OPERATION MANUAL

FOR VIKING
Rev1
 Table of Contents
1.01 Introduction ................................................................................................................................. 3
1.01 Safety .................................................................................................................................... 4

2. INSTALLATION ................................................................................................................................. 5

2.02 Electrical Requirement .......................................................................................................... 5

2.03 Water Addition....................................................................................................................... 5
2.04 Hose Sizes and Expected Flows .......................................................................................... 6
2.05 Monitoring & Control Systems .............................................................................................. 6
2.04 Technical Specification ......................................................................................................... 7
2.07 Operating Clearance ............................................................................................................. 7

3. OPERATION ...................................................................................................................................... 8

3.01 Influence of Key Variables on Output ................................................................................... 8

3.02 Operating procedure ............................................................................................................. 8
3.03 Instructions for Start-up/Shut-down Procedures................................................................. 11
3.03.1 START UP PROCEDURE............................................................................................... 11
3.03.2 TESTING PROCEDURE ................................................................................................. 11
3.03.3 SHUT DOWN PROCEDURE A ....................................................................................... 11
3.03.4 SHUT DOWN PROCEDURE B ....................................................................................... 11
3.04 Protective Devices .............................................................................................................. 11

4. TROUBLE SHOOTING ................................................................................................................... 12

4.01 Trouble Shooting Step by Step ........................................................................................... 12

4.03 Coarser Particles in Concentrate than Screen Aperture .................................................... 13
4.04 Blockages............................................................................................................................ 13
4.05 Location of Mentioned Trouble Shooting Items .................................................................. 13

5. MAINTENANCE............................................................................................................................... 14

5.01 Technical Description of Components ................................................................................ 14

Electrical ........................................................................................................................................ 14
Mechanical ..................................................................................................................................... 15
5.02 Maintenance Inspections and Frequencies ........................................................................ 16
5.03 Recommended Spare Parts List ......................................................................................... 17

6. Abbreviations & Technical Diagrams .......................................................................................... 18

6.01 Abbreviations List ................................................................................................................ 18

6.02 Technical Support ............................................................................................................... 18
6.03 Technical Diagrams ............................................................................................................ 19
1.01 Introduction

The Viking is a Dense Media Separator, used to separate metalliferous ores from waste. It
separates ores based on their density differential. The version of the Viking produced by Gekko
Systems os primarily used as a testing unit. The Viking separates between dis-similar SG material in
the same way as the Inline Pressure Jig (IPJ), therefore it is an ideal method for testing the
separation characteristic of an ore sample.

The Viking uses water mixed with Ferro Silicon, increasing the slurry density, creating a dense media.
The density of the water and Ferro Silicon mixture can be set by varying the percentage of Ferro
Silicon to water.
1.01 Safety

Before Installing and/or Operating this equipment the Owner/Operator is encouraged

to perform a Hazard Identification and Risk Assessment on the unit and its
immediate area.

This Safety Audit should cover at least the following areas:

1. The foundations for the Unit are suitable.

2. The power supply to the Unit is safe and installed in compliance to local
regulations.
3. All operators have been suitable trained and inducted on the use of the Unit.
4. A detailed start up and shut down procedure should be available to the Operator.
5. The area adjacent to the Control Panel is free from tripping hazards.
6. A clearly identified lockout procedure is in place for both the Operator and
Maintenance Personnel.
7. The Operator has ready access to the Emergency Stop.
8. A procedure for Visitor Access near the Unit should be developed.
9. All pipework and Valves are clearly identified and readily accessible.
10. A Maintenance Schedule for the Unit should be developed.
11. All Maintenance should be performed by suitable qualified personnel and a
logbook maintained to record all work performed on the Unit.
12. Control of Access to the Control Panel and to other Machine settings is by
authorised Personnel only.
13. All signs and decals required are present and remain legible.
14. Lifting Facilities for Maintenance Personnel are available and are safe to use.
15. Handrails, steps etc should be provided if required.

Any concerns relating to the safe operation of the Unit that cannot be resolved by
Site Personnel should be directed to Gekko Systems.
 2. INSTALLATION

2.01 Foundation Requirements

Unit is to be set up level. The unit is 1940mm x 1150mm x 1805mm high (Approx 500kg)

2.02 Electrical Requirement

Power requirement = Approx. 1.1 kW, 3ph 415 volt.

The standard configuration is an electric motor driven hydraulic power pack.

The standard configuration is 3 ph 415 volts and earth, however it is possible to supply in virtually any
configuration. This must be specified on order.

2.03 Water Addition

Water supply should be of good quality so that the Ferro Silicon is not contaminated with foreign
particles.
2.04 Hose Sizes and Expected Flows

The pump outlet is a 50NB pipe which has a 5mm linatex inner liner.

Pump outlet

• Pump and pump discharge outlet.

The ideal flow rate, which the pump is to operate at, is in the range, 5 to 8m3/h. The pump flow rate
can be set and controlled with the flowmeter and pump VSD. (See section 2.05, ‘Monitoring and
control system’, for more details).

2.05 Monitoring & Control Systems

The Viking is supplied with a magnetic flow meter on the pump outlet.
 • Magnetic flow meter on pump outlet.

The Viking parameters can be controlled, internally are:

{ PUMP FLOW RATE

{ FERRO SILICON SLURRY DENSITY
The pump flow rate is controlled with a VSD and magnetic flowmeter in a PI control loop.

2.04 Technical Specification

Model DMS02
Design Temperature 25 oC
Pump inlet cone volume 25-30 Litres
Pump outlet cone volume 3-4 Litres

Power Requirement, approx. 1.1 kW 3ph 415volt.

Pump Output Flow capacity 0-30 t/hr

2.07 Operating Clearance

For a comfortable operating zone we have suggested some minimum clearances. There should be at
least 1m around the sides of the Viking, for access.
 3. OPERATION

3.01 Influence of Key Variables on Output

Variables
Impact on
Water Addition concentrate/density Sinks
(Litres) Up Lower Slurry mass/density Increased %Sinks
Down Higher Slurry mass/density Decreased %Sinks
Ferro Silicon Addition
(kg) Up Higher Slurry mass/density Increased %Sinks
Down Lower Slurry mass/density Decreased %Sinks

3.02 Operating procedure

The viking is controlled by the operator by the simple stop/start pushbuttons on the cabinet door adjoining the
unit itself. When started, the pump recirculates solution through the cone where it spills into the launder and
returns to the pump hopper.

The flow of the solution is adjusted by varying the speed of the pump to achieve a constant flow. The setpoint
is entered through the Drive peripheral interface screen, mounted next to the Viking cone. There are two
methods for adjusting the flow setpoint, each described below.

Firstly, the setpoint parameter may be accessed through the parameter menu’s. The following steps demonstrate
this:

• ‘Esc’ or ‘Enter’ to view drive menu’s

• Scroll to ‘Parameters’ and select by pressing ‘Enter’

• Scroll to ‘Speed Control’ and select by pressing ‘Enter’

• Scroll to ‘Process PI’ and select by pressing ‘Enter’

• Scroll to ‘PI Setpoint’ and select by pressing ‘Enter’

• Enter desired setpoint using the numeric keypad, as percentage of full scale, and accept new parameter
by pressing ‘Enter’

• Press ‘Esc’ repeatedly until drive diagnostic menu appears, showing motor speed and load.

Alternatively, the flow setpoint can be adjusted by going straight to the parameter by entering the parameter
number. The following steps demonstrate this:

• ‘Esc’ or ‘Enter’ to view drive menu’s

• ‘Alt’ key to access the alternate function, then the ‘Param #’ key. A new menu will appear, displaying
the first of the many drive parameters.
• Enter the number ‘127’ using the numeric keypad a confirm by pressing ‘Enter’

• Press ‘Enter’ again to edit parameter 127.

• Enter desired setpoint using the numeric keypad, as percentage of full scale, and accept new parameter
by pressing ‘Enter’

• Press ‘Esc’ repeatedly until drive diagnostic menu appears, showing motor speed and load.

PI Setpoint, shown in Parameter file

‘D’, ‘Speed Command’

The flow setpoint is adjusted through

the Drive faceplate, mounted next to
the operating platform adjacent the
cone and launder.
The Flowmeter is scaled to operate in a range of 0 - 20m3/hr, and the drive setpoint is adjusted to a range of 0 –
100%. This means that the percentage setpoint corresponds to flow units, in m3/hr, as represented by the
following table. This table may be used as a reference when setting up the required flow in the Viking.

Drive Flow Actual Flow

Setpoint Setpoint
0% 0 m3/hr
5% 1 m3/hr
10% 2 m3/hr
12.5% 2.5 m3/hr
15% 3 m3/hr
17.5% 3.5 m3/hr
20% 4 m3/hr
22.5% 4.5 m3/hr
25% 5 m3/hr
27.5% 5.5 m3/hr
30% 6 m3/hr Typical Operating Range
32.5% 6.5 m3/hr
35% 7 m3/hr
37.5% 7.5 m3/hr
40% 8 m3/hr
42.5% 8.5 m3/hr
45% 9 m3/hr
50% 10 m3/hr
55% 11 m3/hr
60% 12 m3/hr
65% 13 m3/hr
70% 14 m3/hr
75% 15 m3/hr
80% 16 m3/hr
85% 17 m3/hr
90% 18 m3/hr
95% 19 m3/hr
100% 20 m3/hr
3.03 Instructions for Start-up/Shut-down Procedures

3.03.1 START UP PROCEDURE

1. Ensure all valves are closed and wire baskets are removed.
2. Set the flow rate on the VSD to your required setting. Parameter 83 on the
Alen Bradely VSD is a percentage (0-100%) of the maximum flow rate, 30m3/h
3. Fill the unit with water to approximately the top of the pump feed cone.
4. Press the Pump Start on the control cabinet.
5. Ensure that water begins to flow from the pump outlet, cone weir, back to the
pump inlet cone.
6. Add Ferro Silicon to the pump feed cone, until required slurry density is reached. Insert the
Marcy bucket under the pump outlet cone weir discharge, to measure the slurry density.

3.03.2 TESTING PROCEDURE

1. Insert the Floats wire basket, then the Sinks wire basket.
2. Adjust the flow rate to required setting.
3. Re-measure the slurry density. If to high or low make appropriate action.
4. Wash Sample and ensure that it has been screened to at least the smallest wire basket
aperture.
5. Add sample to the pump outlet cone, at a steady rate. Ensure that not to much sample is
added, avoiding build in the wire baskets.
6. Once sample has been added, remove the sinks basket.
7. Before removal of the floats basket ensure that there is no floats court up in the weir.
Remove Floats basket.
8. Wash Ferro Silicon from the sample in the wire baskets. Ferro Silicon should be washed into
a container to prevent wastage and to reduce consumption of Ferro Silicon.

3.03.3 SHUT DOWN PROCEDURE A

1. Ensure sump valve is closed. Open Pump Outlet Pipe Dump Valve.
2. Stop pump when fully drained.

3.03.4 SHUT DOWN PROCEDURE B

1. Place 20L bucket under sump drain valve. Open Sump drain Valve.
2. Open Pump Outlet Dump Valve.
3. Stop pump when fully drained.
4. Put bucket under sump drain valve. Open Sump Drain Valve. Close Sump Drain Valve when
bucket is full.
5. Stop pump when it is fully drained.
6. Place empty 20L bucket under Sump Drain Valve and wash Ferro Silicon out of sump into
bucket. Repeat until all Ferro Silicon is emptied from sump.

3.04 Protective Devices

The Allen Bradley VSD will fault if there is a blockage in the pumping system. If the VSD faults in this
manner, the fault is displayed on the VSD.
 4. TROUBLE SHOOTING

4.01 Trouble Shooting Step by Step

Fault Possible Counter Measures

Cause
1. Check that power light is on to control box, if not look for
controller in Tripped electrical switches, reset and restart. (electrician only)
electric's box 2. If power light on, look at solenoid power, check solenoid with
Multimeter and do a magnetism test. If there is no power or
Magnetism replace the solenoid.

Fault Possible Counter Measures

Cause
Water
meter
'Very low' 2. Check flow meter, if the reading has dropped on the
Flow Display, turn hutch water up until setting is correct..
4.03 Coarser Particles in Concentrate than Screen Aperture

4.04 Blockages

4.05 Location of Mentioned Trouble Shooting Items

Figure 3. Important locations on Viking (see attachment GA)

 5. MAINTENANCE

5.01 Technical Description of Components

Electrical

Part Description
Number

1.1 kW Motor

1E008A 40mm Magnetic Flow Meter

1E506B Pushbutton Contacts

1E510C Pushbutton contact
1E606N Contactor
1E505A Pushbutton actuator
1E507B Pushbutton actuator
Transformer
1E609D Circuit breaker
1E612C Relay

1.5 kW Variable speed drive

1E191G LCD Keypad

1E521A Isolator

Some part numbers will vary depending on voltage. ( refer spares list)
Mechanical

Part Description
Number

Floats Cone
Pump hopper
Pump impeller
1M800A Bush with vanes

1M800 Shaft
Impeller shaft / vane assy.
Pump housing
Pump discharge pipe
1M750 Floats screen basket
1M750A Sinks screen Basket
1M799 Nylon bush
5.02 Maintenance Inspections and Frequencies

To ensure correct operation of the Viking it is recommended that a Maintenance

Procedure be developed in line with the specific site and operational conditions that
the IPJ operates under.
All adjustable parameters should be recorded so that the unit can be readily set up
following Maintenance or replacement of components.
As a minimum, the Maintenance Procedure should include the following:

FREQUENCY Description Comment

5.03 Recommended Spare Parts List

Order from: Gekko Systems Pty Ltd Ph: (61 3) 5339 5859
321 Learmonth Rd. Ballarat, Vic 3350 Fax: (61 3) 5339 5803

Email services@gekkos.com

NOTE: Postage and handling costs are additional, with all unit prices subject to
change
Prices are available on request
 6. Abbreviations & Technical Diagrams

6.01 Abbreviations List

6.02 Technical Support

Gekko Systems Pty Ltd will provide full technical support and after sales service for every unit sold.

For spare parts listing and technical information please contact,

Gekko Systems Pty Ltd.

321 Learmonth Rd.
Ballarat 3350
Victoria
Australia
Phone (61 3) 5339 5859
Fax (61 3) 5339 5859.

services@gekkos.com

*NOTE: This document is a dynamic document and all input from operator experience would be
greatly appreciated.
6.03 Technical Diagrams

see attached drawings

1. General Arrangement
2. Electrical shematic