Rev.

1 F5-TOC16
2-2012 TABLE OF CONTENTS CSP0000535-01
MCN2012-0038 1

VOLUME I

GENERAL INFORMATION Page No.

1. Foreword..................................................................................................... 1
2. Receiving and Inspection ........................................................................... 2
3. Packing Boxes and Covers ......................................................................... 2
4. Shipping Braces and Bars .......................................................................... 2
5. Maintenance and Start-up Services ............................................................ 2
6. Parts and Repair Orders.............................................................................. 3
7. Storage ........................................................................................................ 3
8. Special Instructions to Equipment Erectors ............................................... 4
9. Original Equipment Manufacturer’s Instruction Manuals....................... 6
10. SAFETY PROCEDURES ....................................................................... 7

INSTALLATION

1. Required Special Tools and Supplies......................................................... 11

2. Tank Support Structure .............................................................................. 12
3. Tank and Component Lifting ..................................................................... 13
4. Assemble the Tanks ................................................................................... 15
5. Install the Tanks ......................................................................................... 15
6. Level the Tanks .......................................................................................... 16
7. Install the False Bottom Sections ............................................................... 16
8. Install the Split Draft Tube ......................................................................... 16
9. Install the False Bottom Grommets ........................................................... 17
10. Install the Mechanism Support Beams ...................................................... 17
11. Install the Radial Launders, Weirs and Baffle Assembly .......................... 18
12. Assemble the Mechanism Assembly ......................................................... 20
13. Install the Mechanism Assembly ............................................................... 22
14. Adjust the Rotor Shaft for Plumb............................................................... 24
15. Install the Split Collar................................................................................. 25
16. Install the Manual Air Inlet Assembly ....................................................... 25
17. Install the Sheaves and Check for Alignment ............................................ 26
18. Install and Tension the Drive Belts ............................................................ 26
19. Install the Belt Guard Assembly ................................................................ 27
20. Install the Feed Box.................................................................................... 28
21. Install the Connection Boxes ..................................................................... 29
22. Install the Dart Valves and Actuators ........................................................ 31
23. Install the Platform Assembly, Stair Assembly and Cable Tray Assembly 33
24. Install the Level Sensor Assembly ............................................................. 34
25. Electrical Power and Controls Installation................................................. 35
26. Final Inspection before Start-up ................................................................. 37
27. Final Mechanical Check by an FLSmidth Serviceman ............................. 3

For confidential use only, not for circulation, distribution or reproduction without prior
permission in writing by FLSmidth. All Rights Reserved.
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LUBRICATION Page No.

1. Lubrication................................................................................................... 39
2. Lubrication Equivalents List ....................................................................... 39

MAINTENANCE

1. Maintenance and Operation WARNING................................................... 40

2. Inspection and General Maintenance ......................................................... 42
3. General Cleaning ........................................................................................ 42
4. Drive V-belt Tension.................................................................................. 42
6. Lubrication ................................................................................................. 43
7. Manual Air Inlet Assembly ........................................................................ 44
8. Dart Valves ................................................................................................. 45
9. Star Rotor.................................................................................................... 46
10. Hood Sectors .............................................................................................. 46
11. Disperser ..................................................................................................... 46
12. Crowder and Standpipe Assembly ............................................................. 46
13. Tanks and Connection Boxes..................................................................... 47
14. Flotation Level Control Assembly ............................................................. 47
15. Fasteners ..................................................................................................... 47
16. Mechanism Assembly Maintenance .......................................................... 48
17. Removal of Complete Mechanism and Installation................................... 49
18. Component Removal and Installation........................................................ 51
19. Motor .......................................................................................................... 51
20. Reducer ....................................................................................................... 52
21. Air Inlet Assembly ..................................................................................... 53
22. Disperser Hood Sectors .............................................................................. 54
23. Disperser ..................................................................................................... 54
24. Crowder and Standpipe .............................................................................. 55
25. Star Rotor.................................................................................................... 56
26. Draft Tube Split Collar............................................................................... 57
27. Fastener Torque Specifications .................................................................. 59

OPERATION

1. General Description.................................................................................... 60
2. Cell Level Controls .................................................................................... 62
3. Start-up and Operation ............................................................................... 63
4. Shutdown .................................................................................................... 65
5. Troubleshooting.......................................................................................... 67
6. Offices ........................................................................................................ 72
7. Standard Warranty...................................................................................... 74

For confidential use only, not for circulation, distribution or reproduction without prior
permission in writing by FLSmidth. All Rights Reserved.
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PARTS LIST

CSP0000535-01 FLSmidth Current Bill of Material

CSP0000535-01 FLS Recommended Spare Parts List

CERTIFIED DRAWINGS

CSP0000535-01 (rev 2) Top Level

605572 (rev 3) General Arrangement – Rougher Duty
605574 (rev 3) General Arrangement – Rougher Scavenger Duty
605573 (rev 4) P & ID
596734 (rev 5) Foundation Fieldbus Junction Box
612481 (rev 2) Platform Assembly – Stream 1,2
612440 (rev 1) Grating Assembly
612714 (rev 3) Mechanism Installation Assembly
605610 (rev 1) Tank/Box Assembly – Stream 1
612711 (rev 1) Tank/Box Assembly – Stream 2
605545 (rev 1) Air Receiver Assembly
605566 (rev 1) Cable Tray Assembly
612438 (rev 1) Platform ASSY – Stream 1
607907 (rev 1) Platform ASSY- Stream 1 - Type 1
607951 (rev 1) Stair Assembly – Connection Box to Tank
607935 (rev 1) Platform ASSY – Stream 1, Type 2
607928 (rev 1) Interconnecting Walkway Assembly – Stream 1
607477 (rev 1) Platform ASSY – Stream 1, Type 3
607908 (rev 1) Platform ASSY – Stream 1 – Type 5
607910 (rev 1) Stair Assembly – Discharge Box to Tank
607949 (rev 1) Platform ASSY – Stream 1 – Type 4
612439 (rev 1) Platform ASSY – Stream 2
611054 (rev 1) Platform ASSY – Stream 2 – Type 6
612466 (rev 1) Stair Assembly – Connection Box to Tank
611073 (rev 1) Platform ASSY – Stream 2 – Type 9
611055 (rev 1) Platform ASSY – Stream 2 – Type 10
611072 (rev 1) Platform ASSY – Stream 2 – Type 7
612478 (rev 1) Interconnecting Walkway Assembly – Stream 2
611070 (rev 1) Platform ASSY – Stream 2 – Type 8
607915 (rev 1) Platform Sub ASSY-1 of Stream 1
607870 (rev 1) Platform Sub ASSY-2 of Stream 1
611060 (rev 1) Platform Sub ASSY-3 of Stream 1
607926 (rev 1) Platform Sub ASSY-4 of Stream 1
607862 (rev 1) Platform Sub ASSY-5 of Stream 1
607903 (rev 1) Stair Assembly
611045 (rev 1) Platform Sub ASSY-1 of Stream 1
611044 (rev 1) Platform Sub ASSY-2 of Stream 2

For confidential use only, not for circulation, distribution or reproduction without prior
permission in writing by FLSmidth. All Rights Reserved.
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611043 (rev 1) Platform Sub ASSY-3 of Stream 2

611042 (rev 1) Platform Sub ASSY-4 of Stream 2
612707 (rev 2) Level Float Assembly
605362 (rev 2) Mechanism Assembly
573575 (rev 1) Air Inlet Pipe Assembly
573588 (rev 2) Motor Mount Rail Assembly
608995 (rev 1) Belt Drive Guard Assembly
602359 (rev 2) Tank 1 Assembly – Stream 1
602361 (rev 2) Tank 2 Assembly – Stream 1
602362 (rev 2) Tank 3 Assembly – Stream 1
612472 (rev 1) Actuator Assembly – Stream 1 - Type 2
612473 (rev 1) Actuator Assembly – Stream 1 - Type 4
612471 (rev 1) Actuator Assembly – Stream 1 – Type 3
612474 (rev 1) Actuator Assembly – Stream 1 – Type 5
612470 (rev 1) Actuator Assembly – Stream 1 & 2 – Type 1
605535 (rev 1) Radial Launder & Weir Assembly
605520 (rev 3) Actuator Assembly
903144 (rev A) Bearing Assembly, Valve Rod Guide
612468 (rev 2) Dart Valve Assembly
607481 (rev 2) Connection Box Assembly
607482 (rev 2) Connection Box Assembly
607483 (rev 2) Discharge Box Assembly
607479 (rev 2) Connection Box Assembly – Rougher Tank
607480 (rev 2) Connection Box Assembly – Rougher Tank
607936 (rev 2) Tank 1 Assembly – Stream 2
607937 (rev 3) Tank 2 Assembly – Stream 2
607938 (rev 2) Tank 3 Assembly – Stream 2
605567 (rev 1) Unistrut Assembly – Cable Tray Support
114808 (rev 4) Torque Specifications

For confidential use only, not for circulation, distribution or reproduction without prior
permission in writing by FLSmidth. All Rights Reserved.
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VOLUME II

ACCESSORY EQUIPMENT

Ultrasonic Level Detector: Vega .................................................................................... TAB 1

(FLSmidth Part No. 612703)
Vega VEGASON-61 Ultrasonic Level Detector Product Overview
Vega VEGASON-61 Ultrasonic Level Detector Specifications
Vega VEGASON-61 Ultrasonic Level Detector Dimension Information
Vega VEGASON-61 Ultrasonic Level Detector Operating Instructions

Vertical Reducer: Siemens ............................................................................................. TAB 2

(FLSmidth Part No. 605515)
Siemens B38V-15 Vertical Reducer Dimension Information
Siemens B38V-15 Vertical Reducer Product Data
Siemens B38V-15 Vertical Reducer Operating and Assembly Manual

Motor 400 HP: ................................................................................................................ TAB 3

(FLSmidth Part No. 605516)
Weg HGF5810, F-2 Frame Motor Technical Data
Weg HGF5810, F-2 Frame Motor Performance Curves
Weg HGF5810, F-2 Frame Motor Dimensional Drawing
Weg HGF5810, F-2 Frame Motor IO&M Manual
Weg Terminal Box Accessory Dimensional Drawing
Weg Space Heater Terminal Box Accessory
Weg Special Stator Terminal Box Accessory
Xstrata Motor and Accessory General Data

Bearing w/ Thrust Washer: SKF .................................................................................... TAB 4

(FLSmidth Part No. 577948)
SKF AXK 4060 Bearing Product Overview
SKF AXK 4060 Bearing Dimension Information
SKF AXK 4060 Bearing Dimensional Drawing
SKF General Bearing Grease Guide

Actuator Assembly: ........................................................................................................ TAB 5

(FLSmidth Part No. 605520)
SMC CS1 Series Air Cylinder Specifications
SMC CS1 Series Air Cylinder Construction Information
SMC CS1 Series Air Cylinder Accessory Bracket Dimension Information
SMC CS1 Series Air Cylinder Operation Manual
SMC AWM Series Separator Regulator Specifications
SMC AWM Series Separator Regulator Characteristic Information
SMC AWM Series Separator Regulator Dimensional Data

For confidential use only, not for circulation, distribution or reproduction without prior
permission in writing by FLSmidth. All Rights Reserved.
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ACCESSORY EQUIPMENT (continued)

SMC AWM Series Separator Regulator Safety Instructions

Metso ND9100 Intelligent Valve Controller Product Features
Metso ND9100 Intelligent Valve Controller Specifications
SMC SJYA724 Air Pilot Valve Specifications
SMC SJYA724 Air Pilot Valve Dimension Information

Flexible Coupling: Fernco .............................................................................................. TAB 6

(FLSmidth Part No. M028457)
Fernco 1056-88, PVC Flexible Coupling Product Overview
Fernco 1056-88, PVC Flexible Coupling Installation Instructions

FINAL MECHANICAL CHECK LIST

For confidential use only, not for circulation, distribution or reproduction without prior
permission in writing by FLSmidth. All Rights Reserved.