and is not permitted to be removed unless all shutdown and
isolation procedures have been observed. Guarding including covers and cabinets of the ISP have been designed
to prevent hazards associated with energy sources including electricity and moving parts.
WARNING
Under no circumstances should guards be removed from ISP systems

whilst in operation.
1.2.3 Isolation Procedures
Work that requires access to the ISP30 and requires guards to be removed shall follow procedures for isolation.
The system of isolation should incorporate a tagging system, a locking system or permit system that also includes a
method for ensuring that isolation is effectively established. The following key points shall be included in the
procedure for isolation:
• Under no circumstances should emergency stop mechanisms be used for equipment isolation.
• The system is locked out at a point where it is not possible to override and start the system from another
point.
• Verification of isolation must occur prior to commencing work to ensure the correct plant has been
isolated.
• All individuals working in a danger zone must have their individual lockout mechanisms at the lockout
point.
• Nobody is permitted to remove anyone else’s lockout mechanism. Each individual is responsible for
removing their tag only.
• In the instance where a person has forgotten to remove their tag prior to leaving the site, a system shall
be in place where a senior manager may remove the lockout provided they are totally satisfied that the
individual (or any other persons) will not be exposed to any danger.
10 Revision 1.1
1.2.4 Stored Energy
Employees required to work around and maintain the ISP30 must be trained in the hidden hazard of stored energy.
Employees must be aware of a) the potential hazard of pressurised air supplied to actuate the drain bung, globe
valve and knife-gate valves, and b) stored electrical energy associated with the variable speed drive.
WARNING
The air mains connection to the ISP30 is pressurised to approximately 600
kPa / 87 psi. Failure to block and bleed pressurised air can lead to
serious injury and procedures for relieving stored energy should be
incorporated into the site’s safe work procedures. These procedures
should also highlight the danger of small leaks where high pressure air
may be escaping.
ELECTRICAL HAZARD
The electrical system should only be accessed by a trained and
authorised person. The ISP electric motor is controlled by a variable
speed drive which stores electrical energy and may still contain lethal
voltage levels well after power has been removed. Before any work is
carried out on the electrical system, it should be isolated, locked out and
tagged. Once all electrical energy is isolated, the technician should test
the electrical system to ensure all power has been removed.
1.2.5 Working at Heights
When working around the ISP30, consideration must always be given to whether the task involves the risk of a
person falling. A working at heights procedure should be developed in line with local laws/regulations and cover
risk assessment, a working at heights permit system, and control measures for identified risks.
Factors to consider when assessing the likelihood and severity of risks that may cause a person to fall include but
are not limited to:
• Condition of work surface eg. uneven surface or surface with unprotected edges
• Bad weather conditions eg. heavy rain or wind
• Type of work to be carried out
• Type of equipment to be used
• Training and experience of people carrying out work
• Equipment, tools or rubbish obstructing work area
• Type of footwear
• Moving surfaces
• Lighting
11 Revision 1.1
1.2.6 Housekeeping Standards
Good housekeeping standards help ensure the safety and longevity of plant equipment. Good housekeeping
involves:
• Immediately cleaning up any rubbish (rags, tramp metal etc)
• Areas adjacent to control panels kept free from tripping hazards
• Cleaning up any spillage as soon as practicable
• Ensuring all signs and decals remain legible
• Provision for tool racks or holders (to ensure tools are not lying on walkways or leaning loosely on
handrails etc)
• Providing only the necessary tools and equipment required for maintenance
1.2.7 Personnel Qualification & Training
All personnel involved in the operation, inspection and maintenance of the ISP30 must be qualified to carry out the
work involved. Appropriate training and instruction must be provided to any personnel lacking the necessary
knowledge and skill to operate and maintain this product. This includes staff, contractors, casuals, new starters,
visitors and anyone else who will be exposed to ISPs.
Training and induction of personnel shall include but is not limited to the following key points:
• Awareness of no entry areas - people must be aware of where they can and cannot go.
• Awareness of correct safety apparel – it must be made clear what items are mandatory and where they
are to be worn (eg. hardhat, safety boots, earplugs, glasses etc).
• Awareness of emergency stop mechanisms – all personnel should be made fully aware of the location of
emergency stop mechanisms and how to operate them.
1.2.8 Noise Levels
ISP30’s are characterised as having low noise emissions but are typically installed in plants where noise levels may
exceed local regulatory dBA thresholds. Attention must be given to local Health and Safety legislation to limit
exposure of plant operating personnel to such noise. As a minimum, Gekko Systems Pty Ltd recommends the use
of hearing protection when working around ISP30s.
1.2.9 Recycling and End of Product Life
At the end of the service life of this product and/or its parts, the relevant materials and parts should be recycled or
disposed of using an environmentally acceptable method as dictated by local laws/regulations. This also includes
any substances of a liquid or gaseous nature.
12 Revision 1.1
2.0 EQUIPMENT INFORMATION
13 Revision 1.1
2.1 InLine Spinner Bowl
The Automatic InLine Spinner Bowl (batch centrifugal concentrator) can be used in a variety of applications within
processing circuits. It can receive up to 6 mm undersize material directly from a trommel or shaking screen, or can
be used to upgrade concentrates from InLine Pressure Jigs, spirals, tables and other similar gravity concentrating
apparatus.
The ISP30 can be installed anywhere within a processing circuit with minimal changes and, due to the secure and
enclosed nature of the unit, concentrate from the bowl can be dropped into an enclosed locked vessel maximising
security.
The fully automated ISP30 can be programmed to flush at any cycle time to maximise recovery for different ores
and reduce the need for multiple units in series. Multiple units in parallel can be used to handle higher feed rates.
Benefits of the ISP30 include zero operating water consumption, a fast dump cycle time, high recoveries for coarse
and fine particles, and low operating costs.
1 ISP Frame 6 Feed Inlet

2 Electrical Cabinet 7 Feed Diversion
3 Spray Bar Water Inlet 8 Tails Outlet
4 Rotary Union Assembly 9 Lifting Lug (4 off)
5 Inspection Hatch (6 off) 10 Water Manifold (refer Fig. 4)
Figure 1. ISP30 General Arrangement
14 Revision 1.1
2.2 Theory of Operation
The inline Spinner unit works by feeding slurry into the base of a spinning, riffled bowl subjecting particles to
multiple G centrifugal forces. These forces enhance all gravity separation but particularly on finer particles.
The bowl operates full of slurry that swirls in a vortex, throwing the denser particles into the riffles located on the
bowl’s inside face. The continuous feed flow forces lighter gangue material out over the edge of the bowl into the
tails launder to be discharged via the tails outlet
Rather than utilising elutriating water, scraper (cutter) bars, mounted parallel to the inner face of the bowl, create
controlled turbulence in the high density zone near the bowl surface. This beneficiates recovery by allowing heavy
particles to replace lighter particles caught in the g-force of the unit. The riffle depth and scraper bars are designed
to maximise the replacement or separation zone. In this way the maximum amount of heavy mineral is recovered
and minimal gangue is recovered to the concentrate.
The spinner is a semi-continuous unit periodically stopping to flush out heavy metal/minerals captured in the riffles.
Fixed spray bars mounted in the interior of the spinner wash and rinse the heavies through the concentrate
discharge port at the base of the bowl to be collected downstream.
1 Feed Inlet (100 mm) 6 Concentrate Outlet

2 Scraper (Vortex) Bar (2 off) 7 Feed Pipe
3 Spray Bar (2 off) 8 Tails Outlet
4 Spinner Bowl 9 Tails Launder
5 Bung Assembly (refer Fig. 5)
Figure 2. ISP30 Internal Features
15 Revision 1.1
2.2.1 Spinner Features
1 Spray Bar (2 off) 3 Spray Bar Water Inlet

2 Spider Frame 4 Scraper Bar (2 off)
Figure 3. Spider Assembly
1 Ball Valve 25 mm (MV-01) 5 Burkert Globe Valve (XV-01)

2 Filter 6 Hex Barb 25 mm
3 3/8” to 6 mm Elbow (2 off) 7 Silencer
4 6 mm Bypass Line 8 1/4” to 6 mm Elbow
Figure 4. Water Manifold for Spider Assembly
16 Revision 1.1
1 Rotary Union Assembly 3 Bung Diaphragm

2 Airline Hose 4 Bung Retainer
Figure 5. Airline Assembly for Bung (1G032)
1 Tails Tee 150NB 4 Feed/Bypass Tee 100NB

2 Bypass Straight 100NB 5 Feed Knife Gate Valve 100NB (XV-02)
Bypass Knife Gate Valve 100NB
3 6 Feed Spool 100NB
(XV-03)
Figure 6. ISP30 Piping Assembly
17 Revision 1.1
2.2.2 Electrical Cabinet

The Electrical Cabinet includes the pneumatic control, motor control and the logic control. For stand-alone spinner
units, the Human Machine Interface (HMI) is mounted on the front of the cabinet where parameters are set for all
timers.
1 Emergency Stop 3 Start (Green) / Sequence Stop (Red) Buttons

2 HMI 4 Isolator (side of cabinet)
Figure 7. Electrical Cabinet Exterior
CCT Breakers
PLC
VSD Isolator
Transformer
Solenoid Bank 3 Ph In / Motor Out

Bung Regulator,
Check & Relief Valve
18 Revision 1.1
Figure 8. Electrical Cabinet Interior
2.2.3 Pneumatic Control
The ISP30 must use instrument quality air to control all actuated valves. The air supply to each of the
instruments is distributed from within the electrical cabinet however a mains connection is required.
The air supply needs to be at least 600 kPa (87 psi) supplied from the plant’s air system or alternatively a stand-
alone compressor. One 6 mm line is required and must be fitted to the regulator external to the electrical cabinet
(Figure 9). The regulator should be set at 600 kPa (87 psi).
Figure 9. Air Supply
Air is distributed within the electrical cabinet by a bank of four solenoid valves (Figures 8 and 10). Air supply to the
bung is additionally controlled via a mini regulator set to 200 kPa (30 psi) and a relief valve (Figure 8).
Figure 10. Air Actuated Valves

A quick check of the airlines may be necessary to make sure that airlines have not come loose during transport.
19 Revision 1.1
2.2.4 HMI Control Panel
The following control panel relates to stand-alone ISP30 spinner units.

NOTE
Alternative units may be controlled via the plant SCADA system.
F1F2
Figure 11. HMI Control Panel F3
On powering up the unit, the Main Menu

Page will be displayed
Selects the Settings Page
Starts the sequence.

MAIN
Stops the sequence
MENU
Automatic / Program mode.
Manual / Operator mode.
Resets Faults
The settings page allows to set the

SETTINGS
operating parameters of the spinner.
PAGE
20 Revision 1.1
Drain button on Home page Opens

the Drain Valve page
Opens the valve.
VALVE Closes the valve

POP UP
PAGE Program / Automatic Mode
Manual / Operator Mode.
Resets the Faults.
Closes the Valve page.
Opens Motor page from Home page.
Starts the motor
MOTOR Stops the motor

POP UP
PAGE Reset Faults
Program / Automatic mode
Manual / Operator Mode
A login is required to adjust commissioning / operating parameters (see below). Login by

pressing settings button from Home page. Enter the username and password provided by
NOTE
Gekko using the keyboard on the screen. Press Enter key to go back to the Settings page
and the login times out after 15 minutes.
21 Revision 1.1
Table 1 below outlines the key controls for each cycle step of the ISP30.
Bowl Spinning
Bypass Open
Feed Open
Bung Open
Sprays On
ISP
Sequence Purpose
Steps
CONCEN-
TRATING      Concentrating
CYCLE
SPINOUT Remove
    
CYCLE excess to tails
SPRAY
Drain
DELAY     
Concentrate
CYCLE
Continuously
Wash
RINSE
    Remaining
CYCLE
Concentrate

Table 1. ISP Step Controls
ISP SETTING Time Unit

CYCLE TIME (CONCENTRATING CYCLE) 30 min
RUN SPEED 80 %
SPINOUT TIME 30 sec
SPIN OUT SPEED 100 %
DUMP TIME 60 Sec
DUMP SPEED 10 %
Table 2. ISP30 Typical Settings
22 Revision 1.1
2.2.5 Control Philosophy
2.2.5.1 Concentrating Cycle
The Concentrating Cycle is the “normal operation” of the spinner where valuable mineral is recovered from the
slurry. Feed passes through the open feed inlet whilst the bowl spins around, providing centrifugal force on each
particle in the bowl. In the concentrating time, heavy particles are forced into the riffles of the spinner bowl whilst
the continuous feed to the bottom of the bowl pushes lighter gangue material out and over the edge of the bowl into
the launder.
The bung is shut to allow build up of material inside the bowl. Sprays are not active during the concentrating phase
however a bypass line at the globe valve ensures a continuous trickle supply to the spray bars to avoid blockage of
the spray outlets.
Turbulence is introduced into the concentrating zone of the bowl using Scraper bars. This helps free any gangue
material trapped within the heavy particle concentrate.
Cycle time needs to be optimised to maximise valuable mineral recovery.
2.2.5.2 Spin Out Cycle
The Spin Out Cycle begins after the Concentrating Cycle time has elapsed. The feed to the spinner bowl is shut off
and diverted to the tails outlet. With the dump valve remaining closed, the bowl speed accelerates for a set period
of time to remove excess water and any unwanted material from the bowl that may reduce the concentrate density.
2.2.5.3 Spray Delay Cycle
The Spray Delay Cycle starts once the Spin Out Cycle time has elapsed.
During the Spray Delay Cycle, the bowl is stationary and the bung open. Free draining solids and water retained in
the bowl make their way to the bottom of the bowl and exit the bowl via the concentrate outlet.
Feed to the spinner bowl remains bypassed to the tails outlet during this step.
2.2.5.4 Rinse Cycle
The Rinse Cycle begins after the Spray Delay Cycle time has elapsed. In this step, the sprays are initiated by
opening the globe valve and the bowl is rotated continuously at a set speed to remove any remaining concentrate
from the bowl.
The Rinse cycle Start and Stop Times in conjunction with the VSD Acceleration, VSD Deceleration and VSD
Speed, controls the average speed and distance through which the bowl is rotated. The VSD parameters are
factory set and should not require adjusting.
The sprays remain active throughout the Rinse Cycle to spray down the solids captured in the bowl riffles. The
sprays are also set against the direction of rotation of the bowl to improve wash down capability.
For normal running, Cycle Time is the only parameter that can be altered
NOTE by the operator. Contact Gekko Systems for Login details if Drain and
Washout Cycles require optimisation.
23 Revision 1.1
2.3 Handling and Storage
The ISP30 should be kept in the upright position. Observe all signage on the ISP30 where provided and avoid
dragging equipment where possible.
Missing or illegible decals should be replaced with Gekko supplied decals.
The ISP30 needs to be set up on a level surface in an area that has clearances of up to 1.5 m in the vertical
direction and 1 m around the sides. A spirit level should be placed on each of the base frame of the ISP30 to
ensure the unit is level in both planes.
2.3.1 Lifting
The ISP30 is fitted with four lifting lugs to assist with lifting manoeuvres. The total mass of the ISP30 is
approximately 850 kg.
The mass of the heaviest single component for maintenance purposes is

NOTE
the ISP bowl. The bowl weighs approximately 245 kg.
Please refer Appendix A for further ISP30 specifications.
2.3.2 Storage
If proper warehousing is not available, ISPs should be kept in the upright position in as dry and well ventilated place
as possible.
Extra precautions for storage may need to be taken for installations where extreme weather conditions may be
expected i.e. Cyclones, flood, volcanic, earthquake regions, extreme cold temperatures.
When the ISP30 is to be inactive for an extended period, the unit should be thoroughly emptied and washed down
with clean water.
24 Revision 1.1
3.0 OPERATIONAL GUIDELINES
25 Revision 1.1
This product has been selected to meet the specifications of your purchase order. This product
must not be operated beyond the parameters specified for the application. If there is any doubt as to the
suitability of the product for the application intended, please contact Gekko Systems Pty Ltd for advice.
3.1 On First Start
Your equipment may have travelled many hundreds of kilometres by various transport means. After installation
and prior to operating your equipment for the first time, visually inspect all features for signs of damage, missing
components, loose fasteners etc. Make appropriate amends as necessary.
3.2 Pre-checks
The following checks must be made prior to operating the ISP for the first time or after a long period of inactivity.
i. The unit is level in both planes referenced off the base of the ISP frame
ii. Instrument air is supplied to the system
iii. Water is connected
iv. The ISP is ready to accept feed
v. Launders are ready to accept ISP discharge
vi. ISP inspection hatches are secure
vii. Security at concentrate discharge outlet
viii. The ISP is powered up
ix. Emergency stop de-activated
x. ISP De-isolated
3.3 Standard Start Up Procedure
i. Press the START button on front of electrical cabinet.

ii. Check spinner bowl is rotating and feed is entering the bowl.
iii. Check cycle parameters. Optimise accordingly.
3.4 Standard Stop Procedure (Sequence Stop)
i. Press the STOP button on the front of the electrical cabinet. The ISP30 will perform a
sequence stop i.e. Will continue running until completion of the Rinse Cycle.
ii. If a STOP is initiated during the Cycle Time, the VSD will immediately increase to 40 Hz to run
the Spin Out Cycle and then complete the remainder of the sequence.
iii. Check bypass valve opens and slurry is actually bypassing ISP.
WARNING
Performing a Sequence Stop does not immediately stop the spinner ie.
the spinner will complete the entire cycle sequence prior to stopping.
Only the Emergency Stop button will initiate an immediate stop.
26 Revision 1.1
3.5 ISP30 Optimisation
For all optimisation procedures, the feed grade should be maintained to

NOTE ensure a constant value so that the concentrate sample isn’t affected by a
high or low feed grade.
3.5.1 Optimising Cycle Time
During the Cycle Time, the feed valve to the bowl is open and the bung closed with the spinner rotating. This time
must be optimised in order to obtain maximum recovery.
a. Set the cycle time, according to the spreadsheet below. The first time should be 10 minutes.
b. Take Feed sample.
c. Take the tails sample.
d. Take concentrate sample.
e. Repeat the process using an increased cycle time until the spreadsheet is completed.
Correct sampling technique should be used to gain representative

NOTE samples. Record and maintain feed rate and scraper bar clearance
during sampling.
Cycle time (mins)

10 30 60 90 120 180 240
Feed Grade (ppm)
Tails Grade (ppm)
Concentrate Grade (ppm)
Table 3. Cycle Time Optimisation
Using the data collected, plot the cycle time versus recovery curve. Select the cycle time at which recovery is
highest and does not improve with increased cycle time.
Figure 12. Recovery vs. Cycle Time Curve
27 Revision 1.1
3.5.2 Optimising Scraper Bar Position
The scraper bar position is factory set at 15 mm but may require adjusting to optimise valuable material recovery.
a. Set the scraper bar clearance, according to the spreadsheet below.

b. Take Feed sample.
c. Take the tails sample.
d. Take concentrate sample.
e. Repeat the process altering scraper bar clearance until the spreadsheet is completed.
Correct sampling technique should be used to gain representative

NOTE
samples. Record and maintain feed rate during sampling.
Scraper Bar Clearance (mm)

5 10 15 20
Feed Grade (ppm)
Tails Grade (ppm)
Concentrate Grade (ppm)
Table 4. Scraper Bar Repositioning
Using the data collected, plot the scraper bar clearance (vortex position) versus recovery curve. Set the clearance
to where recovery is highest.
Figure 13. Recovery vs. Scraper Bar Clearance
28 Revision 1.1
3.6 Hazard control
Operators need to be aware of the following key outcomes of hazards associated with the Gekko Automatic InLine
Spinner Bowl:
• Entrainment in moving spinner components

• Air injection from stored instrument air
• Electric shock
• Remote start
• High Voltage present inside electrical cabinet
• Working at heights
WARNING
Keep hands and objects clear of moving Spinner elements at all times.
Shutdown and isolate the Spinner prior to any maintenance activity.
3.7 Isolation
Although safeguards are provided which prevent access during most phases of this equipment’s operation,
isolation (lock-out and tag-out) will be required at times because of the need to access the ISP during set-up and
maintenance (refer isolation guidelines provided on page 10).
The main isolation points on the ISP30 are:
• Electrical isolation via switch on side of electrical cabinet

• Pneumatic isolation for valves and bung diaphragm
• Isolation of water supply to spray bars
3.8 Unscheduled stops
After any unscheduled stop, the cause of the stop shall be determined. No restart shall be allowed until the cause
is known and clearance from all stations have been obtained.
Controls that bypass any portion of the operating control circuitry shall be locked when not in use. When a bypass
is in operation, the function bypassed shall be under constant and close supervision. Repair of the fault shall be
set as a priority and shall not be run as a long-term solution.
3.9 Emergency
An emergency stop should only be performed if there is a risk of personal injury or equipment damage. In case of
emergency the e-stop button on the front of the electrical cabinet should be depressed. An emergency stop will
stop the spinner completely regardless of sequence
Initiating an emergency stop may cause partial shutdown of other parts of the process either upstream or
downstream of the ISP. The operator must be aware of these interactions.
29 Revision 1.1
4.0 MAINTENANCE
30 Revision 1.1
The following maintenance schedules and procedures are to be followed to ensure the safety and
longevity of your equipment. These procedures must be carried out by trained competent maintenance
personnel following all recommended safety procedures as outlined in this manual. Records of
maintenance should be recorded in the owner’s maintenance management system. If there is any doubt
regarding maintenance of this product, please contact Gekko Systems Pty Ltd for advice.
4.1 Maintenance Management System
A maintenance management program provides a reliable way of ensuring the satisfactory operation of your
equipment whilst in service. A maintenance management program should be incorporated into the operation of the
ISP and shall include, but is not limited, to the following:
(a) Pre-operational servicing including lubrication requirements

(b) Periodic and or condition based servicing
(c) Periodic inspections
(d) Records including, but not limited to, damage reporting
All adjustable parameters should be recorded so that the unit can be

Note
readily set up following maintenance or after replacement of components.
4.2 Maintenance Alert
WARNING
Observe all shutdown and isolation procedures prior to commencement
of any maintenance activities unless specifically advised within a
procedure.
WARNING
Note that the following procedures expose personnel to nip/pinch points
and potential heavy lifting. Observe site safety policies when maintaining
this product.
31 Revision 1.1
4.3 ISP30 Schedule
6 Monthly
Monthly
Other
Daily
Task
Check Spinner Sequence X
Overall visual inspection X
Check for abnormal vibrations X
Listen for abnormal noises X
Visual check for water leaks X
Visual check for oil leaks X
Change gearbox oil (EP220 mineral based) 2500 hours
Lubricate labyrinth seal (NLGI #2 Mineral Grease) 5000 hours

Check security of all fasteners including inspection
X
hatches
Inspect spray water filter (depending upon water quality) X
Inspect spray nozzles for blockage or damage X
Inspect air activated knife gate valves X
Check security of floor anchor bolts X
Check security of scraper bars X
Gearbox oil level X
Check spinner bowl for wear X
Overhaul (recommended) 48 months
32 Revision 1.1
4.3.1 Procedures
4.3.1.1 Replacing Bung Diaphragm ................................................................................................................ 34
4.3.1.2 Scraper Bar Adjustment ...................................................................................................................... 35
4.3.1.3 ISP30 Gearbox Replacement ............................................................................................................. 36
Use anti-seize on all threads. Use washers on all nuts and bolt heads to
NOTE
avoid paint scratching.
Where bolt tightening is required within a procedure, refer Appendix D:

NOTE
Torque Guide for Bolt Tightening.
33 Revision 1.1
4.3.1.1 Replacing Bung Diaphragm
i. Shut down the ISP30 by pressing the STOP button and wait for the entire cycle to complete.
ii. Isolate power (cabinet isolator switch), water (at ball valve) and feed to the unit. NOTE: Lock
Out/Tag Out protocols apply.
iii. Isolate plant air supply. Set regulator to minimum setting then disconnect main 6 mm air supply
line between regulator and cabinet.
iv. Disconnect 6 mm air line to rotary union.
v. Remove inspection hatch lid to give clear access to bung assembly.
vi. Disconnect swivel from compression nipple.
Figure 14 Bung
vii. Unbolt three M10 bolts securing bung retainer to base of spinner bowl.
viii. Remove bung retainer plate (six off M6 bolts) and remove rubber bung diaphragm.
ix. Clean bung retainer recess area and locate new diaphragm. Relocate bung retainer plate.
x. Re-seat and bolt bung retainer assembly to spinner bowl base and reconnect swivel to
compression nipple.
xi. Reconnect air-line to rotary fitting and de-isolate air.
xii. Pour a small amount of water into the bowl. Check no water can escape the bowl.
xiii. When satisfied with bung operation, re-secure inspection hatch lid.
xiv. De-isolate power, water, and feed.
34 Revision 1.1
4.3.1.2 Scraper Bar Adjustment
NOTE The scraper bar position is factory set 15 mm from the spinner bowl.
i. Shut down the ISP30 by pressing the STOP button and wait for the entire cycle to complete.
i. Isolate power at cabinet isolator switch. NOTE: Lock Out/Tag Out protocols apply.
ii. Remove inspection hatch lids relative to scraper bar locations on spider assembly.
iii. Loosen four x M8 Hex bolts on scraper support plate.
iv. Adjust scraper bar in or out to suit application.
v. Tighten hex bolts and repeat for other scraper bar.
vi. Replace inspection hatch lids, secure, and de-isolate the spinner.
1 Scraper Bar 3 M8 Hex Bolt (4 off)

2 Support Plate
Figure 15. Adjusting Scraper (Vortex) Bars
35 Revision 1.1
4.3.1.3 ISP30 Gearbox Replacement
During this procedure, check all components for cleanliness, wear or

NOTE
damage. Clean and/or replace as necessary.
vii. Shut down the ISP30 by pressing the STOP button and wait for the entire cycle to complete.
viii. Isolate power (cabinet isolator switch), water (at ball valve) and feed to the unit. NOTE: Lock
Out/Tag Out protocols apply.
ix. Isolate plant air supply. Set regulator to minimum setting then disconnect main 6 mm air supply
line between regulator and cabinet.
x. Disconnect 6 mm air lines from bung rotary fitting and knife-gate valves.
xi. Disconnect water hose from spray water inlet fitting on spinner lid.
xii. Disconnect swivel from compression nipple on bung diaphragm assembly (refer procedure
4.3.1.1)
xiii. Disconnect feed bypass pipe from tails tee (refer Figure 6).
xiv. Unbolt lid and carefully lift from spinner and set aside.
xv. Unbolt and remove spider assembly (refer figure 3).
xvi. Prepare lifting sling around body of spinner bowl to take up weight when dismantling shaft
coupling to gearbox.
xvii. Unbolt 6 bolts securing shaft coupling plate to spinner bowl.
xviii. Remove spinner bowl.
Bowl
Shaft Coupling Plate
Figure 16. Spinner Bowl Shaft Coupling Arrangement
36 Revision 1.1
Check condition of 70 mm o-ring in recess of top of shaft coupling plate.

NOTE
Replace if damaged or worn.
xix. Use Allen key to unscrew and remove the 6 x M6 cap screws. Hold flinger out of the way to
provide clearance for Allen key. Note: Access to screws via top of coupling plate may assist.
Shaft Coupling Plate M6 Cap Screws
O-RING
SEATED HERE
Flinger
Figure 17. Separate Shaft Coupling from Gearbox
xx. Separate shaft coupling from gearbox (avoid damage to 8 mm drive pins).
Washers
Labyrinth Lower Seal
Drive Pins
Figure 18. Gearbox Top View
xxi. Unbolt gearbox from ISP30 frame.
37 Revision 1.1
xxii. Remove 8 mm breather tube and elbow from the gearbox.
Gearbox
Frame Bolt
Breather
Elbow 8 mm Tube
Figure 19. Gearbox Breather
xxiii. Slide motor and gearbox out of frame.

xxiv. Fit new gearbox with lower labyrinth seal to drive motor.
xxv. Reassemble spinner. Run-out on spinner bowl should be ≤ 3 mm.
NOTE Use Silastic in M6 shaft coupling holes.
To replace upper labyrinth seal: remove 3 x grease nipples and 3 x grub

screws. Fit new seal and tighten to shaft coupling using grub screws.
NOTE
Refit grease nipples. Ensure upper and lower labyrinth seals mesh easily.
Lubricate with NLGI #2 Mineral Grease.
Labyrinth Upper Seal
Grub Screws for Upper Seal x 3

behind 3 x Grease Nipples
Figure 20. Labyrinth Upper Seal
38 Revision 1.1
5.0 TROUBLESHOOTING
39 Revision 1.1
5.1 ISP30 Troubleshooting
Fault Potential Cause Counter measures
Check 3 phase power Call electrician
Gearbox Check gearbox including oil level
Bowl not spinning

E-Stop depressed Reset E-stop. Caution. Only reset E-stop
if safe to do so.
Electrical Cabinet Isolated Observe Log-out Tag-out Protocol
Water supply Connect water supply

Sprays not working
Spray nozzles or filter blocked Unblock or replace
Diaphragm damaged Replace diaphragm
Solids trapped between diaphragm and Remove bung retainer and clean concentrate
Bung not closing concentrate outlet. outelet.
Air supply Check supply, lines and fittings. Caution.

Air under pressure
Bung not opening ‘Check’ valve Confirm valve operation. Replace if faulty
Feed source Check upstream process
No feed Check knife-gate feed valve open / bypass valve

closed. Check air supply to valves.
Knife-gate valves
Caution. Air under pressure
Check knife-gate feed valve closed / bypass
Feed continues during Spin valve open. Check air supply to valves.
Out, Spray Delay and Knife-gate valves
Wash Out Cycles
Caution. Air under pressure
40 Revision 1.1
6.0 OPERATOR TRAINING SIGN OFF SHEET
41 Revision 1.1
Gekko Systems is making every effort to warn, guard, and educate the consumer when using the various kinds of
equipment that we manufacture. Gekko has included this sign off sheet for you and your staff to use in the training
process of operating and maintaining the equipment described in this manual. Gekko recommends training be
inclusive of but not limited to:
(a) Safe work practices including isolation procedures
(b) Correct operation of the InLine Spinner Bowl
(c) Reasons for protective guarding
(d) Need for good housekeeping.
Read the entire manual, sign off, and date in the table below.
NAME SIGNATURE DATE
42 Revision 1.1
7.0 OTHER RELEVANT DOCUMENTATION AND INFORMATION
43 Revision 1.1
7.1 Certification and Supplementary Manuals
Any supplementary instruction manuals and Certificates e.g. materials, hydraulic test, conformities, performance
test curves etc. as determined by the Contract requirements will be sent to the Purchaser separately. If required,
copies of these should be obtained from the Purchaser for retention with this manual.
A comprehensive list of supplementary OEM manuals is contained within Appendix D.
7.2 Change Notes
A record of any product changes made after supply, as agreed with Gekko Systems Pty Ltd, should be retained
with this manual.
44 Revision 1.1
8.0 GEKKO SYSTEMS PTY LTD WARRANTY
45 Revision 1.1
8.1 Warranty And Defects Liability Period
8.1.1 Defects Liability Period
8.1.1.1 Patent Defects

Gekko Systems Pty Ltd (henceforth Gekko) warrants that the Works shall conform to the agreed specification for the Defects Liability Period of
twelve (12) months after commissioning of the Works as per Final Take-over certificate, or eighteen (18) months from delivery whichever is
earlier.
8.1.1.2 Latent Defects

Gekko warrants that the Works shall be free of Latent Defects for a period of at least twelve (12) months from issuing of the Final Take over
Certificate or eighteen (18) months from delivery whichever is earlier. Thereafter Gekko shall have no further contractual liability.
8.1.2 Extent of Warranty

8.1.2.1 Gekko shall be responsible for making good any defects in or damage to any part of the Works which may appear or occur during
Defects Liability Period and which arises from, either:
i. any defective materials, workmanship or design, or
ii. any act or omission of Gekko during the Defects Liability Period.
8.1.2.2 Gekko shall make good the defects or damage as soon as practicable and at its own cost.
8.1.2.3 If any such Defect appears or damage occurs, the Company or the Company’s Representative shall forthwith notify Gekko thereof within
14 days of such defect being identified.
8.1.2.4 If Gekko fails to remedy a defect or damage within a reasonable time, the Company may fix a final time for remedying the defect or
damage as per the following General Terms of Conditions.
8.1.2.4.1 Remedies in case of default in performance
8.1.2.4.1.1 If any part of the whole of the Works contains a defect, the Company shall, without prejudice to any other rights
which the Company may have in terms of the Contract or in law, be entitled -
i. to instruct the Contractor to redo the defective Works; or
ii. to purchase replacement Works from a third party and the Contractor shall be liable to the Company for any excess cost
of the Works incurred by the Company; or
iii. to instruct the Contractor to purchase replacement Works from a third party and the Contractor shall be liable to the
Company for any excess cost of the Works incurred by the Company; or
iv. put the Contractor in breach as per Breach and Termination conditions.
8.1.2.4.1.2 Failure on the part of the Company to implement the provisions of this clause 8.1.2.3.1 shall not prejudice or affect
the rights of the Company to invoke the said provisions in a subsequent delivery of Service.
46 Revision 1.1
8.1.2.5 If Gekko fails to remedy the defect within the time agreed in 4.2.4 above, the Company may use any of the remedies provided for in
terms of this agreement.
8.1.2.6 Nothing in this clause 8.1 shall derogate from Gekko’s liability at common law for latent defects.
8.2 Defects After Taking Over
8.2.1 Defects Liability Period

Where any part of the Works is taken over separately from the whole of the Works, the Defects Liability Period for that part shall commence on
the date it was taken over.
8.2.2 Making Good Defects

Gekko shall be responsible for making good any defect in or damage to any part of the Works which may appear or occur during the Defects
Liability Period and which arises from, either:
i. any defective materials, workmanship or design, or
ii. any act or omission of Gekko during the Defects Liability Period.
Gekko shall make good the defect or damage as soon as practicable and at its own cost.
8.2.3 Notice of Defects

If any such defect appears or damage occurs, the Company or Company’s Representative shall forthwith notify Gekko thereof within 14 days of
the defect becoming apparent.
8.2.4 Extension of Defects Liability Period

The provisions of this Clause shall apply to all replacements or renewals carried out by Gekko as if the replacements and renewals had been
taken over on the date they were completed. The Defects Liability Period for the works shall be extended by a period equal to the period during
which the Works cannot be used by reason of a defect or damage. If only part of the Works is affected the defects liability period shall be
extended only for that part. In neither case shall the defects liability period be extended by more than one year.
8.2.5 Failure to Remedy Defects
8.2.5.1 If Gekko fails to remedy a defect or damage within a reasonable time, the Company may fix a final time for remedying the defect or
damage.
8.2.5.2 If Gekko fails to do so, the Company may:
i. carry out the work itself or by others at Gekko’s risk and cost, provided that it does so in a reasonable manner. The
costs properly incurred by the Company in remedying the defect or damage shall be deducted from the Contract Price,
but Gekko shall have no responsibility for such work, or
ii. require Gekko to grant the Company a reasonable reduction in Gekko Price to be agreed or fixed by Arbitration;
47 Revision 1.1
8.2.6 Removal of Defective Work

If the defect or damage is such that repairs cannot be expeditiously carried out on the Site, Gekko may with the written consent of the
Company’s Representative remove from the Site for the purposes of repair any part of the Works which is defective or damaged. This part of
the Works will be transported to a location designated by Gekko in Johannesburg, South Africa at the cost of Gekko.
8.2.7 Further Tests on Completion

If the replacements or renewals are such that they may affect the performance of the Works, the Company may request that Tests on
Completion be repeated to the extent necessary. The request shall be made by notice within 28 (twenty eight) days after the replacement or
renewal. The Tests shall be carried out in accordance with Clause 8.1.
8.2.8 Right of Access

Until the Taking Over Certificate has been issued, Gekko shall have the right of access to all parts of the Works and to records of the Works.
Such right of access shall be during the Company’s normal working hours at Gekko’s risk and cost. Access shall also be granted to any
authorised representative of Gekko whose name has been communicated in writing to the Company’s Representative. Subject to the
Company’s Representative’s approval, Gekko may also at its own risk and cost make any tests, which it considers necessary.
8.2.9 Joint Occupancy
8.2.9.1 Other work may be performed by others concurrently with the performance of the Works under this Contract. Gekko recognises that the
Works hereunder may be performed under joint occupancy conditions and agrees to co-operate with the Company and other contractors on the
Site so that the Project as a whole will progress smoothly with a minimum of delays due to interference between various Contractors on the Site.
8.2.10 Defects in Company’s Designs

Gekko shall not be liable for any defects resulting from designs furnished or specified by the Company or Company’s Representative.
8.2.11 Gekko to Search for the cause of the Defect

Gekko shall, if required by the Company’s Representative in Writing, search for the cause of any defect, under the direction of the Company’s
Representative. Unless the defect is one for which Gekko is liable under this clause, the cost of the work carried out by Gekko in searching for
the cause of the defect shall be added to the Contract Price.
8.2.12 Schedule of Defects

When the Defects Liability Period for the Works or any part thereof has expired and Gekko has fulfilled all of its obligations under the Contract
for defects in the Works or that section , the Company’s Representative shall issue within 28 (twenty eight) days to Gekko a Taking Over.
48 Revision 1.1
8.2.13 Limitation of liability for Defects:
Gekko’s liability for Defects under this clause 8.2 does not apply if:
• the Company does not comply with Gekko’s manual, operating, storage or handling instructions; or
• the Company uses the goods for any purpose other than the intended use of the goods; or
• the Company has anyone not suitably trained by Gekko, work on the goods (unless Gekko otherwise agrees in writing); or
• the Company installs a spare or replacement part in the goods that Gekko does not supply (unless Gekko otherwise agrees
in writing); or
• the Company’s staff do not undertake the necessary initial training in order to operate the goods.
49 Revision 1.1
9.0 APPENDICES
50 Revision 1.1
APPENDIX A: TECHNICAL SPECIFICATIONS
ITEM UNIT ISP30

Total Mass Kg Approx 850
Frame Support Footprint mm 1060 x 1060
Height to top of Trough (without leg extensions) mm 1010
Bowl Material Cast Machined Polyurethane
Bowl Max Internal Ø mm 882
Bowl Depth mm 450
Bowl Volume L 160
Trough - Rubber Lined
Lid - 3 mm Poly Sprayed (typical)
Water Consumption L Approx 15 per dump cycle
Maximum Particle Size mm 6
3
Maximum Feed Rate m /hr 100
Maximum Feed Rate t/hr 30
Air Quality Required kPa Instrument Air @ 600 kPa
Feed Inlet mm 100 Table D Flange
Tails Outlet mm 150 Table D Flange
Supply Regulator Setting kPa 600
Bung Regulator Setting kPa 200
Motor NP* Voltage V 415
Motor NP Power kW 5.5
Motor NP Full Load Amps A 9.9
Motor NP Hertz Hz 50
Motor NP RPM RPM 1465
Control Voltage V 110
‘* Name Plate
51 Revision 1.1
APPENDIX B: SPARE PARTS LIST
Spare Parts List-Automatic InLine Spinner Bowl

Equipment: ISP30
Module: Template
Description: Automatic InLine Spinner Bowl
Customer: Template
Manufacturer: Gekko Systems Pty Ltd
GEKKO QUANTITY UNIT OF

DESCRIPTION REFERENCE
ITEM USED MEASURE
VSD DISPLAY (VSD LCD;*ELECTRICAL

1E191 1 EACH FIGURE 8
CABINET)
VARIABLE SPEED DRIVE 5.5KW (VSD,

1E192B 1 EACH FIGURE 8
*ELECTRICAL CABINET)
PROCESS LOGIC CONTROL (PLC,
1E301 1 EACH FIGURE 8
*ELECTRICAL CABINET)
1E330 HMI DISPLAY 1 EACH FIGURE 11
TRANSFORMER 415V/110/5A (*ELECTRICAL
1E405J 1 EACH FIGURE 8
CABINET)
MOTOR CIRCUT BREAKER 10A (*ELECTRICAL
1 EACH FIGURE 8
1E609D CABINET)
CONTROL CIRCUIT BREAKER 6A (*ELECTRICAL
1E610A 1 EACH FIGURE 8
CABINET)
1G032 AIR LINE ASSEMBLY 1 EACH FIGURE 5
1G033 SCRAPER BAR (SCRAPER BAR) 2 EACH FIGURE 16

1G034 SPRAY BAR 2 EACH FIGURE 3
8M904 ISP SPRAY NOZZLE L4013 (*SPRAY BAR) 16 EACH FIGURE 3
1M002 FEED PIPE 1 EACH FIGURE 2
1M070B TANK BREATHER 1 EACH FIGURE 20
1M317A BUNG DIAPHRAGM 1 EACH FIGURE 5
1M353 SPINNER BOWL COUPLING (SP-30-0101) 1 EACH FIGURE 18
1M354 BUNG RETAINER 1 EACH FIGURE 5
1M400 ROTARY UNION 1 EACH FIGURE 5
FILTER WITH WHITE CARTRIDGE (*WATER
4M742 1 EACH FIGURE 4
MANIFOLD)
4M742A WHITE CARTRIDGE (*WATER MANIFOLD) 1 EACH FIGURE 4
6M221 BALL VALVE 16MM (*WATER MANIFOLD) 1 EACH FIGURE 4
6M632A KNIFEGATE VALVE 100MM 2 EACH FIGURE 6

FILTER REGULATOR 1/4INCH 0-10BAR (SUPPLY
7M001K 1 EACH FIGURE 9
REGULATOR)
7M006D 4 BANK SOLENOID VALVE (110V) 1 EACH FIGURE 10
SOLENOID VALVE 110VAC (INDIVIDUAL
7M016 - EACH FIGURE 6
SOLENOIDS)
52 Revision 1.1
7M154 GLOBE VALVE 1 EACH FIGURE 4

SAFETY VALVE 1/4INCH (RELIEF VALVE,
7M302 *ELECTRICAL CABINET, *FOR BUNG 1 EACH FIGURE 8
DIAPHRAGM)
MINI REGULATOR 1/8INCH (*BUNG
7M303A 1 EACH FIGURE 8
DIAPHRAGM)
8M108E GASKET 150MM (*KNIFEGATE VALVES) 2 EACH -
8M110A FLINGER 1 EACH FIGURE 18
8M135 ISP O-RING 70MM (SHAFT COUPLING) 1 EACH FIGURE 18
8M810 ISP30 GEARBOX WITH 90ID LABYRINTH SEAL 1 EACH FIGURE 19
8M810A ISP30 MOTOR 415V IP56 1 EACH -
SILENCER PLASTIC 6MM (*ELECTRICAL
7M117C 2 EACH -
CABINET & GLOBE VALVE)
For enquiries contact: spares@gekkos.com
53 Revision 1.1
APPENDIX C: OEM MANUALS LISTING
REFERENCE DOCUMENT PART NAME REVISION DATE MANUFACTURER
A.5.1.2 QUICK START MANUAL VSD May 2002 ALLEN BRADLEY
A.5.1.2 USER MANUAL VSD July 2002 ALLEN BRADLEY
GLOBE
E.1.4.1 OPERATING INSTRUCTIONS 2003 BURKERT
VALVE
MAINTENANCE AND REPAIR GLOBE

E.1.4.1 2005 BURKERT
INSTRUCTIONS VALVE
GLOBE
E.1.4.1 INSTRUCTION MANUAL March 2001 BURKERT
VALVE
KNIFEGATE
E.1.5.1 PRODUCT DATA SHEET September 2005 KEYSTONE
VALVE
GLAND AND PACKING KNIFEGATE

E.1.5.1 January 2005 KEYSTONE
REPLACEMENT ISTRUCTIONS VALVE
KNIFEGATE
E.1.5.1 MATERIAL SPECIFICATIONS November 1998 KEYSTONE
VALVE
KNIFEGATE
E.1.5.1 MATERIAL STANDARDS November 1998 KEYSTONE
VALVE
KNIFEGATE
E.1.5.1 TEST PRESSURE CHART 22 April 1993 KEYSTONE
VALVE
54 Revision 1.1
55 Revision 1.1
APPENDIX D: TORQUE GUIDE FOR BOLT TIGHTENING
Maximum Bolt Loads (Grade 8.8)
Recommended
Size Tensile (kg) Shear (kg) Tightening Torque
(Nm)*
M8 2120 1600 22
M10 3370 2600 22
M12 4890 3800 77
M16 9100 7200 190
M20 14700 11700 370
M24 21200 16800 640
M30 33700 27000 1310
M36 49000 39500 2300
* Torque should be halved when using compressible gaskets.
56 Revision 1.1
10.0 FURTHER ASSISTANCE
57 Revision 1.1
Gekko Systems - Australia, Ballarat Gekko Systems - Australia, Perth

(Head office and Manufacturing Facility) Business Phone +61 8 9328 7200
Business Phone +61 3 5339 5859 Fax Number
Fax Number +61 3 5339 5803 Building A, Suite 5,
Address 321 Learmonth Road Address 661 Newcastle Street
City Ballarat
State Victoria City Leederville
Country Australia State West Australia
Postal Code 3350 Country Australia
Postal Address: Postal Code 6007
Notes PO Box 244 Notes
Wendouree, 3355
Gekko Systems - Canada Gekko Systems - South Africa

Business Phone +1 604 681 2288 Business Phone +27 11 448 1222
Fax Number +1 604 681 2220 Fax Number +27 11 448 1230
Address Suite 400 – 525 Seymour Stree Unit 31 Eastgate Business Park
Address
City Vancouver Marlboro Drive
State BC City Sandton, Johannesburg
Country Canada State
Postal Code V6B 3H7 Country South Africa
Notes Postal Code 2052
Notes
58 Revision 1.1
END OF MANUAL
59 Revision 1.1

ISP30 - User Instructions Operations, Maintenance

Uploaded by

Copyright:

Available Formats

You might also like

ISP30 - User Instructions Operations, Maintenance

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

ISP30 - User Instructions Operations, Maintenance

Uploaded by

Copyright:

Available Formats

ISP30 InLine Spinner Bowl

User Instructions: Operations, Maintenance

Operations & Maintenance Manual

0.2 Dec 2011 S. Waters All Draft manual for review

1.0 Jan 2012 S. Waters All Release

1.1 Feb 2014 Kur. Pamarthi Sections 2 & 3 HMI update

iii Revision 1.1

Gekko also offers a range of proprietary equipment including:

2.0 EQUIPMENT INFORMATION ................................................................................................................... 13

3.0 OPERATIONAL GUIDELINES................................................................................................................... 25

4.0 MAINTENANCE ......................................................................................................................................... 30

5.0 TROUBLESHOOTING ............................................................................................................................... 39

6.0 OPERATOR TRAINING SIGN OFF SHEET ............................................................................................. 41

7.0 OTHER RELEVANT DOCUMENTATION AND INFORMATION .............................................................. 43

8.0 GEKKO SYSTEMS PTY LTD WARRANTY ...............................................................................................45

9.0 APPENDICES ............................................................................................................................................50

10.0 FURTHER ASSISTANCE .........................................................................................................................57

1.0 GENERAL INFORMATION

1.1 About this Manual

1.1.1 Manual Purpose

1.1.2 Manual Scope

• Safety warnings and guidelines associated with ISP30

1.1.3 Manual Use and On-site Application

1.1.5 Warnings, Cautions and Notes

1.2 Safe Work Procedures

Under no circumstances should guards be removed from ISP systems

1.2.3 Isolation Procedures

1.2.4 Stored Energy

1.2.5 Working at Heights

1.2.6 Housekeeping Standards

1.2.7 Personnel Qualification & Training

1.2.8 Noise Levels

1.2.9 Recycling and End of Product Life

2.0 EQUIPMENT INFORMATION

2.1 InLine Spinner Bowl

1 ISP Frame 6 Feed Inlet

Figure 1. ISP30 General Arrangement

2.2 Theory of Operation

1 Feed Inlet (100 mm) 6 Concentrate Outlet

Figure 2. ISP30 Internal Features

2.2.1 Spinner Features

1 Spray Bar (2 off) 3 Spray Bar Water Inlet

Figure 3. Spider Assembly

1 Ball Valve 25 mm (MV-01) 5 Burkert Globe Valve (XV-01)

Figure 4. Water Manifold for Spider Assembly

1 Rotary Union Assembly 3 Bung Diaphragm

Figure 5. Airline Assembly for Bung (1G032)

1 Tails Tee 150NB 4 Feed/Bypass Tee 100NB

Figure 6. ISP30 Piping Assembly

2.2.2 Electrical Cabinet

1 Emergency Stop 3 Start (Green) / Sequence Stop (Red) Buttons

Figure 7. Electrical Cabinet Exterior

Solenoid Bank 3 Ph In / Motor Out

Figure 8. Electrical Cabinet Interior

2.2.3 Pneumatic Control

Figure 9. Air Supply

Figure 10. Air Actuated Valves