Cone Crusher Comparisons Presentation Cone Crusher Comparisons Presentation
METSO MINERALS ROCK CRUSHERS METSO MINERALS ROCK CRUSHERS
Metso Minerals Industries, Inc.
The popular HP Series Cone Crusher & MP Series Cone Crusher are sold in
different a variety of different sizes. There are some differences between the
smaller cone crushers and the larger cone crushers. This presentation will
explain some of those differences.
Crusher Pivot Points Crusher Pivot Points
+
HP200, HP300 (original), HP500, HP700, HP800, MP800, MP1000
HP200, HP300 (original), HP500, HP700, HP800, MP800, MP1000
HP100, HP300 (current), HP400 HP100, HP300 (current), HP400
è Higher pivot point machines
è Results in increased upper head movement è Larger volumetric area between the liners
è Normal pivot point machines
è Results in less upper head movement è Smaller volumetric area between the liners
Crusher Technical Information Crusher Technical Information
Crusher Model
Head Diameter Ø
Connected Horsepower
Countershaft Speed
Capacity @ 3/4"
(STPH)
Crusher Weight (LBS)
HP100 28" 125 750-1200 85-105 11,900
HP200 37" 200 750-1200 165-210 23,000
HP300 44" 300 700-1200 220-265 33,500
HP400 52" 400 700-1000 280-355 50,600
HP500 60" 500 700-950 355-440 73,000
HP700 70" 600 700-950 136,500
HP800 70" 800 700-950 480-600 141,200
MP800 80" 800 685-800 640-760 266,000
MP1000 90" 1000 700-850 794-992 338,000
è Lower speed = higher capacity but coarser product (standards) è Higher speed = lower capacity and finer product (short heads)
Countershaft Rotation Countershaft Rotation
MP800, MP1000 MP800, MP1000 HP100, HP200, HP300, HP400, HP500, HP700, HP800
HP100, HP200, HP300, HP400, HP500, HP700, HP800
è Clockwise rotation of the countershaft.
è Crusher setting decreases (bowl turns down) with insufficient bowl clamping pressure.
è Head rotates clockwise when crushing.
è Left hand thread locking bolt.
è Counter-clockwise rotation of the countershaft.
è Crusher setting increases (bowl turns out) with insufficient bowl clamping pressure.
è Head rotates counter-clockwise when crushing.
è Right hand thread locking nut.
Jack Shaft Arrangement Jack Shaft Arrangement
è The jack shaft arrangement is being used on most large cone crushers.
è The motor sheave is fitted between two jack shaft bearings.
è The drive motor is connected to the jack shaft with a coupling.
Motor Sheave Coupling Drive Motor
Jack Shaft Bearing Crusher Sheave
Crusher Drive Belts
Drive Belt Tensioning Device Drive Belt Tensioning Device
è Crusher drive belt tensioning devices are being used on most large cone crushers.
è When using this device, the drive motor never moves, the belts stay in proper tension as a tensioning drum is pushed against the back of the belts under spring pressure.
è The unit being used is called an ACS system named after the company that makes it
(Appleton Control Systems).
ACS System
Crusher Mounting Arrangement Crusher Mounting Arrangement
è At some crusher installations (predominately large crushers), you will find that the main frame is grouted into position.
è In past years, you would find that the crusher was shimmed up under each corner to
compensate for foundation irregularities, then the entire crusher base flange was grouted into position.
è In the recent past, you will find that crusher mounting pads (sole plates) are shimmed and grouted into position.
è You will seldom see smaller cone crushers grouted into position.
è Metso Deep Pour Grout (up to 8”) or HP Grout (up to 1/2”).
Fully Grouted
Grouted Pads
Main Frame Liner Arrangement Main Frame Liner Arrangement
HP700, HP800, MP800, MP1000 HP700, HP800, MP800, MP1000 HP100, HP200, HP300, HP400, HP500
HP100, HP200, HP300, HP400, HP500
Note: Original main frame liners are made of mild steel, optional wear resistant steel liners and rubber coated liners are available, see your RPTD’s for details.
Main Frame “U” Seals Main Frame “U” Seals
HP200, HP300, HP400, HP500, HP700, HP800, MP800, MP1000 HP200, HP300, HP400, HP500, HP700, HP800, MP800, MP1000 HP100
HP100
Two Plastic Strips One Full “U” Seal
Note: The “U” seals are glued into position with Loctite Depend 330.
Tramp Release Arrangement Tramp Release Arrangement
Crusher Release Oil Pressure # Cylinders Pull Out
HP 100 1700 PSI (117 Bar) 6 3/8"
HP 200 1700 PSI (117 Bar) 6 3/4"
HP 300 1700 PSI (117 Bar) 6 Flush
HP 400 1700 PSI (117 Bar) 6 1"
HP 500 2400 PSI (165 Bar) 6 1"
HP 700 2600 PSI (179 Bar) 9 7/8"
HP 800 2800 PSI (193 Bar) 9 7/8"
MP800 1800 PSI (124 Bar) 12 N/A
MP1000 1800 PSI (124 Bar) 16 N/A
HP100, HP200, HP300, HP400, HP500 HP100, HP200, HP300, HP400, HP500
Note: Threads coated with Loctite 277, pressure is checked daily (8 hours).
Tramp Release Arrangement Tramp Release Arrangement
MP1000 MP1000 Adjustment Ring
Main Frame
Accumulator Clearing Jack
Adjustment Ring
Cup & Cone
Tramp Release Arrangement Tramp Release Arrangement
Adjustment Ring
Main Frame
Accumulator Clearing Jack
Adjustment Ring
MP800 MP800 Cup & Cone
Accumulator Nitrogen Pre-charge Accumulator Nitrogen Pre-charge
Crusher Nitrogen Pre-charge HP 100 1200 PSI (83 Bar) ± 50 PSI (3.4 Bar) HP 200 1200 PSI (83 Bar) ± 50 PSI (3.4 Bar) HP 300 1200 PSI (83 Bar) ± 50 PSI (3.4 Bar) HP 400 1000 PSI (69 Bar) ± 50 PSI (3.4 Bar) HP 500 1500 PSI (103 Bar) ± 50 PSI (3.4 Bar) HP 700 1500 PSI (103 Bar) ± 50 PSI (3.4 Bar) HP 800 1500 PSI (103 Bar) ± 50 PSI (3.4 Bar) MP800 1500 PSI (103 Bar) ± 50 PSI (3.4 Bar) MP1000 1500 PSI (103 Bar) ± 50 PSI (3.4 Bar)
Note: Nitrogen only! checked every 30 days (200 hours)
Bowl Clamping Arrangement Bowl Clamping Arrangement
Dust Shell
Adjustment Ring Clamping Ring
Clamping Cylinder
Dust Shell
Adjustment Ring Clamping Ring
Support Tube
HP100 HP100 HP200, HP300, HP400, HP500, HP700, HP800
HP200, HP300, HP400, HP500, HP700, HP800
Pump on @ 2400PSI Pump off @ 2800PSI Pump on @ 235PSI Pump off @ 365PSI
Bowl Clamping Arrangement Bowl Clamping Arrangement
MP1000 MP1000
Pump on @ 2400PSI Pump off @ 2800PSI
Dust Shell Dust Shell
Adjustment Ring Clamping
Cylinder
Clamping Ring Clamping Ring
Clamping Cylinder
Adjustment Ring
MP800 MP800
Main Frame Pin
Main Frame Pin Arrangement Main Frame Pin Arrangement
Main Frame Pin
Main Frame Adjustment Ring
Pin Bushing Adjustment Ring
Main Frame
HP100, HP400, HP500, HP700, HP800 HP100, HP400, HP500, HP700, HP800 HP200, HP300
HP200, HP300
Main Frame Pin Arrangement Main Frame Pin Arrangement
MP800
MP800 MP1000MP1000
Pin Bushing
Main Frame Pin Adjustment Ring
Main Frame Pin Bushing
Main Frame Pin Adjustment Ring
Main Frame
Hydraulic Motor Adjusting System Hydraulic Motor Adjusting System
- One hydraulic motor
HP100, HP200, HP300, HP400, HP500, HP700
HP800, MP800
- Two hydraulic motors - dual speed - Slow speed = setting adjustment - High speed = bowl removal
MP1000
- Four hydraulic motors - dual speed - Slow speed = setting adjustment - High speed = bowl removal
Adjust Under Load Feature Adjust Under Load Feature
è The HP200, HP300, HP400, HP500, HP700, HP800, MP800 and MP1000 are all designed and sold with “Adjust Under Load” capabilities.
è The HP100 is the only crusher that we do not adjust under load, this is due to the bowl clamping arrangement.
è The two most important items that come into play if the customer is using the adjusting under load feature is; 1) using the proper grease on the threads and 2) making sure that the adjust under load relief valve is set correctly (see service alert #122).
è Power units are supplied with the adjust under load relief valve set at zero.
Power Unit Push Button Station Power Unit Push Button Station
“On / Off”
Push Button
“Run / Adjust”
Selector Switch
“Open Setting”
Push Button
“Close Setting”
Push Button
“Pressurize”
Push Button
“Power On”
Lamp
“Low Clamping Pressure” Lamp
“Clear”
Push Button
“Low Release Pressure” Lamp
HP100, HP200, HP300, HP400, HP500, HP700 HP100, HP200, HP300, HP400, HP500, HP700
Power Unit Push Button Station Power Unit Push Button Station
HP800 HP800 Power On Lamp
Power On / Off Push Button
Low Release Pressure Lamp
Low Clamping Pressure Lamp
High Oil Temp Low Oil Level
Dirty Filter
Open / Close
Bowl Removal / Run
Clear
Local / Remote
Remote Lamp
Pressurize Reset
Power On / Off
Power Unit Push Button Station Power Unit Push Button Station
Power On Lamp
Power On / Off Push Button
Manual / Run Selector Switch
Bowl Removal / Run Selector Switch Low Release Pressure
Lamp
Low Clamping Pressure Lamp
High Oil Temp
Open Setting Push Button
Closed Setting
Pressure Reset Push Button
Tramp Release Pressure Gauge Bowl Clamping
Low Oil Level
Clear / Release
Selector Switch Clamping Cylinder
Pressurize
MP800, MP1000 MP800, MP1000
Bowl Liner Retention Arrangement Bowl Liner Retention Arrangement
Bowl Liner Bowl Hopper
Bowl
Liner Bolt
Backing Material Bowl Liner
Bowl
Liner Wedge Bolt Assembly
Backing Material
HP700 (original) HP700 (original) HP200, HP300, HP400, HP500, HP700 (current), HP800
HP200, HP300, HP400, HP500, HP700 (current), HP800
MP800, MP1000 MP800, MP1000
Bowl Liner Retention Arrangement Bowl Liner Retention Arrangement
Bowl Wedge
Bowl Ring (MP1000 only)
Shims
Bowl Liner
Wedge Retainer Wedge Bolt
Special Nut &
Retainer Shims
è The MP800 wedges fit into a slot.
è Shims are added or removed from under the wedge to obtain proper midpoint contact on the incline surface of the wedges..
Crusher Liner Metallurgy Crusher Liner Metallurgy
Crusher XT520 XT610 XT710 XT720
HP100 X X
HP200 X X
HP300 X X
HP400 X X
HP500 X X
HP700 X X X
HP800 X X X
MP800 X X X
MP1000 X X X
Bowl Liner
Mantle
XT520 = 14% Manganese w/Molybdenum XT610 = 14% Manganese (formerly 510) XT710 = 18% Manganese
XT720 = 22% Manganese
Thread Pitch Thread Pitch
è 1-1/2” Thread Pitch / 45°
è Left Hand Thread
è Template part number 4660 0101
HP100
HP300, HP400, HP500, HP700, HP800
è 2” Tread Pitch / 45°
è Right Hand Thread
è Template part number 7962 4000
MP800
è 4” Tread Pitch / 45° - Double Lead (looks like 2” thread) è Right Hand Thread
è Template part number 7962 4000 è 1-1/2” Thread Pitch / 45°
è Right Hand Thread
è Template part number 4660 0101
HP200
MP1000
è 75mm Tread Pitch è Right Hand Thread
è Template part number 7962 4001
Bowl Turning Pins Bowl Turning Pins
HP700, HP800, MP800, MP1000 HP700, HP800, MP800, MP1000 Bowl
Cable & Clevis Cable & Clevis
Turning Pin Turning Pin
Bowl Installation Procedure Bowl Installation Procedure
è Due to the weight of the larger cone crusher bowl assemblies, the installation procedure will be slightly different then with the smaller cones.
è Prior to bowl installation (new machine or reworked bowl), the bowl, adjustment ring and clamping ring threads are to be coated with a Dry Film Lubricant, two coats are required and a four hour cure time must be given.
è After the dry film lube has cured, a special High Content Molybdenum Based Anti-seize (25%) is applied to the threads.
è This kit is part number 10 04810822.
HP700, 800, MP800, 1000 HP700, 800, MP800, 1000
Backing Material Requirement Backing Material Requirement
Standard Epoxy Backing Material
Metso Minerals “Standard Epoxy Backing” is a general purpose backing material used in cone crushers undernormal operating conditions. This backing material has a compressive strength of 16,000 PSI and a cure time of 6 hours at 70°F.
HP Epoxy Backing Material
Metso Minerals “HP Epoxy Backing” is an intermediate strength backing material used in cone crushers operating intougher applications. This backing material has a compressive strength of 16,500 PSI and a cure time of 5 hours at 70°F.
WF Epoxy Backing Material
Metso Minerals “WF Epoxy Backing” is an ultra performance backing material used in such crushers as the HP700, HP800, MP800 and MP1000 in highly demanding applications. This backing has a
compressive strength of 18,000 PSI and a cure time of 7 hours at 70°F.
Note 1) Nordbak (former name of our backing material), is no longer a trade name of Metso Minerals, it is now a trade name and product of the Loctite company.
Note 2) Zinc should not be used as a liner backing material with the HP or MP Crushers as the high temperature may dimensionally damage the head bore!
Note 3) The MP short head bowl liners do not use backing material.
Head Bushing Arrangement Head Bushing Arrangement
HP100 HP100
Head Ball (bronze) Upper & Lower
Head Bushing (one-piece)
Head Bushing Arrangement Head Bushing Arrangement
HP100, HP400, HP700 (current), HP800, MP800, MP1000
HP100, HP400, HP700 (current), HP800, MP800, MP1000
HP200, HP300, HP500, HP700 (original) HP200, HP300, HP500, HP700 (original)
- Tight fit, no flange and set screws - Tight fit, flange and cap screws
Anti-spin Mechanism Anti-spin Mechanism
Universal Joint Spline Shaft
è The newer MP800 and MP1000 Cone Crushers are using an anti-spin mechanism or bachstop clutch arrangement.
è The anti-spin mechanism reduces shock loads when initiating the feed.
è The anti-spin mechanism reduces dynamic loads during operation.
è See service bulletin #425266 or service alert
#167 for lube spec.
Head Turning Plate Head Turning Plate
MP1000 MP1000 Head Turning Plate
Eye Bolt
Two Eye Bolts 180° Apart Lifting Cables
Blocking
Socket Arrangement Socket Arrangement
HP200, HP300, HP400, HP500, HP700, HP800, MP800, MP1000
HP200, HP300, HP400, HP500, HP700, HP800, MP800, MP1000
HP100 HP100
- One piece socket / socket liner - Made of steel
- Two piece socket / socket liner - Socket made of steel.
- Socket liner made of bronze.
Counterweight Guard Arrangement Counterweight Guard Arrangement
WELD ON BOLT ON WELD ON BOLT ON
HP100 X X
HP200 X X
HP300 X X
HP400 X X
HP500 X X
HP700 X X
HP800 X X
MP800 X X
MP1000 X X
CRUSHER MODEL
ORIGINALLY CURRENTLY
Counterweight Guard History
Note: All counterweight guards are made of a wear resistant steel.
Counterweight Guard Arrangement Counterweight Guard Arrangement
Welded On CWT Guard Welded On CWT Guard Bolted On CWT Guard
Bolted On CWT Guard
Counterweight “T” & “U” Seals Counterweight “T” & “U” Seals
è The HP100, HP200, HP300, HP400, HP500 use integral counterweight “T” & “U” seals.
è The HP700, HP800, MP800 & MP100 use plastic “T” & “U” seals.
è Regarding the large crusher “T” & “U” seal, you will find that the upper “T” & “U” seal is a different color then the lower “T” & “U”
seal (orange and blue).
Counterweight
“U” Seal
“T” Seal Counterweight
Guard
Stationary Counterweight Shields Stationary Counterweight Shields
Stationary Counterweight Guard
è Stationary counterweight guards are a popular option with the larger crushers.
è Stationary counterweight guards prevents crushed material from contacting the counterweight guard.
Crusher Gears & Pinions Crusher Gears & Pinions
è The HP100, HP200, HP300, HP400, HP500, HP700, HP800 (original), MP800 (original) and MP1000
(original) all use a straight tooth bevel gear and pinion.
è The newer HP800, MP800 and
MP1000 all use a spiral bevel gear and pinion for a quieter operation.
è Backlash for the new gear and pinion checked at the crusher sheave.
Gear Pinion
Eccentric
Countershaft
Thrust Bearings
Lube Oil Pump Flow Rates Lube Oil Pump Flow Rates
Crusher Capacity (Liters) HP 100 25-30 (95-114) HP 200 25-30 (95-114) HP 300 30-35 (114-132) HP 400 50-55 (189-208) HP 500 60-65 (227-246) HP 700 125-130 (473-492) HP 800 125-130 (473-492)
MP800 200 (757)
MP1000 200 (757)
è The function of the lube pump oil flow is to keep the crusher bronze bushings cool and lubricated.
è The effect of poor oil flow is lower oil pressure, higher oil temperature, wider temperature differential and a continuous running oil cooler.
è Larger crushers have higher flow rates, smaller crushers have lower flow rates.
Lube Oil Pump Arrangement Lube Oil Pump Arrangement
HP800, MP800, MP1000 HP800, MP800, MP1000 HP100, HP200, HP300, HP400, HP500, HP700
HP100, HP200, HP300, HP400, HP500, HP700
Internal Gear Pump - Viking External Gear Pump - Permco
ADVANTAGES
• Two moving parts (rotor & Idler)
• Two bushings operate in the oil
• Flexible design
Lube Oil Pump Arrangement Lube Oil Pump Arrangement
HP800, MP800, MP1000 HP800, MP800, MP1000 HP100, HP200, HP300, HP400, HP500, HP700
HP100, HP200, HP300, HP400, HP500, HP700
Internal Gear Pump (Viking) External Gear Pump (Permco)
DISADVANTAGES
• Low speed pump (speed reducer required)
• Has an overhung bearing load
• Can utilize a leaking pump shaft seal
• Can be a loud pump
• Considered a medium pressure pump
ADVANTAGES
• High speed pump
• No overhung bearing load
• No speed reducer needed
• No leaking pump seal
• Quiet
DISADVANTAGES
• Four bushings operate in the oil
• Considered a medium pressure pump
Main Relief Valve Setting Main Relief Valve Setting
è The function of the main relief valve is to limit the amount of oil pressure that enters the crusher and to protect the pump.
è It should be mounted vertically and
positioned right next to the countershaft box.
è * Indicates mounted at the pump.
Crusher PSI (Bar)
HP100 35 (2.4)
HP200 35 (2.4)
HP300 35 (2.4)
HP400 50 (3.4)
HP500 50 (3.4)
HP700 150 (10.3) * HP800 150 (10.3) * MP800 200 (13.8) * MP1000 200 (13.8) *
Main Relief Valve Position Main Relief Valve Position
HP700, HP800, MP800, MP1000 HP700, HP800, MP800, MP1000 HP100, HP200, HP300, HP400, HP500
HP100, HP200, HP300, HP400, HP500
Mounted at the Countershaft Box Mounted at the Pump
Lube Oil Filter Arrangement Lube Oil Filter Arrangement
HP400, HP500 HP400, HP500 HP100, HP200, HP300
HP100, HP200, HP300 HP700, HP800, MP800, MP1000HP700, HP800, MP800, MP1000
Farley Arlon Nugent
Lube Oil Filter Element Lube Oil Filter Element
HP100, HP200, HP300, HP400, HP500, HP700
HP100, HP200, HP300, HP400, HP500, HP700 HP800, MP800, MP1000HP800, MP800, MP1000
50 Micron - Bag 25 Micron - Pleated
Lube Oil Tank Breather Lube Oil Tank Breather
HP100, HP200, HP300 HP100, HP200, HP300 All (original)
All (original) HP700, HP800, MP800, MP1000HP700, HP800, MP800, MP1000
Airmaze - Oil Bath Donaldson - Dry Stauff - Dry
Countershaft Box Blower Unit Countershaft Box Blower Unit
è A countershaft box blower unit is used on the some HP500, all HP700, all HP800, all MP800 & all MP1000
crushers due to their slower countershaft speeds (used at countershaft speeds less then 800RPM).
è The blower unit forces air into the crusher which allows the crusher, drain line and oil tank to maintain
atmospheric conditions.
è This blower unit air filter breather should be checked every week and replaced as required.
è Should turn on with under crusher belt.
Air Filter Blower Unit Air Line to Crusher
Lube Oil Cooler (radiator type) Lube Oil Cooler (radiator type)
HP400, HP500, HP700, HP800
HP400, HP500, HP700, HP800 HP100, HP200, HP300HP100, HP200, HP300 - Young - OCS1000 (and larger)
- Oil in the bottom two ports - Oil out the one top port
- Young - OCS600 (and smaller) - Oil in the one bottom port - Oil out the two top ports
Lube Oil Cooler Lube Oil Cooler
MP800, MP1000 MP800, MP1000
è Fan #1 turns on at 120°F (49°C) and off at 115°F (46°C)
è Fan #2 turns on at 125°F (52°C) and off at 110°F (43°C).
è 50PSI (3.4 Bar) bypass valve.
è Oil in the bottom two ports.
è Oil out the top one port.
Lube Oil Tank Temperature Lube Oil Tank Temperature
è The temperature of the oil in the oil tank should be proper prior to starting the oil pump.
è Oil immersion heaters fitted into the tank should be energized 24/7.
è Proper oil tank temperature prevents over-loading the pump motor.
è Once the pump is running, drain line oil temperature must be higher then 60ºF (16ºC).
- Should be 80ºF (27ºC) or higher
HP100, HP200, HP300, HP400, HP500
HP700, HP800, MP800, MP1000
- Should be 90ºF (32ºC) or higher
Lube Oil Temperature Lube Oil Temperature
- Maximum of 9ºF (5ºC) with radiator type oil cooler fan off - Maximum of 15ºF (8ºC) with radiator type oil cooler fan on
HP100, 200, 300, 400, 500 Preferred Temperature 100F to 130F
HP700, 800, MP800, 1000 Preferred Temperature 100F to 130F
Note: If the maximum temperature differential is exceeded, most likely the bushings within the crusher have closed in due to abnormal operating conditions.
- Maximum of 12ºF (7ºC) with radiator type oil cooler fan off - Maximum of 20ºF (11ºC) with radiator type oil cooler fan on
Temperature Sensors Temperature Sensors
è Remote temperature devices are used to convert oil temperature to a digital readout.
è At times the digital readout is simply displayed in the operators room.
è At other times the temperature signal is routed to an automation program, where the program will display warnings, alarms or will automatically take a corrective action step based on abnormal operating temperature.
Remote Temperature Device (RTD)
Lube Oil Pressure Lube Oil Pressure
- Normal Oil Pressure: 20PSI to 40PSI - ISO 150 (EP4)
HP100, HP200, HP300, HP400, HP500, HP700, HP800
MP800, MP1000
- Normal Oil Pressure: 20PSI to 70PSI - ISO 150 (EP4)
Lube Oil Pressure Switch Setting Lube Oil Pressure Switch Setting
è The low oil pressure switch should be mounted near the crusher and at the same elevation as the countershaft box.
Crusher PSI (Bar)
HP100 12 (0.8)
HP200 12 (0.8)
HP300 12 (0.8)
HP400 12 (0.8)
HP500 12 (0.8)
HP700 15 (1.0)
HP800 15 (1.0)
MP800 15 (1.0)
MP1000 15 (1.0)
Pressure Sensors Pressure Sensors
è Pressure transducers are used to convert countershaft box oil pressure to a digital readout.
è At times the digital readout is simply displayed in the operators room.
è At other times the pressure signal is routed to an automation program, where the program will display warnings, alarms or will automatically take a corrective action step based on abnormal operating
pressure.
Pressure Transducer
TC Automation System TC Automation System
è The Metso Minerals TC Automation package is being used on may large cone crusher.
è The TC500 is used on the HP500 and smaller machines, the TC1000 is used on the HP700 and larger machines.
è Can run in power, setting or manual modes.
è See TD7-275 for mechanical logic.
- uses pressure, temperature & current sensors - uses vibration sensors (accelerometers)
- automatic or operator activated setting control - improved productivity due to maximizing the
cavity level & optimal setting - overload warnings & protection - liner wear detection
- auto calibrate feature
- trended data is saved for 60 days
SKF Accelerometers SKF Accelerometers
è Accelerometers are being used predominately on large crushers to electronically monitor adjustment ring movement.
è At times, the signal from the
accelerometer is used to simply turn on a warning lamp in the operators room indicating ring movement.
è At other times the vibration signal is routed to an automation program, where the program will display warnings, alarms or will automatically take a corrective action step based on abnormal vibration levels.
è See TD7-049 for set-up procedures.
Accelerometer
Power Transducers Power Transducers
è Power transducers are used to convert drive motor power draw to a digital readout.
è At times the digital readout is simply displayed in the operators room.
è At other times the power signal is routed to an automation program, where the program will display warnings, alarms or will automatically take a corrective action step based on abnormal operating power.
Current Transformer (CT)
Power Transducer
Tooth Counters Tooth Counters
è Two tooth counters are used in conjunction with an automation program.
è As the pinion gear moves, the proximity switches are used to determine direction of rotation and to count teeth.
è The tooth count is translated into crusher setting.
Tooth Counters
Eccentric Bushing Temperature Eccentric Bushing Temperature
è The Crusher eccentric bushing
temperature is measured using an RTD located directly below the bushing which provides a 4-20 mA analog signal.
è If the bushing temperature reaches 60°F (33°C) above the crusher drain line oil temperature, activate a “high eccentric bushing oil temperature alarm” and stop the feed.
Temperature is Measured Here
Socket Liner Temperature Socket Liner Temperature
è The Crusher socket liner oil temperature is measured using a thermocouple
located in one of the oil grooves near the center of the socket liner which provides a 4-20 mA analog signal.
è If the socket liner oil temperature reaches 60°F (33°C) above the Crusher drain line oil temperature, activate a
“high socket liner oil temperature alarm” and stop the feed.
Temperature is Measured Here
Countershaft Bushing Temperature Countershaft Bushing Temperature
è The Crusher outer countershaft box bushing temperature is measured using a temperature sensor mounted in the
countershaft box with it’s probe contacting the outer countershaft box bushing.
è If the outer box bushing temperature reaches 130°F (54°C), activate a “high countershaft box bushing temperature warning” and recheck the Crusher drive belt tension.
è It is recommended to evaluate the operating temperature after several months and then reset the warning to 10°F (6°C) above the normal high temperature.
Temperature is Measured Here
Countershaft Speed Sensor Countershaft Speed Sensor
è Countershaft speed sensors are used with many large cone crushers.
è At times, the signal from the sensor is used to simply turn on a warning lamp in the operators room indicating a slowing crusher.
è At other times, the signal is routed to an automation program, where the program will display warnings, alarms or will automatically stop the crusher feed based on abnormal operating speed.
è Speed sensors prevent downtime associated with stall outs and extends drive belt life.
Speed Sensor
Crusher Coast Down Time Crusher Coast Down Time
è Coast down time is the amount of time in seconds that it takes the crusher sheave to come to a stop after the crusher drive motor has been turned off.
è Check the crusher coast down time at the end of each shift.
è The operator should compare crusher coast down from one day to another looking for changes from the normal coast down time.
- Should be over 30 seconds
HP100, HP200, HP300, HP400, HP500
HP700, HP800
Note: A decrease in coast down time may indicate that the bushings within the crusher have closed in due to abnormal operating conditions.
- Should be between 60 to 90 seconds
MP800, MP1000
- Should be between 60 to 120 seconds
Read Your Instruction Manual Read Your Instruction Manual
è Do you understand the crusher that you are working on?
è A crusher instruction manual is readily available for any cone crusher you work on.
è Whenever in question, read the manual for the crusher you will be working on to learn its operating and maintenance
characteristics, pressures, and limitations.
