Summary of Contents for SPIRAC SANDSEP SA200
- Page 1 Installation, Operation & Maintenance Manual For SANDSEP ® Grit Washing and Dewatering www.spirac.com I v.2 I 12/2023...
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Page 2: Table Of Contents
Installation, Operation & Maintenance Manual SANDSEP ® TABLE of CONTENTS Section Contents Page 1.0 INTRODUCTION GENERAL PRODUCT IDENTIFICATION PRODUCT DESCRIPTION DECLARATION OF CONFORMITY 2.0 INSTALLATION GENERAL ASSEMBLING THE TROUGH CONNECTION OF SPIRALS MOUNTING THE DRIVE ASSEMBLY ELECTRICAL WELDING 3.0 OPERATION PRE-START CHECKS OPERATIONAL CHECK-LIST EXTENDED SHUT-DOWN... - Page 3 Installation, Operation & Maintenance Manual SANDSEP ® APPENDIX A APPENDIX B APPENDIX C APPENDIX D APPENDIX E APPENDIX F APPENDIX G APPENDIX H SANDSEP ® Page 2 of 42...
- Page 4 Installation, Operation & Maintenance Manual SANDSEP ® APPENDIX Reference Contents CONVEYOR DATA SHEETS LUBRICATION CHECK SHEETS DRAWINGS GEARBOX PARTS LISTS MOTOR PARTS LISTS MOTOR TYPE TEST CERTIFICATES WELDING PROCEDURES OTHER EQUIPMENT SANDSEP ® Page 3 of 42...
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Page 5: Introduction
INTRODUCTION GENERAL We welcome you as a user of SPIRAC Sandseps. Your Sandsep is a product of careful engineering and skilled workmanship. We believe you have the best machine possible for the service intended. With reasonable care and preventive maintenance it will give you long, efficient, trouble-free service. -
Page 6: Product Description
Installation, Operation & Maintenance Manual SANDSEP ® PRODUCT DESCRIPTION The figure below (Figure 1.3a) shows the principal parts of the Sandsep. Drawings of the particular Sandsep can be found in Appendix . Figure 1.3a - Principal Parts of the Sandsep The incoming flow of material is directed into the Sandsep via the Inlet Flange. -
Page 7: Declaration Of Conformity
Installation, Operation & Maintenance Manual SANDSEP ® Figure 1.3b - Flow Pattern Within Sandsep There are two threaded outlets at the lowest point on the trough; these are for emptying the unit when servicing or putting into storage. The upper port (with the ball valve) is to discharge majority of the fluid to waste. -
Page 8: Installation
Installation, Operation & Maintenance Manual SANDSEP ® INSTALLATION GENERAL These instructions must be carried out in the order stated to prevent machine damage and personal injury. Check Sandsep package for shortages and damage immediately upon arrival (an absolute must!). Prompt reporting to the courier agent, with notations on the freight bill, will expedite satisfactory adjustment by the courier. -
Page 9: Connection Of Spirals
Installation, Operation & Maintenance Manual SANDSEP ® Check that the trough-sections are positioned in the correct order. The trough-ends are marked with letters to show the order in which they should be assembled. Make sure that the sealing strip or gasket is placed between the trough-sections. Fix the trough-sections together with the bolts, nuts and washers provided (see Figure 2.2a). -
Page 10: Mounting The Drive Assembly
Installation, Operation & Maintenance Manual SANDSEP ® Centre the spiral sections in the trough using heavy wooden blocks or steel profiles. Check with a tri-square that the spiral sections are in line before they are welded together. Weld alternately on both sides of the join. Grind the weld carefully to remove sharp edges and unevenness. -
Page 11: Electrical
Installation, Operation & Maintenance Manual SANDSEP ® Fasten the locking bolt, spring washer and stepped spacer to the spirals drive shaft in order to fasten this in the gearboxes drive bore (see Fig 2.4b). When the spiral’s drive shaft is firmly positioned in the drive bore the locking bolt should be tightened to the torque specified (refer Sect. -
Page 12: Welding
Installation, Operation & Maintenance Manual SANDSEP ® No-Speed Protection Devices such as zero speed switches to shut off the power in the event of any incident that might cause the Sandsep to stop operating. Safety shut off switch with power lock-out provision at Sandsep drive. Emergency stop switches readily accessible whenever required. -
Page 13: Operation
Installation, Operation & Maintenance Manual SANDSEP ® OPERATION PRE-START CHECKS Only persons completely familiar with the safety aspects (as detailed in Sect. 7.0) should be permitted to operate the Sandsep. The operator should thoroughly understand these instructions before attempting to use the Sandsep. Failure to follow these precautions may result in serious personal injury or damage to equipment. -
Page 14: Operational Check-List
Installation, Operation & Maintenance Manual SANDSEP ® OPERATIONAL CHECK-LIST The following should be used upon initial start-up and after extended shut-down periods. Operate Sandsep empty for 1-2 hours, making a continuous check for heating of gearbox bearings and noisy operation. Check that the discharge of the Sandsep is clear before opening inlet flow device. -
Page 15: Maintenance
Installation, Operation & Maintenance Manual SANDSEP ® MAINTENANCE GENERAL Generally it is necessary to establish routine periodic inspections of the entire Sandsep to ensure continuous maximum operating performance. Practice good housekeeping. Keep the area around the Sandsep and drive assembly clean and free of obstacles to provide easy access and to avoid interference with the function of the Sandsep or drive. -
Page 16: Lubrication
Installation, Operation & Maintenance Manual SANDSEP ® LUBRICATION Please refer to the Lubrication Check Sheet located in Appendix for Grease and Oil types for your particular conveyor. SURFACE COATING This section describes how the Sandseps surfaces should be treated, if made of stainless steel or not. - Page 17 Installation, Operation & Maintenance Manual SANDSEP ® Stainless steel should not come into contact with steel of other qualities during transportation or assembly. Wood, cloth or plastic should be used to pad the stainless steel when lifting or transporting the Sandsep. The heat input during welding leads to the formation of chromium oxides on the steel surface.
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Page 18: Maintenance Time Table
Installation, Operation & Maintenance Manual SANDSEP ® MAINTENANCE TIME TABLE The following checks outlined below are recommendations only. They can be adjusted to suit the operation time of the Sandsep or incorporated into existing site maintenance procedures. It is important, particularly with all new equipment that it be monitored for performance / potential hazards and as a result specific procedures developed. -
Page 19: Service
Installation, Operation & Maintenance Manual SANDSEP ® SERVICE REPLACING THE GLAND PACKING Empty Sandsep of all material. Unscrew the gland cover screws and slide the cover back along the drive shaft. Figure 5.1a - Gland Cover Screws Figure 5.1b - Packing Box Assembly Remove the packing and clean the packing box seats. - Page 20 Installation, Operation & Maintenance Manual SANDSEP ® Steel Plate Technical data concerning the liners steel and plastic qualities is specified on the drawings. Liners can often be replaced without the spiral being totally removed. However servicing is easier without the spiral in the trough. Replacing the Plastic Liner - The new plastic liners are either delivered ready shaped or flat.
- Page 21 Installation, Operation & Maintenance Manual SANDSEP ® Figure 5.2c - Levering Out the Liner Figure 5.2d - Pulling Out the Liner Push the new liner under the spiral, making sure the wear indicator strip is at the bottom. It is important to secure the liner under the retainer blocks on each side of the trough (Figure 5.2e &...
- Page 22 Installation, Operation & Maintenance Manual SANDSEP ® Figure 5.2g Replacing the Steel Liner - This section describes the replacement of both steel bar and steel plate liners. The majority of the steps are common to both procedures. Where the steps differ, this is noted in the text.
- Page 23 Installation, Operation & Maintenance Manual SANDSEP ® Check that the bars are all in line. For steel plate liner:- place welds opposite each other along the length of the trough. For steel bars:- Put welds (75run/250pitch) along the length of the bar. The welds should alternate from the left to the right hand side of the bar (125pitch).
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Page 24: Replacing The Spiral
Installation, Operation & Maintenance Manual SANDSEP ® Figure 5.2l Figure 5.2m REPLACING THE SPIRAL There should be no welded joints in the spiral closer than 4 spiral-turns to the spirals coupling disc. Unfasten the bolts holding the protective cover and remove it from the trough. Check the new spiral has the dimensions given on the drawing and check against the existing spiral. -
Page 25: Replacing The Drive Shaft
Installation, Operation & Maintenance Manual SANDSEP ® REPLACING THE DRIVE SHAFT Unfasten the bolts holding the protective cover and remove it from the trough. Un-bolt the spirals coupling disc from the drive shafts coupling disc. Figure 5.4a - Removing the Spiral Remove the spiral from the trough or move it forward enough so that the drive shaft can be removed via the trough. - Page 26 Installation, Operation & Maintenance Manual SANDSEP ® Figure 5.4c - Gland Cover Screws Figure 5.4d - Using an Extractor Tool Use an extractor tool to push the drive shaft into the trough. Remove the key from the gearbox keyway before the drive shaft goes through the packing box. NB - The end of the drive shaft must be protected so that the threads are not damaged.
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Page 27: Troubleshooting
REMEDY Worn spiral screw Replace spiral Sandsep output is too Material being conveyed is not as Contact SPIRAC originally specified Excess material causing spiral to rise Reduce material inflow. Install and interfering with lids/cross bars anti-lift bars Foreign object in conveyor... - Page 28 Installation, Operation & Maintenance Manual SANDSEP ® PROBLEM CAUSE REMEDY Determine and correct cause of failure and Blown Fuse replace fuse Motor protection device Reset protective device. Identify and correct activated cause for failure Sandsep Fails to Start Motor protection device faulty or will not reset Check protection device for faults Motor not connected for...
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Page 29: Safety
The following instructions should always be observed when handling or working with the sandsep – SPIRAC equipment is supplied conforming to AS 4024.1 - 2006 - Safeguarding of Machinery and complies providing all guards remain locked in place with the bolts supplied. -
Page 30: Spare Parts
Liner Trough Section RECOMMENDED SPARE PARTS SPIRAC have endeavoured to provide you with equipment that will give you continued and long lasting service. However, we recommend that the following wear items be kept as a minimum to ensure uninterrupted service: SANDSEP ®... -
Page 31: Supplier Contact
SANDSEP Drawings in “APPENDIX”, also quoting the drawing number. SUPPLIER CONTACT SPIRAC has Sales Offices throughout the world. Manufacturing is undertaken in Australia and Sweden. If you are unsure of your Agent, please make your initial contact to – America Australia and Asia Pacific SPIRAC (USA) Inc. -
Page 32: Conveyor Data Sheets
Installation, Operation & Maintenance Manual SANDSEP ® APPENDIX A CONVEYOR DATA SHEETS... - Page 33 Installation, Operation & Maintenance Manual SANDSEP ® Document Number : Enter SPIRAC Project Number Here–CDS-01 Project : Enter Project Name Here SPIRAC Client : Enter SPIRAC Client Name Here Conveyor Type : SA260-SPX/SS SPIRAC Conveyor Tag : Enter SPIRAC Project Number Here-...
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Page 35: Lubrication Check Sheets
Installation, Operation & Maintenance Manual SANDSEP ® APPENDIX B LUBRICATION CHECK SHEETS... - Page 36 Installation, Operation & Maintenance Manual SANDSEP ® LUBRICANT CHECK SHEET Part to be lubricated Gearbox Recommended lubricant BP Energol GR-XP 220 (or equiv) Change Frequency 6 - 12 months Oil Volume Refer Gearbox Tag Plate Part to be lubricated Bell Housing Gland Packing – Buraflon 5846 / 6.35 Recommendable lubricant Castrol Grease EPL2 Multi Purpose Extreme Pressure Change Frequency...
- Page 37 Installation, Operation & Maintenance Manual SANDSEP ® APPENDIX C DRAWINGS...
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Page 38: Gearbox Parts Lists
Installation, Operation & Maintenance Manual SANDSEP ® APPENDIX D GEARBOX PARTS LISTS... -
Page 39: Motor Parts Lists
Installation, Operation & Maintenance Manual SANDSEP ® APPENDIX E MOTOR PARTS LISTS... -
Page 40: Motor Type Test Certificates
Installation, Operation & Maintenance Manual SANDSEP ® APPENDIX F MOTOR TYPE TEST CERTIFICATES... -
Page 41: Welding Procedures
Installation, Operation & Maintenance Manual SANDSEP ® APPENDIX G WELDING PROCEDURES... -
Page 42: Other Equipment
Installation, Operation & Maintenance Manual SANDSEP ® APPENDIX H OTHER EQUIPMENT...
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