HEXA

Screw Conveyor & Compactor

Jeffcon Engineering Sdn Bhd (578553 H)

No. 4, Jalan Anggerik Mokara 31/53, Seksyen 31, Kota Kemuning, 40460 Shah Alam, Selangor
Darul Ehsan, Malaysia.

Tel : 603-5121 4373 / 5121 4363 Fax : 603-5122 1568

Website : www.jeffcongroup.com
Email : sales@jeffcongroup.com
 Jeffcon Engineering Sdn Bhd

Table of Contents
1. Introduction
a) Screw Conveyor & Compactor
b) Scope of Operational and Maintenance Manual.

2. Safety and Precaution

a) Caution against safety operation
b) Safety Measures

3. Construction
a) Spiral Screw Conveyor & Compactor
b) Trough Linings
c) Compactor
d) Drive Power Unit
e) Support Structure & Ceiling Suspension
f) Optional Equipment

4. Product Specifications and Relevant Standard

5. Precaution on Operation Handling

a) Before Starting Operation
b) Operation
c) Stopping

6. Operational Procedure

7. Maintenance and Inspection

a) General Precaution
b) Maintenance and Inspection
c) If the machine is Stop and Prolong from Operation

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8. Lubrication

9. Troubleshooting
a) General
b) Troubleshooting List

10. Safety Device (Optional)

a) Torque Limiter
b) Brake Provided Motor
c) Operation of Safety Device

11. Design
a) Process Design
b) Features of Screw Conveyor & Compactor

12. Material List

13. Operation Maintenance & Management

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1. Introduction
1.1 Screw Conveyor & Compactor
Intermittent Screw Conveyor & Compactor are excellent in transferring or
removing, de-watering, compacting debris and suspended substances from waste
water or intake streams. Our simple design and fewer components mean longer life,
quick installation and low cost maintenance. Efficient, cost effective, durable and
dependable, they are far lower in overall costs.

1.2 Scope of Operational & Maintenance Manual

This manual applies to the main body of the Intermittent Screw Conveyor &
Compactor and its accessories. For the accessories of each unit apparatus,
appropriate maintenance and operation manuals are attached.

2. Safety and Precaution

This section contains importance on safety issues regarding the Screw Conveyor &
Compactor. Read carefully before you proceed with installation, service, or operation
of the equipment.

2.1 Caution against safety operation

This manual is mainly for the operators and the maintenance personnel.
 Operators and must be well educated in all daily operations
 Service, maintenance, and management personnel must be technically skilled
and with a good education on Screw Conveyor & Compactor.

WARNING
Read this manual before operating or servicing this equipment. It is
important to understand the instructions prior to using or maintaining the
equipment.
Safety regulations must be obeyed. Negligence may cause serious injuries
or damage to the equipment.

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2.2 Safety Measures

Incorrect use, inadequate maintenance, or carelessness may cause personal injury,
material damage, or equipment failure. Personnel using or servicing the equipment
must have sufficient knowledge and expertise to carry out their tasks. It is therefore
important to read, understand, and adhere to the directions in this manual.

a) Always isolate the conveyor main power source and ensuring that the conveyor
cannot be started before commencing any servicing work.
b) Avoid any compression injuries when removing or replacing spiral. Note that
the spiral can slide out through when the conveyor is inclined.
c) Never put arms, legs or any loose objects in the conveyor if the main power
source has not been locked off.
d) The protective cover should not be removed when in operation.
e) Make sure no one is working before the conveyor is started.
f) Personnel working with the conveyor should use protective clothing if
hazardous materials are being conveyed.

 Always follow the safety regulations, general or local, when working on

electrical equipment.
 Note and report incidents and potential dangerous situations through
attentive awareness of events occurring in the vicinity of the equipment.
 There is a possible risk for personal injuries when repairing, servicing, or
installing the conveyor.

Caution against Safety Operation

In the beginning of the operation, operator must read and understand this
manual and maintenance manual completely.

Unexpected trouble shall cause for a careless operation and a poor operation.

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3. Construction
This machine is constructed as follows. Screw Conveyor and Compactor installed at a
situated area transfer the suspended substances contained in that influent water. The
suspended substances caught on the Screw conveyor into the compactor portion by
which the substances are thrown into the carrying–out facility.

Above shown illustration of a Screw Conveyor component parts assembly

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Spiral Screw
The Spiral Screw Conveyor is manufactured from high tensile steel with a minimum
breaking strength above 500N/mm2 The steel is cold rolled with substantial increased in
hardness and wear resistant.

Compactor
The Compactor is part of the system attach with the Conveyor which compacts the
debris that need to be thrown out into the carrying-out facility. It is manufactured from
high tensile steel with a minimum breaking strength above 500N/mm2 The steel is cold
rolled with substantial increased in hardness and wear resistant.

Trough Linings
The Spiral Screw Conveyor is equipped and protected with lining to against wearing
and tear. It is replaceable. Linings can be custom make for plant upon request, specified
for ordering.

Drive Power Unit

The Drive Power Unit is an electrical component which drives the reduction gearbox to
the Spiral Screw Conveyor. The Drive Power unit can be replaced at the inlet end of the
conveyor or at the outlet end. It also depends on the material need to be conveyed.

Support Structure and Ceiling Suspensions.

The conveyors are standard for with supporting structure or ceiling suspended of
correct length and design. On site installation, bolting and anchorage are necessary to
accommodate concrete flooring and interfering structures.

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Optional Equipments
Pivot and wheel frames or carriages for traversing conveyors, as alternative to standard
supporting structure.

a) Electronic overload protection system.

b) Gland boxes for the drive shaft in wet conveying applications.
c) Axial support bearings for long, pushing spirals. The axial support bearing is fitted
at the non-powered trough end plate avoiding compression of the spiral.
d) Rotation guards.
e) Inspection doors
f) Sliding gates for discharge boxes.
g) Trough flushing equipment.
h) De-watering unit removes water in the sludge before being sent out.

Lubricating point
The drive shaft bearing, the shaft end bearing are lubricated by a centralized lubricating
system using manual grease. The end portion is made from a flexible tube so that it may
follow adjustment, etc.

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4. Product Specifications and Relevant Standard

Technical Specifications

Max. Handling Spiral Spiral Motor

Item Standard Other
Model Capacity Dia. Speed Rating
No. Material Material
(m3/hr) (mm) (rpm) (kW)
JSC – 150
1 1.2 130
JSCP – 150
JSC – 200
2 3.4 180
JSCP – 200
JSC – 250
3 6.0 230
JSCP – 250
JSC – 280
4 9.0 260
JSCP – 280
0.75
JSC – 300
5 11.0 280 20 ~ 35 ~ S.S G.I.
JSCP – 300
15.0
JSC – 350
6 16.0 330
JSCP – 350
JSC – 400
7 25.0 380
JSCP – 400
JSC – 450
8 34.0 400
JSCP – 450
JSC – 500
9 42.0 480
JSCP – 500

Note : (a) S.S - Stainless Steel (AISI Grade 304 or Grade 316)
(b) GI - Galvanized Mild Steel

Components Material / Specifications

Item No. Components Material / Specifications
1. Drive Unit Gear Motor IP 55
2. Conveyor Trough S.S / GIMS
3. Structure Support GIMS
4. Control Panel 415V, 3Ph, 50Hz (IP 55)
5. Drive Unit Power Rating 0.75- 5.5kW (415V, 3Ph, 50Hz)
6. Trough Liner / Wet Trough Nylon / FRP / PE
7. Drainage Duct / Support Structure / Cover S.S / GIMS
8. Compactor Sieve S.S / GIMS

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5. Precautions on Operation (Handling)

This machine is rotated in the normal direction, as standard. Do not attempt operation
in the reverse direction.

Before Starting Operation, confirm the Operation Checklist in Table 1. Further,

communicate with personal to that effect.

Table 1: Operation Checklist 1

No. Item Action

1. The oil level in the gearbox is proper. Add oil up to the proper level. (Do not
(In the case of oil lubrication). use improper oil)

2. Check that the discharge of the Remove any obstacle, etc.

conveyor is clear before feeding any
material.

3. There is no obstacle in the inside of Remove the obstacle, etc.

the frame or in any area where the
screw conveyor, etc. move.

4. No part is rusted. Remove rust.

5. No part is broken or worn out. Replace broken or worn-out parts.

6. No mounting bolt or foundation bolt Tighten or replace new.

is loosened.

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Operation
Before starting operation, communicate with other personals and confirm safety
sufficiently. During the operation, confirm the Operation Checklist in Table 2.

Table 2. Operation Checklist 2.

No. Item Action

1. There is no abnormal sound and/or If any, stop the machine and examine the
abnormal vibration. cause.

2. Current values during operation are If abnormal, stop the machine and
normal. examine the cause.
(Compare with the values obtained
during normal operation.)

4. The spiral screw is misaligned Stop the machine and adjust.

5. Insulation of the motor and the Stop the machine and check with a circuit
electric apparatus is normal. tester. If improper, repair or replace the
motor.

6. There is no abnormal heating. Stop the machine and check the oil level,
etc.

7. During Operation, cover, etc. should Do not remove the cover, etc
not be removed.

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6. Operational Procedure
Operation:

1. Before initial operation of the unit.

a. Check all bolts and nuts are secured.
b. Clear all debris and remove any obstruction or metal objects that could damage
the screw.
c. Screw and Drive unit accurately aligned for smooth operation of the unit.

2. When in operation of the unit :

a. Do not climb on top of the Screw conveyor / compactor even if it is not working
(apart from danger of falls, there is real risk of damaging it the unit.
b. Do not work on electric motor unless you have disconnected the machine from
the electric supply source (risk of electrocution)
c. Do not wash the machine using the jet of water that could come in contact with
electrical parts.

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7. Maintenance and Inspection.

In order to use the machine for a longer life span and more economically, daily
maintenance and inspection are important.

General Precautions

a) Before inspecting the drive shaft, etc., turn off the power supply and stop the
machine at the definite position.
b) Before starting maintenance and inspection, turn off the power supply and mount an
indication plate “CHECK” or “REPAIR” on the operation panel, so that other
personals will not attempt to start the machine.
c) When inspecting the inner of the frame, wear a safety band without fail to prevent
from falling.
d) If there is a possibility that a toxic gas is produced or lack of oxygen conditions
occurs inside the basin, before starting inspection, measure the toxic gas
concentration and oxygen concentration and confirm that they are above the
required levels.
e) In any place where, even if these concentrations are above the required levels, the
toxic gas production of lack of oxygen condition is liable to occur, conduct forced
ventilation continuously.

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Maintenance and Inspection

Below are check point for the maintenance as a general model for a minimum
maintenance.
Before starting the maintenance work, always make sure that the main electrical switch`
must be switched off and locked to prevent accidents.

1. Check oil level in Drive Unit monthly.

2. Check for condensation of the oil. If water is present, drain, flush and refill to
operating level with manufacturer’s recommended lubricant.
3. Check all bolts and nuts are secured monthly.
4. Lubricating all rotating parts, bearings with recommended lubricant weekly.

If the machine is stop and prolong from Operation.

In such case, take note on the following task.
a) Prolonging the machine from operating may cause the Spiral Screw and the
Compactor to be defective. Conduct idle operation for about 10 minutes once
everyday without fail.
b) For rotating shaft at the end of the Spiral Screw. Lubricate with lubrication
recommended and grease nipples are supplied on each unit of the conveyor unit.
c) Inspect for corrosion or loosening of bolts and nuts.
d) Inspect for deformation, distortion, etc. of the Spiral Screw and Compactor.
e) For the Gear Box, refer to the Gear Reducer Operation Manual.

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8. Lubrication
Table 4. shows the lubrication list for this machine. Proper lubrication is essential for
prolonging the life span of the machine.

Frequency and
Location Oil or Grease Quantity Frequency
Method
1. Oil lubrication
Royal Purple
Gear Box
gear oil # 220
(Synergy EP
gear oil) For the quantity frequency and method, refer to the
2. Grease attached “Gear Box Operation Manual”
lubrication
Liutium
Complex
(Molyblex)Citgo
Axial
Liutium Complex Proper Once a
Support Grease Gun
(Molyblex)Citgo quantity month
Bearings

Drive Screw Liutium Complex Proper Once a Application suing a

Shaft (Molyblex)Citgo quantity month brush, etc.

Notes :
1. The oil (grease) quantity in this list shows the quantity per unit.
2. For lubrication, use the oil or grease shown in this list, or equivalent.
3. The frequency in this list shows a guide for oil or grease replacement. In the actual
maintenance, determine the optimum frequency base on the condition of oil or
grease.

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9. Troubleshooting.

9.1 General
During maintenance inspections, be alert for signs of motor, conveyor and compactor
trouble. Common symptoms are listed for reference to troubleshoot immediately and to
avoid costly repairs and shutdown.

9.2 Troubleshooting List

PROBLEM CAUSE REMEDY

Determine and Correct Cause of
Blown Fuse.
Failure and Replace Fuse.
Reset Protective Device. Identify
Conveyor Fails to Motor Protection Device Activated.
and Correct Cause for Failure.
Start
Check Connection Diagram in
Motor not Connected for proper
Conduit Box Cover and Correct
voltage.
the Wiring.
Spiral Jam from Foreign Object
Remove Object and Restarts.
entering trough.

Gearbox Seizure due to no oil. Remove Gearbox and Service.

Conveyor Starts but
Motor Protection Check Connection Diagram in
Setting on Motor Protection
Device Trips Conduit Box Cover and Correct
incorrect.
Immediately the Wiring.
Check Connection Diagram in
Motor Improperly connected. Conduit Box cover and correct
the wiring.

Loose Drive Station. Check and Re-tighten.

Excessive vibration Unstable Ground Conditions. Rectify.

Loose Support / trough Connections

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Worm Spiral Screw Replace Spiral.

Conveyor output is
Material being Conveyed is not as
too Low. Contact JEFFCON.
originally specified.

Check Connections Diagram on

Insufficient Cooling Air Volume due
Conduit Box and Correct
to Obstructed Air Flow.
Wiring.

The problem may not be solved

Motor Allowable duty cycle is
Motor Overheats by a larger unit. Review with
exceeded. Too many starts per Hour.
Manufacturer.

Single phasing due to break or loose

connection in supply line or Blown Repair supply line. Replace fuse.
Fuse.

Excess Material causing Spiral to

Reduce Material Inflow. Install
rise and interfering with Lids / Cross
Anti-lift Bars.
Bars.

Foreign Object in Conveyor. Remove Objects.

Spiral Screw
Jamming Liner has come loose and wedged Remove and Replace Liner.

itself inside the Spiral. Confirm and replace / re-weld

Incorrect Alignment of Screw when

Reconnect two phase wire.
Welding causing Eccentric Rotation.

Conveyor runs in Electrical Cable leads wired

Reconnect two phase wires.
Wrong Direction incorrectly

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10.Safety Device (Optional)

A safety device is for a purpose during operation of the machine, when emergency
occurs or defects, it is then enable. The following device is components with built in
safety devices.

Torque Limiter. (Optional)

The Gear Reducer is equipped with a torque limiter. If a torque (load) exceeds the
specified value is applied, the torque limiter operates automatically and instantaneously
stops the motor and protects each apparatus.
For handling in detail, refer to the attached “Torque limiter-provided Gear Box
Operation Manual.

Brake-provided Motor
In the event that the motor stops or the power supply is interrupted during operation,
the OFF-brake operates without fail and stops the Spiral Screw instantly.
For handling in detail, refer to the attached “FB Brake-provided Motor Operation
Manual”.

Restarting after Safety Device has operated

Restarting should be done after the cause of the safety device operation has been
located and removed.

Operation of the Safety Device

If the safety device operates, it is necessary to inspect the following components shown
at Table 3. Safety Device Checklist

Table 3. Safety Device Checklist

No. Apparatus Items

1. Drive Unit 1. Motor and Reducer are not Abnormal.

2. Spiral Screw correctly Align.

3. Spiral Screw has caught no foreign

Objects.

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11.Design
The Screw Conveyor & Compactor is design for removing debris and suspended
substances from waste water or intake streams. Our simple design and fewer
components means longer life, quick installation and low cost maintenance. Efficient,
cost effective, durable and dependable, they are far lower in overall costs.

Process Design.
The Screw Conveyor / Compactor system is installed in many fields and handling of
various materials that may be wet, half fluid, sludgy, uneven or hygienically
demanding. However, every conveyor is custom built to give maximum efficiency for
the specified material being conveyed.

Features of Screw Conveyor / Compactor

a. The Screw Conveyor / Compactor type, which ensures positive scrapping and
transferring of debris or powder substances. It has higher filling rate and can convey
large items and sticky materials with no hassle.
b. Simple operation. It can be operated automatically with timer control
or combination of timer.
c. Power consumption is low.
d. It is factory tested for quality assurance.
e. The construction of Screw Conveyor / Compactor assures durability, corrosion
resistance and aesthetic value.
f. Structurally and mechanically the Screw Conveyor / Compactor can be custom
designed to take a wide range of system application or depth and diameter.
g. It is silent in operation.
h. It is less maintenance through operation since the Wear trough used is the lower
part of the conveyor.
i. It does not pose any health hazards and complete automation, pumping and
conveyors system can be easily incorporated.
j. The Spiral Screw is made of high tensile steel and has good corrosion resistant.

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12.Material Specifications

No. Parts Material Other Material

1 Side Walls S.S 304 / 316 Galvanized Mild Steel

2 Bottom Floor S.S 304 / 316 Galvanized Mild Steel

3 Top Covers S.S 304 / 316 Galvanized Mild Steel

4 Troughs for screw dia. 200mm S.S 304 / 316 Galvanized Mild Steel

5 Troughs for screw dia. 280mm S.S 304 / 316 Galvanized Mild Steel

6 Troughs for screw dia. S.S 304 / 316 Galvanized Mild Steel

7 Support S.S 304 / 316 Galvanized Mild Steel

13.Operation Maintenance and Management.

a) The Machine is operated continuously in the normal direction, as a rule, but for the
purpose of check or in an emergency, it can be operated in the reverse direction.
However, the operation of the reverse direction should be avoided during or just
after the wiper operation.
b) No specific care is required during the operation. However it is important to check
daily with special care about heating, rotating condition, vibration and normal
sound of the Gearbox Reducer and the bearing section.
c) It can be said, in order to operate the machine in the best condition is to conduct
periodical inspection according to maintenance checklist.

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