Barmac Sales Manual April2011
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1/66 Sales Manual BARMAC B-SERIES VSI
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BARMAC B-SERIES VSI SALES MANUAL
Contains sales information for the following Barmac VSI models:
Barmac B9100SE VSI Barmac B7150SE VSI Barmac B6150SE VSI Barmac B5100SE VSI
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Contents
Section 1 – Product Overview .......................................................... page 5 Introduction .................................................................................................. page 6 Product History ............................................................................................ page 7 Principles of Operation ................................................................................ page 11 Application ................................................................................................... page 13 Features & Benefits ..................................................................................... page 16 Component Identification ............................................................................. page 19 Product Support Services ............................................................................ page 25 Suggested Marketing Tactics ...................................................................... page 27
Section 2 – Model Specific Information ........................................ page 33 Barmac B9100SE VSI ................................................................................. page 35 Barmac B7150SE VSI .................................................................................. page 43 Barmac B6150SE VSI ................................................................................. page 51 Barmac B5100SE VSI ................................................................................. page 59
Each model specific section contains the following: Dimension Drawings; Machine Specifications; Machine Configurations; Parts.
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SECTION 1 – PRODUCT OVERVIEW
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Introduction The Barmac B-Series Vertical Shaft Impactor (VSI) is unique due to its crushing process. Whereas most other types of crusher use metallic parts to crush rock, the Barmac VSI uses the rock fed into the machine to crush itself. This autogenous crushing process produces the best-shaped aggregate on the market today.
The high velocity impact crushing achieved in a Barmac B-Series VSI improves the soundness and shape of stone, reducing product moisture and easing the screening task while producing superior products at a minimum cost.
Unmatched performance With thousands of units operating in aggregate and mineral processing installations around the world Barmac B-Series VSIs, with their rock-on-rock crushing action, have an established track record of cost savings, durability and unmatched performance in the variety of tasks to which they have been applied. These include the production of quality aggregates, sand, material for heap leaching, pre-grinding and finished industrial minerals products.
Lowest total cost Many benefits of the Barmac B-Series VSI are the result of designers listening to customers. This has led to the development of a user-friendly VSI which gives the lowest possible total cost per tonne by improving energy efficiency, reducing wear rates, lengthening intervals between servicing, reducing the time required to perform service tasks, as well as improving crushing performance and control.
Adaptable and versatile The Barmac B-Series VSI is an excellent third or fourth stage reduction unit and has demonstrated a unique ability to operate in many demanding and diverse crushing operations in construction, industrial minerals, metallic minerals and waste and recycling applications. This is possible because of the unique free impact crushing and grinding action and the ability to fine-tune this process by simply changing rotor speed or cascade ratio.
Coupled with lower wear costs, the result has seen the Barmac B-Series VSI find applications not only in traditional quarry and mining plants, but also in a range of industrial mineral and specialist crushing operations.
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Product History Like many successful inventions the Barmac VSI was born out of necessity. The Wellington City Council’s Kiwi Point Quarry in Wellington, New Zealand, is where the seed of an idea blossomed into the product that became the Barmac VSI. The idea for the machine was created by a pressing quarry problem - high quality stone was abundant but the crushing plant could not produce the fines or shape required in order to make pumpable concrete. Also, the equipment in the quarry badly needed replacing. But instead of purchasing a second hand cone crusher to fix the problem, as would almost certainly have been done if he’d had previous quarrying experience, the Barmac VSI’s inventor, Jim Macdonald, went in search of a more practical solution.
Other plants in the area were using Rod Mills and Hammer Mills to overcome the difficulty, but the high costs involved in both capital and operation were impractical. Macdonald decided to experiment with the Rock-On-Rock crushing process. He thought about what sort of rock crusher could be made in the Council’s workshop and, as breaking stones is only a brute force activity, believed it shouldn’t be too hard to come up with something.
The solution was based on two ideas: 1) Steel chutes with a stone lining which stopped wear that he had already seen and, 2) Stones can be broken if they are banged together hard enough.
Based on this he came up with the idea of spinning a wear resistant chute through which stones were thrown into a stone bed sitting in a circular chamber. The first experimental machine ran in the quarry, one Saturday morning, for about ten minutes. This session was abruptly halted when a tip assembly flew off inside the machine with an almighty bang. That was the end of the experiment for the time being, but Macdonald discovered they had a most remarkable product, with cubical shaped chips in all sizes. This was unusual, particularly in very hard greywacke rock. It was decided to take the matter further so the machine was mechanically designed through the Council’s design office.
Initial Commercialisation Bryan Bartley and Jim Macdonald met in 1970 to talk about the invention and the final result of this discussion was a partnership. By that time Macdonald’s provisional patent had run out and he was thinking of giving up on the idea - the quarrymen at Kiwi Point were tired of bolting in Ni-Hard wear tip parts every 2 ½ hours!
Bartley was able to persuade his employers, Winstone Ltd, to let him build a machine for testing at Hunua quarry in South Auckland. After some development work Bartley began using tungsten carbide inserts
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from used rock drill bits as tips in the rotor. This extended the operating time from 2 ½ hours to six weeks making the machine commercially viable.
The next big step, made nearly ten years later, was a joint effort between the two men to overcome a recognised drawback of the machine, that of taking shingle with a few big stones. The problem was that feed size to the rotor was a maximum of 60mm (2½“), whereas competing machines could accept larger stones of up to 100mm (4”). In the early days of commercialisation the machine was called a Macdonald Impactor and by this time about 150 had been manufactured.
The solution to their problem was to allow the rotor to continue passing the smaller stones and to add the bigger ones as a separate flow into the breaking chamber. This became the dual feed machine, or Duopactor, and it worked well for the purpose it was designed. It also threw up an additional benefit they hadn’t expected – it produced more fine material.
They then found that if the big stone cascade feed was replaced by the rotor size feed material there was also a proportionate increase in the amount of fine material produced. This meant that for the same motor power and with no extra wear costs, some 30% extra material smaller than 10mm could be produced. This was a significant leap forward in energy efficiency and cost reduction. The ratio of the cascade feed to the rotor flow also provided an extra means of controlling the grading of the final product. This is an important practical advantage leading towards computer control and automation.
Global Commercialisation Right from the outset it was obvious that Macdonald and Bartley were not interested in manufacturing or selling the units. Their main interest lay in designing and developing commercially viable improvements that would add value to the intellectual property. Macdonald and Bartley formed a company that was to own the intellectual property, designs, patents and trademarks relating to their inventions.
It was during this period that Bryan Bartley and Jim Macdonald decided to re-brand the MacDonald Impactor using their respective names as the basis. They came up with Barmac.
Summary The manufacture and worldwide distribution of the Barmac VSI takes place from Metso New Zealand Limited’s world class facilities in Matamata, New Zealand. Metso New Zealand Limited exports 95% of its products to the network of Metso distributors around the world.
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9/66 Sales Manual BARMAC B-SERIES VSI Barmac VSI Model History
See next page for improvements from one model to the next.
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Improvements – model to model
Earliest Machines (1978 to 1983) MKI Rotopactor to MKII Rotopactor
Better feed method.
Integrated transmission.
MKII Rotopactor to MKI Duopactor
First cascade.
Smaller for portability.
Early Duopactors (1983 to 1989)
Cascade.
Service access.
Barmac Duopactor (1989 to 1994)
Extended model range.
Industrial minerals/laboratory focus.
Three port rotor.
Barmac Hydracascade Duopactor (1994 to 1999)
Cascade in hopper (Hydracascade).
Real time control of cascade.
Serviceability.
Stronger flanged transmission.
B1100 Series (1999 to 2004)
Lower overall height.
Better feed control.
Better cascade control into hopper.
Electronic protection system (VOCS).
B1100SE Series (2004 to present)
Reliability.
Increased capacity range for each model (increased power).
Improved serviceability – rooflifter and inspection door.
First automation.
Improved productivity.
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Principles of Operation The Barmac B1100SE Series autogenous VSI crusher uses a rock lined rotor that acts as a high velocity dry stone pump hurling a continuous rock stream into a stone lined crushing chamber.
Material fed into the top of the machine is accelerated in the crusher's rock lined rotor, achieving exit velocities of up to 85 metres (275 feet) per second. The rotor continuously discharges into the crushing chamber. This process replenishes the rock lining, while at the same time maintains a rock-on-rock chain reaction of crushing and grinding.
A second stream of material in a controlled quantity can be cascaded into the crushing chamber turbulence causing a supercharging of the particle population within the chamber, improving the energy transfer. This, in combination with other variables of rotor diameter and speed and crushing chamber profile, enhances power efficiency, reduces wear, plus provides an efficient means of controlling the grinding and crushing action, to either maximise or minimize fines.
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Control of crushed product sizes The crusher offers a number of controllable variables which affect the final product grading.
Rotor Speed: Increasing rotor speed increases the particles’ kinetic energy and increases the reduction achieved.
Cascade: Increasing the cascade flow decreases the reduction ratio achieved whilst increasing the capacity of the crusher.
Feed Gradation: Changing the size distribution of the feed to the crusher will affect the size distribution of the crushed product.
Screen Aperture: When operating in closed circuit the final product size produced by the crusher is controlled by the screen aperture.
Rotor Diameter: Different rotor diameters are available for some models. Changing to a larger diameter rotor effectively increases the tip speed and the effect is similar to increasing the rotor speed with the addition that the longer grinding arm in the rotor produces more fines than a smaller diameter rotor with the same tip speed. Larger diameter rotors also reduce the chamber volume, therefore increasing interparticle interaction. This is beneficial for fine feed, fine product applications.
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Application Barmac VSI crushers are operating in aggregate and mineral processing installations around the world with an established track record of cost savings, durability and unmatched performance. Metso has the technology and experience in applying and servicing the Barmac VSI across the globe in an extensive variety of applications, processing a diverse range of materials.
The unmatched producer of superior concrete and asphalt aggregate Less cement can be used and stronger concrete created by using Barmac VSI product. The superior shape of Barmac VSI produced aggregate allows for improved compressive strength, reduced compaction, low pump pressures and improved finishability.
A proven producer of quality manufactured sand Superior particle shape and consistent gradation are a direct result of the rock-on-rock principle of the VSI crusher. Impact, grinding and abrading within the crusher simulates the action of nature, eroding the particles to a cubical shape.
The perfect pre-mill crusher to improve mill circuit performance The Barmac VSI reduces power requirements and increases mill capacity by reducing the top size and increasing the fineness of the mill feed. Mill liner life is increased by providing a finer mill feed, allowing the use of smaller mill balls to achieve the required size reduction.
The producer of fine products for the industrial minerals industry The Barmac VSI’s crushing action gives a product with a large surface area, which gives increased recovery of the desired mineral. The free impact reduction will preferentially crush a more friable mineral when separating a desirable product from a waste material.
The only viable crusher for extremely abrasive fine material The rock-on-rock crushing principle of the Barmac VSI minimizes metallic wear resulting in low maintenance and wear costs. The low wear of internal components ensures extremely low contamination of fine products by wearing metal parts.
Selecting and applying a Barmac VSI Selecting and applying a Barmac VSI correctly requires the understanding of many different application and economic factors. The rock-on-rock crushing action achieved in the Barmac VSI produces crushing results that are different to normal tertiary and quaternary compression type crushing.
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Rock-on-rock crushing produces cubical aggregate that performs well in concrete, asphalt and base mixtures. It should be considered for fine crushing, particularly of abrasive materials, as it is not mechanically restricted in the same way as compression crushers are at fine settings. If applied correctly, rock-on-rock crushing offers the lowest wear cost per tonne of any impact crushing method.
In most instances the Barmac VSI is applied in the last crushing phase in any crushing circuit. It is at this stage of the process where the crushing of the final product(s) is performed, be it the production of superior shaped aggregates, manufactured sand, mill feeds or liberation/separation of a particular mineral from its host rock.
Aggregates and sand The quarry industry has been the traditional home of the Barmac VSI. They have consistently demonstrated their ability to produce high quality cubical shaped aggregates that meet all major construction specifications. Barmac VSIs are particularly successful in producing road-base, top dressing chip, concrete and asphalt aggregates, and manufactured sand. In these applications, Barmac VSIs can be operated either in open or closed circuit, depending on the types of aggregates and the specifications required.
Industrial minerals With features such as controlled product grading, preferential crushing, low production costs and the ability to produce finely graded products, the addition of a Barmac VSI can optimize the performance of most industrial mineral processing installations.
In this sector, Barmac VSIs are popular as cost-effective fine crushing equipment for the abrasive industry. Diamond mines are another sector that is becoming increasingly associated with the Barmac VSI, which is looked upon as effective equipment for liberating diamonds from gangue minerals. Fine crushing cement clinker is fast becoming the Barmac VSI’s forte with its proven ability as a cost-effective pre-grinder.
Mining In mining (metallic minerals), the Barmac VSI, with its high capacity and ability to produce finely graded products such as mill feed, sinter feed or material for heap leach operations, is an ideal machine to replace high cost, inefficient crushing and milling equipment. The addition of a Barmac VSI to an existing circuit can save considerable capital funds when increased production is required from an existing milling circuit.
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Waste recycling Waste recycling is not only environmentally responsible, it is also economically viable. As the areas of recycling continue to increase and the global community moves closer towards higher environmental consciousness, the Barmac VSI is establishing market areas where it can outperform other methods of recycling recovery efficiency.
Recycled materials not only take the form of mineral aggregates for the construction industry, but also glass, slags and other waste products that can be processed and profitably sold. The Barmac VSI provides the perfect means of treating these materials. The versatility of the Barmac VSI allows it to be used to great effect in many applications.
Contracting The Barmac VSI is now included as part of Metso’s portable plant range. There is a Barmac VSI option available if your portable application calls for superior cubical, well-shaped product.
Metso pioneered the development of fully mobile crushing and screening plants. Our track- and wheelmounted portable plant concepts are fully adaptable to all mobile crushing needs, opening up a whole new range of business opportunities for contractors, quarry operators, recycling and mining applications.
Mobile processing is continuing to increase its market share. Besides full portability, mobile processing offers several others advantages like flexible process adjustability, less trucking, less manpower needs and compliance with strict environmental standards.
>>Do you want to know more? For more information about applying a Barmac B-Series VSI please read the Barmac B-Series Vertical Shaft Impactor Application Handbook. You’ll find this publication in the MM Marketing Toolbox and at www.barmactechinfo.com
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Features & Benefits The complete range of Barmac VSI crushers incorporates rock-on-rock crushing technology that has revolutionized the aggregates and minerals industries worldwide. The rock-on-rock Barmac VSI offers the modern operator product grading control by optimizing numerous variables:
Variation of rotor speed.
Choice of crushing chamber cavity rings.
Adjustment of cascade feed ratio.
Selection of different diameter rotors.
Designed for low service requirements and ease of operation, the Barmac VSI will readily fit into any existing or proposed crushing plant.
Barmac B-Series VSI Benefits
Accepts sticky feeds.
Accepts all in feeds.
Competitive capital cost, especially when compared with conventional crushing equipment.
Low service and maintenance requirements along with minimum operating and wear costs.
Rock-on-rock technology minimizes wear part requirements.
Quick and easy installation. Crushers require minimum support structure and are also ideal as mobile units.
Ability to control product grading, maximizing or minimizing fines production.
Produces a product of superior cubical shape.
Superior mineral liberation and increased recovery rates.
Preferential crushing action.
Integrated monitoring, safety and control systems.
More tolerant than conventional crushers to difficult feed conditions.
Simple, reliable grease lubrication.
Range of models available to suit any capacity in tertiary or quaternary applications.
The User-Friendly VSI crusher The Barmac VSI is designed with ease of installation in mind. Assembly, installation and commissioning can be achieved by two people in 2-3 days. Foundation requirements are minimal due to the light weight of the machine and the minimal dynamic forces when in operation. Existing support work can be used or a support structure can be supplied.
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The Barmac VSI provides higher capacity for a given motor size, easier servicing and reduced operating costs. Benefits have been achieved by an improved machine design, including a new hopper configuration, radical crushing chamber variations and the development of new rotor technology. Service time is drastically reduced with complete access to all rotor parts, simplifying wear part replacement procedures.
The roof lifter has been developed to provide quick and easy access to the internal workings of the Barmac VSI. This allows for rapid rotor and wear part changes and minimizes down time while maximizing availability. The simple and reliable design of the roof lifter means only one person is required for operation and can eliminate the requirement for an external crane.
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Features
Benefits
Cascade
A 10% increased capacity using the same power can be achieved with no effect on the product “Live” product grading flexibility Automation possibility gives greater production
Visible cascading
Easier tuning of crusher performance
Autogenous crushing action
Low wear costs Low contamination of product Good product shape High broken faces count Desirable product grading
Rock lined chutes
Low wear on crusher body
Parts range
Maximized wear parts performance which reduces costs
Operates balanced
Does not need to be bolted to concrete structure
IC3000
Full process automation and monitoring
VSI Operational Control System (VOCS)
Prevents damage to the crusher Maximizes crusher performance
Door & Roof lifter interlock
Safety for operators
Model range
A model is available to suit any tonnage
Clay and moisture tolerant
Production flexibility
Product grading is independent of parts condition
Continuity of production
Rotor selection in most models
Production flexibility
Low capital cost
Rapid return on investment
Original rock-on-rock VSI
35+ years experience to be shared
On-going R&D
Reduced operating costs Maximizes crusher performance
Low crusher weight
Small installation structure Can be installed on compacted gravel Light lifts when servicing
Bolt-in gussets in chamber
Easy to tune crushing chamber build-up
Low noise when operating
Safety for operators
Deep rotor technology
Reduced wear costs Better performance, increased capacity
Chamber door access
Reduced service time
Roof lifter access
Reduced service time. No need for crane to access
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Component Identification All Barmac VSI machines and parts manufactured by Metso are covered by a universal component numbering system, which is used in conjunction with the Barmac VSI parts book.
Besides standardizing all Barmac VSI internal systems, the component numbers, combined with standard manufacture systems, allow much more accurate batch and record keeping, as well as flexibility to add, subtract or change models without confusion.
Reference to a crusher or crusher part (other than bearing cartridge or rotor components or consumables) in the field should include the serial number of that component so Barmac VSI engineering can check records and avoid confusion of model or style. This will enable design improvements to be made to new machines while still ensuring that correct components are supplied for older machines.
The next three pages provide a visual guide of the Barmac VSI’s crusher and rotor components.
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21/66 Sales Manual BARMAC B-SERIES VSI Rotor and Wear Parts – Deep Rotor
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Options
Automation
IC3000 Experience has proven that the key to profits in the aggregate production and minerals processing industries lie in the ability to produce consistent products of high quality.
As in other industries, automation plays a critical role in achieving that consistency. When a Barmac VSI crusher is combined with an IC3000 automation system, crushing load is monitored and regulated, minimizing the risk of inconsistent product. This also results in greater crushing efficiency and, ultimately, improved product quality and cost-efficiency.
However the benefits of applying the IC3000 automation system to the crushing process is not limited to load regulation. The IC3000 also provides improved safety features for protection of operators and the crusher. Maintenance time is reduced with the integrated automatic lubrication system. This reduces risk to the crusher from damage due to under or over greasing.
Metso has developed the IC3000 automation system to provide increased flexibility and versatility, while supporting easy operation and maintenance. This allows seamless integration of a Barmac VSI crusher with the rest of the plant. Not only that, the IC3000 will also integrate with site level SCADA systems using industry standard communications protocols.
A Barmac VSI crusher in combination with a Nordberg IC3000 automation system offers the ultimate in consistent, efficient and profitable crushing.
Advantages of IC3000
Simple and user friendly operator interface
Robust and reliable hardware platform
Supports connection to plant level control systems
Improved event, alarm and data logging
Maximizing production potential
IC3000 – Basic Circuit
Prevent unsafe access to crusher.
Lubricates crusher.
Prevent overloading of crusher.
Monitors and protects crusher from excessive vibration.
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Incorporates hydraulic power pack for cascade gate control.
Logs events, warnings and alarms.
Automatic start & stop sequences.
System diagnostics.
Records crushing data.
Interface for plant level system.
IC3000 – Advanced Circuit
All features of IC3000 – Basic Circuit.
Automated feeder control.
Automated cascade control.
IC3000 Control System Layout
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Product Support Services Metso provides a complete service support package for the Barmac VSI range. The skills and knowledge acquired from over 35 years of manufacturing, applying and servicing the Barmac VSI allow the best solutions to be given to the customer to help maximise the potential of their operation.
To ensure the best service to Barmac VSI customers, Metso provides a comprehensive product support team of dedicated professionals, based at the factory and in strategic locations around the globe.
Genuine quality Because we have a larger installed equipment and customer base than anyone in the industry, we always carry high levels of spare and wear parts, and have more expert service personnel across the globe ready to serve our customers. This means when our customers choose a Barmac VSI they have the security of knowing that every piece of equipment is backed by unmatched parts availability and service.
Our genuine, high quality parts give customers the assurance of correct metallurgy, precise engineering and ideal suitability for trouble-free operation, so they can produce the quality products the equipment is designed to produce, providing value for them and, in turn, their customers.
Protecting business through Equipment Protection Plan (EPP) The Equipment Protection Plan (EPP) has been designed to provide our customers with the security of extended coverage on the key components of their crushing and screening equipment after the standard warranty period of 1 year or 2000 hours has expired.
The EPP should be incorporated in the original equipment sales agreement, and it covers the main components of a wide range of MCT crushers and track-mounted plants, including the Barmac VSI. Overall, the value of the components covered by the EPP represents up to 75% of the complete equipment value. This product offers our customers a significant opportunity to reduce their unexpected maintenance cost in case of major failure.
This Equipment Protection Plan reduces customer's performance risk and provides the customer with a more speedy replacement or repair procedure. Along with the EPP, Metso offers 5 years/10,000 hours of shared risk with the customer, providing that customer continuously uses Metso genuine spare and wear parts, and purchases every 1000 hour Inspection Service for the EPP covered equipment.
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EPP Covered Components for Barmac VSI
Technical and Sales Support information Technical and sales support information required for the Barmac VSI can be found in the Technical Data and MM Marketing Toolbox databases, which are both accessible from your Home Page on Lotus Notes, or at www.barmactechinfo.com
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Suggested Marketing Tactics The Barmac VSI is an ideal third or fourth stage crusher designed to crush the complete range of ores, rocks and minerals. The Barmac rock-on-rock crushing principle has revolutionized material reduction by providing a crusher that produces excellent reduction at a low operating cost.
Barmac VSIs combine high velocity impact crushing with attrition crushing to produce cubical product & quality sand. Barmac VSIs are unique amongst all vertical shaft impactors due to the pure rock-on-rock principle. Impeller shoes or impact anvils are not needed to achieve reduction.
Why choose a Barmac B-Series VSI?
Superior cubically shaped product.
The lowest possible cost per tonne.
Greater machine availability, giving more production.
Greater component availability.
Improved energy efficiency.
Lower wear costs.
Improved crushing performance and control.
Versatility to operate in many demanding and diverse applications.
Cost effective serviceability.
Technical and application support through Metso’s global network.
The Barmac VSI rock-on-rock crusher is best suited as a final phase crusher in most crushing circuits. The unique rock-on-rock crushing action allows excellent reduction and the promotion of greater amounts of fine material than conventional crushing technology.
Due to the rock-on-rock crushing action the Barmac VSI tends to produce the best shape of any crusher on the market. Therefore in certain quarry applications, such as concrete, asphalt and sealing chip applications, it increases the saleability of the final product considerably. In mining applications it is utilised as a fine crusher and in this application the Barmac VSI has been referred to as a 'vertical shaft mill'.
The crushing action of a rock-on-rock crusher generates more fine particles than conventional compression crushing. This can be particularly beneficial in a multitude of fine crushing and sand manufacturing applications. Crushing of finer particles has a combination of all the processes that generate particle reduction in a Barmac VSI.
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The benefits of the Barmac VSI in the following applications are discussed in more detail:
Shaping.
Fine Crushing.
Preferential Crushing.
Disagglomeration.
Dry Scrubbing.
Shaping Particles crushed by the autogenous crushing action of a Barmac VSI crusher are subjected to exactly the same conditions as sand and gravel when transported in water. The residence time of particles in the crushing chamber range from between 5 to 20 seconds. During this time each particle is subjected to hundreds of particle interactions from both coarse and fine particles resulting in cleavage, impact, abrasion and attrition of the particles.
In the process, the crushing action concentrates on several properties of a particle:
Areas of softer material.
Areas or planes of weakness.
Mineral boundaries.
Flat or thin edges of a particle.
The effects are twofold; to reduce softer material at a rate far greater than medium to hard mineralogy's of the particle and to produce cubical shaped aggregates. The reduction of the softer material results in a harder, more resilient product, desirable in many applications of quality shaped material.
The production of cubical shaped aggregates is extremely important in many of the applications Barmac VSIs have been applied, whether it is shaping quarry aggregates, providing shaped industrial minerals products or reducing and shaping recyclable materials. The better shape achieved increases the saleability of the final product, adding value to the Barmac VSI operator's business.
Fine Crushing The high energies usually required for crushing fine particles in conventional compression crushing equipment are not required in a Barmac VSI. The transference of energy from the spinning rotor to the particles is very efficient, resulting in high reduction and the production of large quantities of fine particles. The percentage of fines required can be altered by changing the rotor tip speed, chamber configuration, rotor size, cascade ratio and feed gradation
This technology is effectively employed in fine crushing and manufactured sand applications. Product from the crusher has cubical shape which mimics the natural sand the product is replacing in concrete © Metso 2011
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construction. Continued research in this area has shown that the use of manufactured sand when administered in the right proportions can have a positive effect on the final strength properties of concrete.
In mining applications the Barmac VSI is utilised for fine crushing of ore. The crushing action promotes particle breakage along planes of weakness such as mineral boundaries, joints and micro fractures. The ability of the Barmac VSI to produce a product with a high proportion of fines improves milling circuit performance by reducing the energy requirement of the mill and increasing plant capacity. Furthermore, the improved shape of the mill feed can produce increased media and wear plate life.
The benefit of employing a Barmac VSI as a pre-grinder is a rapidly growing area of sales. In this application the crusher is used as a means of conditioning the feed in either an open or closed circuit prior to entering the mill. This has been proven to improve mill capacity and decrease power requirements.
Due to free impact crushing process used in autogenous VSI crushers, Barmac VSIs are under no mechanical stress when producing fine crushed product and consequently suffer no long term maintenance cost penalty as a result of fine crushing. A compression crusher which must be operated with a small closed side setting results in increased mechanical stress within the crusher, which decreases liner wear and reduces the mechanical service life of the unit.
Barmac VSIs are currently employed in the fine crushing of such materials as bauxite, fused alumina, quartzite, cement clinker, abrasive limestone and many more difficult and abrasive materials as required in the quarrying and mineral processing industries.
Preferential Crushing In certain applications the Barmac VSI is a proven preferential crusher. For this to be successful there needs to be a difference in strength between the gangue or waste rock (secondary minerals in some applications) and the valuable minerals that require liberation.
The nature of the crushing action and the variation of strength tends to crush friable material faster than the harder material. This feature can be of great benefit in applications where the valuable mineral content is present as a significantly harder or softer component of the ore, as in free gold applications or where mineralization occurs along cleavage planes.
The process of preferential crushing allows easier and effective separation between the components of an ore. This allows much better rates of recovery and improvements in circuit efficiency. The crushing action of the Barmac VSI allows it the ability to liberate minerals, or preferentially crush deleterious © Metso 2011
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material, without over crushing the valuable minerals. This enables increased recovery of valuable minerals. To achieve the right degree of preferential crushing, Barmac VSI variables such as rotor tip speed, chamber configuration, rotor size, cascade ratio and feed gradation can be altered to give the best results.
Disagglomeration In some applications compression crushing techniques will lead to an agglomeration of the crusher product. In these applications a Barmac VSI can successfully be applied as a disagglomerator to separate particles into a granular product for benefication.
At low energies within the crushing chamber, abrasion and attrition of the particles occur. This action breaks up the crusher feed resulting in better efficiencies downstream. Then, with conventional screening and separation methods, fine particles can be separated from coarser particles. The effect of using a Barmac VSI to disagglomerate can, and in most cases will, have a very beneficial effect on the whole plant, improving efficiencies throughout.
The processes and equipment downstream of the Barmac VSI receive material of superior quality making them able to process more with greater accuracy, thus increasing output and resulting in energy savings. Equipment upstream of the Barmac VSI can have their operating parameters altered to allow increased throughput. The process they are trying to achieve is then taken over by the Barmac VSI.
Due to low kinetic energy required in most of these applications this is when maximum use of the Barmac VSI's cascade ability can be made. It has been reported that up to 60% cascade can be used when in this type of application. This results in throughputs far in excess of any competing crusher while still achieving the same end results.
Dry Scrubbing Some applications require the removal of surface contaminants from valuable material to improve the final product. The rock-on-rock crushing action of the Barmac VSI lends itself well as a tool in achieving this. The attrition and abrasion reduction mechanisms that occur at low tip speeds act to free deleterious materials without reducing valuable materials. This results in a high quality end product.
The typical dry scrubbing application is to separate aggregates that have a clay component, such as glacial deposits. The crushing action of the Barmac VSI and the use of cascade feed allows effective cleaning of the aggregate at rates far greater than any competing crusher.
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Circuit design considerations
Surge bin Ideally a surge bin or surge pile should be installed ahead of a Barmac VSI crusher. This reduces surging to the machine and downstream plant and maintains optimum feed conditions. Surge capacity should be sized to allow a minimum of 10-15 minutes continuous crushing.
Screen sizing and apertures Correct sizing of screens is important to ensure the operation of the Barmac VSI is successful. Screen efficiencies should be kept as high as possible. Typically, screen efficiency should be a minimum of 85% to 90%. Apertures should be sized to ensure accurate separation of finished product and efficient separation. In manufactured sand applications the use of slotted media is beneficial. Also, anti-blinding synthetic medias should be considered and screens sized accordingly.
Tramp protection Suitable protection to stop tramp metal or over-size being fed to the machine should be provided. Failure to do so can lead to component failure.
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SECTION 2 – MACHINE SPECIFIC INFORMATION
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Barmac B9100SE VSI
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Dimension Drawings & Specifications – B9100SE
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Configurations The Barmac B9100SE VSI is available in Single Drive and Dual Drive arrangements, with Roof Lifter and non-Roof Lifter options.
Main Module The crusher consists of:
Hydracascade feed hopper with hydraulic gate adjustment system.
Integrated cascade assembly for control of product gradation.
Crusher base with grease lubricated shaft line assembly, suitable for feed material temperature from -20 to maximum of 65°C (-4 to 149°F).
High efficiency crushing chamber with reversible, side-view rotor access door.
Antivibration mounts which dissipate the crusher vibration during operation.
Liners to protect the base from wear. Manufactured from mild steel plate, these liners provide adequate protection in most applications.
Integrated transmission drive tunnel with belt guards.
Adjustable heavy duty motor mount structure with screw adjusters.
Safety interlock system designed to prevent the crushing from being opened whilst the machine is in operation, and to prevent re-start when the crusher is open for maintenance or inspection.
One rotor with full set of wear parts.
Rotor Four standard rotor options are available:
990 (39”) Deep
990 (39”) Standard
840 (33”) Deep
840 (33”) Standard
Specific configuration information for Barmac B9100SE VSI can be found in the B9100SE Installation Book and Product Specification form. Please visit www.barmactechinfo.com or the Technical Data database, which is accessible from your Home Page on Lotus Notes.
© Metso 2011
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Parts B9100SE Crusher
Standard Top - It will be necessary to have an overhead crane to remove the crusher roof for regular maintenance. A roof lifter option is available to facilitate this need.
Roof Lifter Top - The roof lifter option provides easy access to the crushing chamber and rotor. This is powered by the same hydraulic system used for cascade and feed control.
Fine Cavity Ring Upgrade - The fine cavity ring promotes longer material retention in the crushing chamber resulting in a finer product.
Hopper Extension - The hopper extension provides a lip to attach dust sealing should that be necessary for the installation.
Extra Chamber Gussets - Extra gussets are useful to increase chamber build-up in very fine or dry applications, or when feed rate drops below normal for extended periods of time. The objective is to protect the structure of the crushing chamber.
Single Drive Bottom - A single drive configuration provides for a single electric motor. By default it is installed to the right of the service door, but this may be requested on the left or changed at a later date.
Dual Drive Bottom - For higher power options it is necessary to install two electric motors in dual drive configuration. This choice is based on the customer's application needs.
HT SLA Upgrade - The high temperature shaft line assembly can withstand feed material from 60 to maximum of 100°C (140 to 212°F). This replaces the standard shaft line assembly described in the main module.
XL Base Liner Upgrade - Manufactured from hard wearing hard-faced plate, the extra life base liners provide increased wear resistance. Upgraded liners are recommended for highly abrasive materials and high tonnage operations. This replaces the standard base liners described in the main module.
Base Water Spray - The water spray kit has been developed to minimize build-up of material in the base of the crusher when processing sticky product. The water spray kit is generally used in conjunction with the non-stick base liners option.
Non-Stick Liners - The non-stick base liners have been developed for use when processing sticky material to avoid excessive build-up in the base where the build-up could cause wear on the underside of the rotor. In extreme circumstances, the non-stick base liners can be used in conjunction with the base water spray kit.
Control System
VOCS - A basic protection system to monitor crusher vibration and temperature of shaft line assembly and motors.
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VOCS 100m Cable - This is the cable between the VOCS controller (in control room) and the data sender on the crusher. The 100m (330') cable is supplied separately and can be substituted for the 50m (165') cable supplied.
VOCS Strobe - This is a bright flashing light that can be linked to the VOCS alarm system to warn operators that there is a problem with the VSI.
VOCS Siren - This is a loud siren/alarm that can be linked to the VOCS alarm system to warn operators that there is a problem with the VSI.
Mechanical Vibration Switch - This mechanical vibration switch provides the most basic level of protection when wired to the crusher electrical circuit.
Automatic Lubrication - The automatic lubrication system is designed to supply the shaft line assembly with measured amounts of grease during the machines operation. The system consists of a pump, timer, and power source.
Hydraulic Handpump - A hand pump is the minimum choice for manual control of the cascade / crusher feed, and for operation of the roof lifter if fitted.
Electric/Hydraulic Pump - This system is a combination of small electric motor and hydraulic pump. It is used to adjust the cascade / crusher feed at the push of a button (or integrate to a plant control system), and to operate the roof lifter if fitted.
IC3000 - An advanced control and protection system to maximise crusher productivity with integrated safety and lubrication systems. The crusher can be controlled from the integrated display interface or via connection with a wider plant automation system.
Hose Extension - Standard hoses are 10m (33'). The extension provides and additional 5m, totaling 15m (49').
Option 1 - Profibus - Choose the needed cable length between E1 cabinet (beside crusher) and E2 cabinet (in control room).
Option 2 - MCC - Choose the needed cable length between E2 cabinet (in control room) and motor starter panel.
Option 3 - Display - A display extension is needed when the E2 cabinet is not visible / accessible in the crusher control room. Remote screen set is composed by a screen support, a cover for the control box and needed cables.
Ethernet Module - Ethernet 343-1 Lean module to enable ethernet communication to customer's SCADA system.
DP/DP Coupler - Profibus DP/DP coupler module to enable ethernet communication to customer's SCADA system.
Crusher Support
Support Frame - The support frame suspends the crusher on its antivibration mounts, and integrates the support legs and maintenance platform.
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B9100SE Support Legs - Support legs attach to the support frame and lift the VSI off the ground so that conveyors (or something else) can be set up to clear the material discharge from the machine. Short legs provide 1.2m (49") clearance below the crusher, and long legs 2.1m (81"). They are only available if the support frame has been selected.
Skid Frame - The skid frame is fixed at the bottom of the legs and therefore is only available if legs have been selected. The skid allows the crusher to be dragged horizontally to move the VSI around a site when needed.
Maintenance Platform - The platform provides full access for regular VSI maintenance. By default it complies with Australian Standard 1657-1992. If compliance with other national standards is needed, contact Metso New Zealand Limited for guidance. It may be possible to utilize engineering contractors in the destination country to validate the design to their local standards.
Service Tools
Tool Kit - A basic tool kit for maintenance and servicing of the VSI.
Service Boom - The service boom is bolted to the side of the crusher and allows lifting of the rotor and shaft line assembly (separately) for maintenance operations. It is necessary to have some other overhead lifting device to remove the top of the crusher, or select the roof lifter option.
Rotor Service Arm - The rotor service arm is bolted to the side of the crusher and allows lifting of the rotor for maintenance operations. It is necessary to have some other overhead lifting device to remove the top of the crusher, or select the roof lifter option.
Chain Block - A simple manually-operated chain hoist used in conjunction with the service boom or rotor service arm.
Rotor Balancer - A necessary tool to ensure rotors are properly balanced after repair work.
Pulley Lifting Tool - A convenient tool for the safe removal and fitting of pulleys. Recommended where pulley changes are frequent (eg. for speed changes).
Maintenance Ladder - A ladder that hooks onto the crusher side door, for personnel access to the roof and hopper.
Safety Decals - Choose the standard appropriate to the customer's region.
Speed & Power
Motor - WEG crusher duty motors are specifically designed to meet demanding requirements of the rock crushing industry. These motors are designed for vertical mounting and have exceptional high starting and breakdown torque. Data sheets are available to check the electrical compatibility for your customer.
Drive Kit - Drive kit includes all needed pulleys, taper locks, and vee belts. Several different speeds may be selected to enable speed changes.
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Documentation
Owner's Manuals - English language component manuals will be substituted where the selected language is not available.
Rotor
Fixed Feed Eye Ring - The fixed feed eye ring is only available for the 990 rotor.
Turnable Feed Eye Ring - The turnable feed eye ring gives the option for multiple wear lives. The ring can be turned to 3 positions.
Flat Distributor - The flat distributor provides the most clearance through the rotor to allow maximum throughput, but the reduced thickness reduces the wear life. It is used for low abrasive material.
Cone Distributor - The cone distributor has a thicker profile than the flat and will last longer. It is the best compromise between throughput and wear life for standard rotors.
Heavy Cone Distributor - The heavy cone distributor has the longest wear life of any distributor and is recommended for DTR rotors.
2-Piece Distributor - The 2-piece distributor allows for easier replacement with pieces weighing only 22kg (outer) and 13kg (inner). (48 and 27 lbs).
Tips -
Tip Shape:
"Hanger" tips promote good buildup inside the rotor, but less protection to the outside of the rotor. Use with very dry feed or when moisture in the feed tends to wash the build-up out.
"Extended Hanger" tips promote less build-up in the rotor, but offer better protection to the outside of the rotor. Use where build-up is naturally good.
"EXL Extended Hanger" tips have larger tungsten pieces for longer life. These tips promote less build-up in the rotor, but offer better protection to the outside of the rotor. Use where build-up is naturally good.
"Laminated" tips have a dual layer of tungsten to provide the best wear life in applications where oversize material or tramp metal may be present in the feed material.
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Tungsten Grade:
"Hard" has medium abrasion resistance and high impact resistance.
"Extra Hard" has high abrasion resistance and medium impact resistance.
"XX Hard" has very high abrasion resistance for the longest possible tip life, but the impact resistance is quite low. Use where feed sizes are smaller and there is no risk of oversize material or tramp metal.
"LF" is the dual tungsten designation with both hard and extra hard tungsten. This provides high abrasion resistance and medium impact resistance.
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Configuration:
"Split" tips allow the position to be swapped for extended wear life, or for replacement of only the worn portion.
"1-Piece" tips provide the best protection against wear from fine material.
Standard Split T/CWP - Standard T/CWPs provide a single wear life, but depending on wear characteristics can be swapped from tip position to cavity wear plate position for additional service life. Split T/CWPs allow for replacement of only the worn portion.
Standard 1P T/CWP - Standard T/CWPs provide a single wear life, but depending on wear characteristics can be swapped from tip position to cavity wear plate position for additional service life. 1-piece T/CWPs provide the best protection against wear from fine material.
Reversible Split T/CWP - Reversible T/CWPs provide a second wear life by turning 180°, and are also interchangeable from tip position to cavity wear plate position for additional service life depending on wear characteristics. Split T/CWPs allow for replacement of only the worn portion.
Reversible 1P T/CWP - Reversible T/CWPs provide a second wear life by turning 180°, and are also interchangeable from tip position to cavity wear plate position for additional service life depending on wear characteristics. 1-piece T/CWPs provide the best protection against wear from fine material.
Fabricated T/CWP - Fabricated T/CWPs provide the maximum impact resistance, but with a reduced wear life.
Trail Plate - Various trail plate shapes are available to tune the material build-up within the rotor. Generally use wider trail plates for drier material that doesn't naturally build up, and narrower for stickier material. Tungsten edged versions have longer wear life.
Standard Top WP - The standard top wear plate provides minimum protection to the top face of the rotor. It is expected that the periphery of the rotor will wear slowly and require periodic repair.
Lipped Top WP - The lipped wear plate provides protection to the top face and periphery of the rotor body top plate. This becomes the sacrificial wear plate and protects the rotor body from need of frequent repair.
Lipped Bottom WP - The lipped bottom wear plate provides protection to the bottom plate of the rotor, and is useful when material build-up or feed rate is very high.
Cavity Bracket - The cavity bracket set provides better protection to the rotor when chamber build-up is very high or for some other reason there is a lot of material bouncing back on the rotor. Cannot be used in conjunction with reversible T/CWPs.
To access individual parts pages and rotor parts information for a Barmac B9100SE VSI please visit www.barmactechinfo.com
© Metso 2011
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Barmac B7150SE VSI
© Metso 2011
INTERNAL DOCUMENT
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Dimension Drawings & Specifications – B7150SE
© Metso 2011
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Configurations The Barmac B7150SE VSI is available in Single Drive and Dual Drive arrangements, with Roof Lifter and non-Roof Lifter options.
Main Module The crusher consists of:
Hydracascade feed hopper with hydraulic gate adjustment system.
Integrated cascade assembly for control of product gradation.
Crusher base with grease lubricated shaft line assembly, suitable for feed material temperature from -20 to maximum of 65°C (-4 to 149°F).
High efficiency crushing chamber with reversible, side-view rotor access door.
Antivibration mounts which dissipate the crusher vibration during operation.
Liners to protect the base from wear. Manufactured from mild steel plate, these liners provide adequate protection in most applications.
Integrated transmission drive tunnel with belt guards.
Adjustable heavy duty motor mount structure with screw adjusters.
Safety interlock system designed to prevent the crushing from being opened whilst the machine is in operation, and to prevent re-start when the crusher is open for maintenance or inspection.
One rotor with full set of wear parts.
Rotor Two standard rotor options are available:
840 (33”) Deep
840 (33”) Standard
Specific configuration information for Barmac B7150SE VSI can be found in the B7150SE Installation Book and Product Specification form. Please visit www.barmactechinfo.com or the Technical Data database, which is accessible from your Home Page on Lotus Notes.
© Metso 2011
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Parts B7150SE Crusher
Standard Top - It will be necessary to have an overhead crane to remove the crusher roof for regular maintenance. A roof lifter option is available to facilitate this need.
Roof Lifter Top - The roof lifter option provides easy access to the crushing chamber and rotor. This is powered by the same hydraulic system used for cascade and feed control.
Extra Chamber Gussets - Extra gussets are useful to increase chamber build-up in very fine or dry applications, or when feed rate drops below normal for extended periods of time. The objective is to protect the structure of the crushing chamber.
Single Drive Bottom - A single drive configuration provides for a single electric motor. By default it is installed to the right of the service door, but this may be requested on the left or changed at a later date.
Dual Drive Bottom - For higher power options it is necessary to install two electric motors in dual drive configuration. This choice is based on the customer's application needs.
HT SLA Upgrade - The high temperature shaft line assembly can withstand feed material from 60 to maximum of 100°C (140 to 212°F). This replaces the standard shaft line assembly described in the main module.
XL Base Liner Upgrade - Manufactured from hard wearing hard-faced plate, the extra life base liners provide increased wear resistance. Upgraded liners are recommended for highly abrasive materials and high tonnage operations. This replaces the standard base liners described in the main module.
Base Water Spray - The water spray kit has been developed to minimize build-up of material in the base of the crusher when processing sticky product. The water spray kit is generally used in conjunction with the non-stick base liners option.
Non-Stick Liners - The non-stick base liners have been developed for use when processing sticky material to avoid excessive build-up in the base where the build-up could cause wear on the underside of the rotor. In extreme circumstances, the non-stick base liners can be used in conjunction with the base water spray kit.
Control System
VOCS - A basic protection system to monitor crusher vibration and temperature of shaft line assembly and motors.
VOCS 100m Cable - This is the cable between the VOCS controller (in control room) and the data sender on the crusher. The 100m (330') cable is supplied separately and can be substituted for the 50m (165') cable supplied.
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VOCS Strobe - This is a bright flashing light that can be linked to the VOCS alarm system to warn operators that there is a problem with the VSI.
VOCS Siren - This is a loud siren/alarm that can be linked to the VOCS alarm system to warn operators that there is a problem with the VSI.
Mechanical Vibration Switch - This mechanical vibration switch provides the most basic level of protection when wired to the crusher electrical circuit.
Automatic Lubrication - The automatic lubrication system is designed to supply the shaft line assembly with measured amounts of grease during the machines operation. The system consists of a pump, timer, and power source.
Hydraulic Handpump - A hand pump is the minimum choice for manual control of the cascade / crusher feed, and for operation of the roof lifter if fitted.
Electric/Hydraulic Pump - This system is a combination of small electric motor and hydraulic pump. It is used to adjust the cascade / crusher feed at the push of a button (or integrate to a plant control system), and to operate the roof lifter if fitted.
IC3000 - An advanced control and protection system to maximise crusher productivity with integrated safety and lubrication systems. The crusher can be controlled from the integrated display interface or via connection with a wider plant automation system.
Hose Extension - Standard hoses are 10m (33'). The extension provides and additional 5m, totaling 15m (49').
Option 1 - Profibus - Choose the needed cable length between E1 cabinet (beside crusher) and E2 cabinet (in control room).
Option 2 - MCC - Choose the needed cable length between E2 cabinet (in control room) and motor starter panel.
Option 3 - Display - A display extension is needed when the E2 cabinet is not visible / accessible in the crusher control room. Remote screen set is composed by a screen support, a cover for the control box and needed cables.
Ethernet Module - Ethernet 343-1 Lean module to enable ethernet communication to customer's SCADA system.
DP/DP Coupler - Profibus DP/DP coupler module to enable ethernet communication to customer's SCADA system.
Crusher Support
Support Frame - The support frame suspends the crusher on its antivibration mounts, and integrates the support legs and maintenance platform.
B7150SE Support Legs - Support legs attach to the support frame and lift the VSI off the ground so that conveyors (or something else) can be set up to clear the material discharge from the machine. Short legs provide 1.5m (58") clearance below the crusher, and long legs 2.3m (91"). They are only available if the support frame has been selected.
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Skid Frame - The skid frame is fixed at the bottom of the legs and therefore is only available if legs have been selected. The skid allows the crusher to be dragged horizontally to move the VSI around a site when needed.
Maintenance Platform - The platform provides full access for regular VSI maintenance. By default it complies with Australian Standard 1657-1992. If compliance with other national standards is needed, contact Metso New Zealand Limited for guidance. It may be possible to utilize engineering contractors in the destination country to validate the design to their local standards.
Service Tools
Tool Kit - A basic tool kit for maintenance and servicing of the VSI.
Service Boom - The service boom is bolted to the side of the crusher and allows lifting of the rotor and shaft line assembly (separately) for maintenance operations. It is necessary to have some other overhead lifting device to remove the top of the crusher, or select the roof lifter option.
Rotor Service Arm - The rotor service arm is bolted to the side of the crusher and allows lifting of the rotor for maintenance operations. It is necessary to have some other overhead lifting device to remove the top of the crusher, or select the roof lifter option.
Chain Block - A simple manually-operated chain hoist used in conjunction with the service boom or rotor service arm.
Rotor Balancer - A necessary tool to ensure rotors are properly balanced after repair work.
Pulley Lifting Tool - A convenient tool for the safe removal and fitting of pulleys. Recommended where pulley changes are frequent (eg. for speed changes).
Maintenance Ladder - A ladder that hooks onto the crusher side door, for personnel access to the roof and hopper.
Safety Decals - Choose the standard appropriate to the customer's region.
Speed & Power
Motor - WEG crusher duty motors are specifically designed to meet demanding requirements of the rock crushing industry. These motors are designed for vertical mounting and have exceptional high starting and breakdown torque. Data sheets are available to check the electrical compatibility for your customer.
Drive Kit - Drive kit includes all needed pulleys, taper locks, and vee belts. Several different speeds may be selected to enable speed changes.
Documentation
Owner's Manuals - English language component manuals will be substituted where the selected language is not available.
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Rotor
Turnable Feed Eye Ring - The turnable feed eye ring gives the option for multiple wear lives. The ring can be turned to 3 positions.
Flat Distributor - The flat distributor provides the most clearance through the rotor to allow maximum throughput, but the reduced thickness reduces the wear life. It is used for low abrasive material.
Cone Distributor - The cone distributor has a thicker profile than the flat and will last longer. It is the best compromise between throughput and wear life for standard rotors.
Heavy Cone Distributor - The heavy cone distributor has the longest wear life of any distributor and is recommended for DTR rotors.
2-Piece Distributor - The 2-piece distributor allows for easier replacement with pieces weighing only 22kg (outer) and 13kg (inner). (48 and 27 lbs).
Tips -
Tip Shape:
"Hanger" tips promote good buildup inside the rotor, but less protection to the outside of the rotor. Use with very dry feed or when moisture in the feed tends to wash the build-up out.
"Extended Hanger" tips promote less build-up in the rotor, but offer better protection to the outside of the rotor. Use where build-up is naturally good.
"EXL Extended Hanger" tips have larger tungsten pieces for longer life. These tips promote less build-up in the rotor, but offer better protection to the outside of the rotor. Use where build-up is naturally good.
"Laminated" tips have a dual layer of tungsten to provide the best wear life in applications where oversize material or tramp metal may be present in the feed material.
-
Tungsten Grade:
"Hard" has medium abrasion resistance and high impact resistance.
"Extra Hard" has high abrasion resistance and medium impact resistance.
"XX Hard" has very high abrasion resistance for the longest possible tip life, but the impact resistance is quite low. Use where feed sizes are smaller and there is no risk of oversize material or tramp metal.
"LF" is the dual tungsten designation with both hard and extra hard tungsten. This provides high abrasion resistance and medium impact resistance.
-
Configuration:
"Split" tips allow the position to be swapped for extended wear life, or for replacement of only the worn portion.
© Metso 2011
"1-Piece" tips provide the best protection against wear from fine material.
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Standard Split T/CWP - Standard T/CWPs provide a single wear life, but depending on wear characteristics can be swapped from tip position to cavity wear plate position for additional service life. Split T/CWPs allow for replacement of only the worn portion.
Standard 1P T/CWP - Standard T/CWPs provide a single wear life, but depending on wear characteristics can be swapped from tip position to cavity wear plate position for additional service life. 1-piece T/CWPs provide the best protection against wear from fine material.
Reversible Split T/CWP - Reversible T/CWPs provide a second wear life by turning 180°, and are also interchangeable from tip position to cavity wear plate position for additional service life depending on wear characteristics. Split T/CWPs allow for replacement of only the worn portion.
Reversible 1P T/CWP - Reversible T/CWPs provide a second wear life by turning 180°, and are also interchangeable from tip position to cavity wear plate position for additional service life depending on wear characteristics. 1-piece T/CWPs provide the best protection against wear from fine material.
Fabricated T/CWP - Fabricated T/CWPs provide the maximum impact resistance, but with a reduced wear life.
Trail Plate - Various trail plate shapes are available to tune the material build-up within the rotor. Generally use wider trail plates for drier material that doesn't naturally build up, and narrower for stickier material. Tungsten edged versions have longer wear life.
Standard Top WP - The standard top wear plate provides minimum protection to the top face of the rotor. It is expected that the periphery of the rotor will wear slowly and require periodic repair.
Lipped Top WP - The lipped wear plate provides protection to the top face and periphery of the rotor body top plate. This becomes the sacrificial wear plate and protects the rotor body from need of frequent repair.
Lipped Bottom WP - The lipped bottom wear plate provides protection to the bottom plate of the rotor, and is useful when material build-up or feed rate is very high.
Cavity Bracket - The cavity bracket set provides better protection to the rotor when chamber build-up is very high or for some other reason there is a lot of material bouncing back on the rotor. Cannot be used in conjunction with reversible T/CWPs.
To access individual parts pages and rotor parts information for a Barmac B7150SE VSI please visit www.barmactechinfo.com
© Metso 2011
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Barmac B6150SE VSI
© Metso 2011
INTERNAL DOCUMENT
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INTERNAL DOCUMENT
Dimension Drawings & Specifications – B6150SE
© Metso 2011
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INTERNAL DOCUMENT
Configurations The Barmac B6150SE VSI is available in Single Drive arrangement, as a Roof Lifter or non-Roof Lifter machine.
Main Module The crusher consists of:
Hydracascade feed hopper with hydraulic gate adjustment system.
Integrated cascade assembly for control of product gradation.
Crusher base with grease lubricated shaft line assembly, suitable for feed material temperature from -20 to maximum of 65°C (-4 to 149°F).
High efficiency crushing chamber with reversible, side-view rotor access door.
Antivibration mounts which dissipate the crusher vibration during operation.
Liners to protect the base from wear. Manufactured from mild steel plate, these liners provide adequate protection in most applications.
Integrated transmission drive tunnel with belt guards.
Adjustable heavy duty motor mount structure with screw adjusters.
Safety interlock system designed to prevent the crushing from being opened whilst the machine is in operation, and to prevent re-start when the crusher is open for maintenance or inspection.
One rotor with full set of wear parts.
Rotor One standard rotor options is available:
690 (27”) Deep
Specific configuration information for Barmac B6150SE VSI can be found in the B6150SE Installation Book and Product Specification form. Please visit www.barmactechinfo.com or the Technical Data database, which is accessible from your Home Page on Lotus Notes.
© Metso 2011
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Parts B6150SE Crusher
Extra Chamber Gussets - Extra gussets are useful to increase chamber build-up in very fine or dry applications, or when feed rate drops below normal for extended periods of time. The objective is to protect the structure of the crushing chamber.
HT SLA Upgrade - The high temperature shaft line assembly can withstand feed material from 60 to maximum of 100°C (140 to 212°F). This replaces the standard shaft line assembly described in the main module.
XL Base Liner Upgrade - Manufactured from hard wearing hard-faced plate, the extra life base liners provide increased wear resistance. Upgraded liners are recommended for highly abrasive materials and high tonnage operations. This replaces the standard base liners described in the main module.
Base Water Spray - The water spray kit has been developed to minimize build-up of material in the base of the crusher when processing sticky product. The water spray kit is generally used in conjunction with the non-stick base liners option.
Non-Stick Liners - The non-stick base liners have been developed for use when processing sticky material to avoid excessive build-up in the base where the build-up could cause wear on the underside of the rotor. In extreme circumstances, the non-stick base liners can be used in conjunction with the base water spray kit.
Control System
VOCS - A basic protection system to monitor crusher vibration and temperature of shaft line assembly and motors.
VOCS 100m Cable - This is the cable between the VOCS controller (in control room) and the data sender on the crusher. The 100m (330') cable is supplied separately and can be substituted for the 50m (165') cable supplied.
VOCS Strobe - This is a bright flashing light that can be linked to the VOCS alarm system to warn operators that there is a problem with the VSI.
VOCS Siren - This is a loud siren/alarm that can be linked to the VOCS alarm system to warn operators that there is a problem with the VSI.
Mechanical Vibration Switch - This mechanical vibration switch provides the most basic level of protection when wired to the crusher electrical circuit.
Automatic Lubrication - The automatic lubrication system is designed to supply the shaft line assembly with measured amounts of grease during the machines operation. The system consists of a pump, timer, and power source.
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Hydraulic Handpump - A hand pump is the minimum choice for manual control of the cascade / crusher feed, and for operation of the roof lifter if fitted.
Electric/Hydraulic Pump - This system is a combination of small electric motor and hydraulic pump. It is used to adjust the cascade / crusher feed at the push of a button (or integrate to a plant control system), and to operate the roof lifter if fitted.
IC3000 - An advanced control and protection system to maximise crusher productivity with integrated safety and lubrication systems. The crusher can be controlled from the integrated display interface or via connection with a wider plant automation system.
Hose Extension - Standard hoses are 10m (33'). The extension provides and additional 5m, totaling 15m (49').
Option 1 - Profibus - Choose the needed cable length between E1 cabinet (beside crusher) and E2 cabinet (in control room).
Option 2 - MCC - Choose the needed cable length between E2 cabinet (in control room) and motor starter panel.
Option 3 - Display - A display extension is needed when the E2 cabinet is not visible / accessible in the crusher control room. Remote screen set is composed by a screen support, a cover for the control box and needed cables.
Ethernet Module - Ethernet 343-1 Lean module to enable ethernet communication to customer's SCADA system.
DP/DP Coupler - Profibus DP/DP coupler module to enable ethernet communication to customer's SCADA system.
Crusher Support
Support Frame - The support frame suspends the crusher on its antivibration mounts, and integrates the support legs.
B6150SE Support Legs - Support legs attach to the support frame and lift the VSI off the ground so that conveyors (or something else) can be set up to clear the material discharge from the machine. Short legs provide 1.4m (54") clearance below the crusher, and long legs 2.2m (87"). They are only available if the support frame has been selected.
Skid Frame - The skid frame is fixed at the bottom of the legs and therefore is only available if legs have been selected. The skid allows the crusher to be dragged horizontally to move the VSI around a site when needed.
Service Tools
Tool Kit - A basic tool kit for maintenance and servicing of the VSI.
Rotor Service Arm - The rotor service arm is bolted to the side of the crusher and allows lifting of the rotor for maintenance operations. It is necessary to have some other overhead lifting device to remove the top of the crusher, or select the roof lifter option.
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Chain Block - A simple manually-operated chain hoist used in conjunction with the service boom or rotor service arm.
Rotor Balancer - A necessary tool to ensure rotors are properly balanced after repair work.
Pulley Lifting Tool - A convenient tool for the safe removal and fitting of pulleys. Recommended where pulley changes are frequent (eg. for speed changes).
Maintenance Ladder - A ladder that hooks onto the crusher side door, for personnel access to the roof and hopper.
Safety Decals - Choose the standard appropriate to the customer's region.
Speed & Power
Motor - WEG crusher duty motors are specifically designed to meet demanding requirements of the rock crushing industry. These motors are designed for vertical mounting and have exceptional high starting and breakdown torque. Data sheets are available to check the electrical compatibility for your customer.
Drive Kit - Drive kit includes all needed pulleys, taper locks, and vee belts. Several different speeds may be selected to enable speed changes.
Documentation
Owner's Manuals - English language component manuals will be substituted where the selected language is not available.
Rotor
Turnable Feed Eye Ring - The turnable feed eye ring gives the option for multiple wear lives. The ring can be turned to 3 positions.
Flat Distributor - The flat distributor provides the most clearance through the rotor to allow maximum throughput, but the reduced thickness reduces the wear life. It is used for low abrasive material.
Cone Distributor - The cone distributor has a thicker profile than the flat and will last longer. It is the best compromise between throughput and wear life for standard rotors.
Tips -
Tip Shape:
"Hanger" tips promote good buildup inside the rotor, but less protection to the outside of the rotor. Use with very dry feed or when moisture in the feed tends to wash the build-up out.
"Extended Hanger" tips promote less build-up in the rotor, but offer better protection to the outside of the rotor. Use where build-up is naturally good.
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"EXL Extended Hanger" tips have larger tungsten pieces for longer life. These tips promote less build-up in the rotor, but offer better protection to the outside of the rotor. Use where build-up is naturally good.
-
Tungsten Grade:
"Hard" has medium abrasion resistance and high impact resistance.
"Extra Hard" has high abrasion resistance and medium impact resistance.
"XX Hard" has very high abrasion resistance for the longest possible tip life, but the impact resistance is quite low. Use where feed sizes are smaller and there is no risk of oversize material or tramp metal.
-
Configuration:
"Split" tips allow the position to be swapped for extended wear life, or for replacement of only the worn portion.
"1-Piece" tips provide the best protection against wear from fine material.
Standard Split T/CWP - Standard T/CWPs provide a single wear life, but depending on wear characteristics can be swapped from tip position to cavity wear plate position for additional service life. Split T/CWPs allow for replacement of only the worn portion.
Standard 1P T/CWP - Standard T/CWPs provide a single wear life, but depending on wear characteristics can be swapped from tip position to cavity wear plate position for additional service life. 1-piece T/CWPs provide the best protection against wear from fine material.
Reversible Split T/CWP - Reversible T/CWPs provide a second wear life by turning 180°, and are also interchangeable from tip position to cavity wear plate position for additional service life depending on wear characteristics. Split T/CWPs allow for replacement of only the worn portion.
Reversible 1P T/CWP - Reversible T/CWPs provide a second wear life by turning 180°, and are also interchangeable from tip position to cavity wear plate position for additional service life depending on wear characteristics. 1-piece T/CWPs provide the best protection against wear from fine material.
Trail Plate - Various trail plate shapes are available to tune the material build-up within the rotor. Generally use wider trail plates for drier material that doesn't naturally build up, and narrower for stickier material. Tungsten edged versions have longer wear life.
Standard Top WP - The standard top wear plate provides minimum protection to the top face of the rotor. It is expected that the periphery of the rotor will wear slowly and require periodic repair.
Lipped Top WP - The lipped wear plate provides protection to the top face and periphery of the rotor body top plate. This becomes the sacrificial wear plate and protects the rotor body from need of frequent repair.
Lipped Bottom WP - The lipped bottom wear plate provides protection to the bottom plate of the rotor, and is useful when material build-up or feed rate is very high.
To access individual parts pages and rotor parts information for a Barmac B6150SE VSI please visit www.barmactechinfo.com © Metso 2011
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59/66 Sales Manual BARMAC B-SERIES VSI
Barmac B5100SE VSI
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Dimension Drawings & Specifications – B5100SE
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Configurations The Barmac B5100SE VSI is available in Single Drive arrangement with Roof Lifter as standard.
Main Module The crusher consists of:
Hydracascade feed hopper with hydraulic gate adjustment system.
Integrated cascade assembly for control of product gradation.
Crusher base with grease lubricated shaft line assembly, suitable for feed material temperature from -20 to maximum of 65°C (-4 to 149°F).
High efficiency crushing chamber with reversible, side-view rotor access door.
Antivibration mounts which dissipate the crusher vibration during operation.
Liners to protect the base from wear. Manufactured from mild steel plate, these liners provide adequate protection in most applications.
Integrated transmission drive tunnel with belt guards.
Adjustable heavy duty motor mount structure with screw adjusters.
Safety interlock system designed to prevent the crushing from being opened whilst the machine is in operation, and to prevent re-start when the crusher is open for maintenance or inspection.
One rotor with full set of wear parts.
Rotor One standard rotor options is available:
500 (20”) Deep
Specific configuration information for Barmac B5100SE VSI can be found in the B5100SE Installation Book and Product Specification form. Please visit www.barmactechinfo.com or the Technical Data database, which is accessible from your Home Page on Lotus Notes.
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Parts B5100SE Crusher
Extra Chamber Gussets - Extra gussets are useful to increase chamber build-up in very fine or dry applications, or when feed rate drops below normal for extended periods of time. The objective is to protect the structure of the crushing chamber.
HT SLA Upgrade - The high temperature shaft line assembly can withstand feed material from 60 to maximum of 100°C (140 to 212°F). This replaces the standard shaft line assembly described in the main module.
XL Base Liner Upgrade - Manufactured from hard wearing hard-faced plate, the extra life base liners provide increased wear resistance. Upgraded liners are recommended for highly abrasive materials and high tonnage operations. This replaces the standard base liners described in the main module.
Base Water Spray - The water spray kit has been developed to minimize build-up of material in the base of the crusher when processing sticky product. The water spray kit is generally used in conjunction with the non-stick base liners option.
Non-Stick Liners - The non-stick base liners have been developed for use when processing sticky material to avoid excessive build-up in the base where the build-up could cause wear on the underside of the rotor. In extreme circumstances, the non-stick base liners can be used in conjunction with the base water spray kit.
Control System
VOCS - A basic protection system to monitor crusher vibration and temperature of shaft line assembly and motors.
VOCS 100m Cable - This is the cable between the VOCS controller (in control room) and the data sender on the crusher. The 100m (330') cable is supplied separately and can be substituted for the 50m (165') cable supplied.
VOCS Strobe - This is a bright flashing light that can be linked to the VOCS alarm system to warn operators that there is a problem with the VSI.
VOCS Siren - This is a loud siren/alarm that can be linked to the VOCS alarm system to warn operators that there is a problem with the VSI.
Mechanical Vibration Switch - This mechanical vibration switch provides the most basic level of protection when wired to the crusher electrical circuit.
Automatic Lubrication - The automatic lubrication system is designed to supply the shaft line assembly with measured amounts of grease during the machines operation. The system consists of a pump, timer, and power source.
Hydraulic Handpump - A hand pump is the minimum choice for manual control of the cascade / crusher feed, and for operation of the roof lifter if fitted.
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Electric/Hydraulic Pump - This system is a combination of small electric motor and hydraulic pump. It is used to adjust the cascade / crusher feed at the push of a button (or integrate to a plant control system), and to operate the roof lifter if fitted.
IC3000 - An advanced control and protection system to maximise crusher productivity with integrated safety and lubrication systems. The crusher can be controlled from the integrated display interface or via connection with a wider plant automation system.
Hose Extension - Standard hoses are 10m (33'). The extension provides and additional 5m, totaling 15m (49').
Option 1 - Profibus - Choose the needed cable length between E1 cabinet (beside crusher) and E2 cabinet (in control room).
Option 2 - MCC - Choose the needed cable length between E2 cabinet (in control room) and motor starter panel.
Option 3 - Display - A display extension is needed when the E2 cabinet is not visible / accessible in the crusher control room. Remote screen set is composed by a screen support, a cover for the control box and needed cables.
Ethernet Module - Ethernet 343-1 Lean module to enable ethernet communication to customer's SCADA system.
DP/DP Coupler - Profibus DP/DP coupler module to enable ethernet communication to customer's SCADA system.
Crusher Support
Support Frame - The support frame suspends the crusher on its antivibration mounts, and integrates the support legs.
B5100SE Support Legs - B5100SE Support legs attach to the support frame and lift the VSI off the ground so that conveyors (or something else) can be set up to clear the material discharge from the machine. Legs provide 1.0m (40") clearance below the crusher. They are only available if the support frame has been selected.
Skid Frame - The skid frame is fixed at the bottom of the legs and therefore is only available if legs have been selected. The skid allows the crusher to be dragged horizontally to move the VSI around a site when needed.
Service Tools
Tool Kit - A basic tool kit for maintenance and servicing of the VSI.
Service Boom - The service boom is bolted to the side of the crusher and allows lifting of the rotor and shaft line assembly (separately) for maintenance operations. It is necessary to have some other overhead lifting device to remove the top of the crusher, or select the roof lifter option.
Chain Block - A simple manually-operated chain hoist used in conjunction with the service boom or rotor service arm.
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Rotor Balancer - A necessary tool to ensure rotors are properly balanced after repair work.
Pulley Lifting Tool - A convenient tool for the safe removal and fitting of pulleys. Recommended where pulley changes are frequent (eg. for speed changes).
Safety Decals - Choose the standard appropriate to the customer's region.
Speed & Power
Motor - WEG crusher duty motors are specifically designed to meet demanding requirements of the rock crushing industry. These motors are designed for vertical mounting and have exceptional high starting and breakdown torque. Data sheets are available to check the electrical compatibility for your customer.
Drive Kit - Drive kit includes all needed pulleys, taper locks, and vee belts. Several different speeds may be selected to enable speed changes.
Documentation
Owner's Manuals - English language component manuals will be substituted where the selected language is not available.
Rotor
Single Position Feed Eye Ring - The single position feed eye ring is only available for the 500 rotor.
Cone Distributor - The cone distributor has a thicker profile than the flat and will last longer. It is the best compromise between throughput and wear life for standard rotors.
Tips -
Tip Shape:
"Hanger" tips promote good buildup inside the rotor, but less protection to the outside of the rotor. Use with very dry feed or when moisture in the feed tends to wash the build-up out.
"Tile" tips provide the best rotor protection, but with reduced rotor build-up. Use where build-up is naturally good.
-
Tungsten Grade:
"Hard" has medium abrasion resistance and high impact resistance.
"Extra Hard" has high abrasion resistance and medium impact resistance.
"XX Hard" has very high abrasion resistance for the longest possible tip life, but the impact resistance is quite low. Use where feed sizes are smaller and there is no risk of oversize material or tramp metal.
Fabricated T/CWP - Fabricated T/CWPs provide the maximum impact resistance, but with a reduced wear life.
500 Trail Plate - Tungsten edged versions have longer wear life.
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Standard Top WP - The standard top wear plate provides minimum protection to the top face of the rotor. It is expected that the periphery of the rotor will wear slowly and require periodic repair.
To access individual parts pages and rotor parts information for a Barmac B5100SE VSI please visit www.barmactechinfo.com
© Metso 2011
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© Metso 2011
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