HP & MP - Crusher Comparisons

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METSO MINERALS ROCK CRUSHERS Cone Crusher Comparisons Presentation 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.

Metso Minerals Industries, Inc. Aftermarket Training Department 20965 Crossroads Circle Waukesha, Wisconsin 53186 USA

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Crusher Pivot Points

+

HP100, HP300 (current), HP400 è Higher pivot point machines

HP200, HP300 (original), HP500, HP700, HP800, MP800, MP1000

è Results in increased upper head movement

è Normal pivot point machines

è Larger volumetric area between the liners

è Results in less upper head movement è Smaller volumetric area between the liners

2 © Metso Corporation

May 2005

Crusher Comparison's

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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

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)

3 © Metso Corporation

May 2005

Crusher Comparison's

136,500

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Countershaft Rotation

HP100, HP200, HP300, HP400, HP500, HP700, HP800

MP800, MP1000

è Clockwise rotation of the countershaft.

è Counter-clockwise rotation of the countershaft.

è Crusher setting decreases (bowl turns down) with insufficient bowl clamping pressure.

è Crusher setting increases (bowl turns out) with insufficient bowl clamping pressure.

è Head rotates clockwise when crushing.

è Head rotates counter-clockwise when crushing.

è Left hand thread locking bolt.

è Right hand thread locking nut.

4 © Metso Corporation

May 2005

Crusher Comparison's

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Jack Shaft Arrangement Crusher

Drive Belts

è è è

The jack shaft arrangement is being used on most large cone crushers. The motor sheave is fitted between two jack shaft bearings. The drive motor is connected to the jack shaft with a coupling.

Drive Motor

Coupling

Motor Sheave

Crusher Sheave

Jack Shaft Bearing

5 © Metso Corporation

May 2005

Crusher Comparison's

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Drive Belt Tensioning Device è è

è

ACS System

6 © Metso Corporation

May 2005

Crusher Comparison's

Crusher drive belt tensioning devices are being used on most large cone crushers. 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. The unit being used is called an ACS system named after the company that makes it (Appleton Control Systems).

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Crusher Mounting Arrangement è

Fully Grouted

è

è

è è

Grouted Pads 7 © Metso Corporation

May 2005

Crusher Comparison's

At some crusher installations (predominately large crushers), you will find that the main frame is grouted into position. 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. In the recent past, you will find that crusher mounting pads (sole plates) are shimmed and grouted into position. You will seldom see smaller cone crushers grouted into position. Metso Deep Pour Grout (up to 8”) or HP Grout (up to 1/2”).

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Main Frame Liner Arrangement

HP100, HP200, HP300, HP400, HP500

HP700, HP800, MP800, MP1000

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.

8 © Metso Corporation

May 2005

Crusher Comparison's

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Main Frame “U”Seals Two Plastic Strips

HP100

One Full “U”Seal

HP200, HP300, HP400, HP500, HP700, HP800, MP800, MP1000

Note: The “U” seals are glued into position with Loctite Depend 330.

9 © Metso Corporation

May 2005

Crusher Comparison's

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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

Note: Threads coated with Loctite 277, pressure is checked daily (8 hours).

10 © Metso Corporation

May 2005

Crusher Comparison's

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Tramp Release Arrangement Adjustment Ring

Adjustment Ring

Cup & Cone

Main Frame

Accumulator

MP1000 Note: The accumulators face towards the main frame gussets. 11 © Metso Corporation

May 2005

Crusher Comparison's

Clearing Jack

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Tramp Release Arrangement Adjustment Ring

Adjustment Ring

Cup & Cone

Main Frame

Accumulator

MP800 Note: The accumulators face outwards. 12 © Metso Corporation

May 2005

Crusher Comparison's

Clearing Jack

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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)

13 © Metso Corporation

May 2005

Crusher Comparison's

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Bowl Clamping Arrangement Clamping Ring Dust Shell

Clamping Ring

Dust Shell

Support Tube

Clamping Cylinder

Adjustment Ring HP200, HP300, HP400, HP500, HP700, HP800 Pump on @ 2400PSI Pump off @ 2800PSI

14 © Metso Corporation

May 2005

Crusher Comparison's

Adjustment Ring HP100 Pump on @ 235PSI Pump off @ 365PSI

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Bowl Clamping Arrangement Clamping Ring

Clamping Ring

Dust Shell

Dust Shell

Clamping Cylinder

Clamping Cylinder

Adjustment Ring

MP1000

MP800 Pump on @ 2400PSI Pump off @ 2800PSI

15 © Metso Corporation

May 2005

Adjustment Ring

Crusher Comparison's

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Main Frame Pin Arrangement Adjustment Ring

Main Frame Pin

Main Frame

Main Frame HP200, HP300

16 © Metso Corporation

May 2005

Adjustment Ring

Crusher Comparison's

Main Frame Pin

Pin Bushing

HP100, HP400, HP500, HP700, HP800

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Main Frame Pin Arrangement Adjustment Ring

Pin Bushing

Adjustment Ring

Pin Bushing

Main Frame Pin

Main Frame MP800

17 © Metso Corporation

Main Frame Pin

Main Frame

May 2005

Crusher Comparison's

MP1000

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Hydraulic Motor Adjusting System HP100, HP200, HP300, HP400, HP500, HP700 - One hydraulic motor

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

18 © Metso Corporation

May 2005

Crusher Comparison's

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Adjust Under Load Feature è

è

è

è

19 © Metso Corporation

May 2005

Crusher Comparison's

The HP200, HP300, HP400, HP500, HP700, HP800, MP800 and MP1000 are all designed and sold with “Adjust Under Load”capabilities. The HP100 is the only crusher that we do not adjust under load, this is due to the bowl clamping arrangement. 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). Power units are supplied with the adjust under load relief valve set at zero.

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Power Unit Push Button Station “On / Off” Push Button

“Power On” Lamp

“Low Clamping Pressure”Lamp

“Run / Adjust” Selector Switch

“Close Setting” Push Button

“Open Setting” Push Button

“Low Release Pressure”Lamp

“Pressurize” Push Button

“Clear” Push Button

HP100, HP200, HP300, HP400, HP500, HP700

20 © Metso Corporation

May 2005

Crusher Comparison's

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Power Unit Push Button Station Power On / Off Push Button

Low Clamping Pressure Lamp

Power On Lamp

Low Release Pressure Lamp

Low Oil Level

Dirty Filter

High Oil Temp Bowl Removal / Run Open / Close Pressurize Reset Clear

Power On / Off

Local / Remote HP800 Remote Lamp

21 © Metso Corporation

May 2005

Crusher Comparison's

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Power Unit Push Button Station Power On Lamp

Low Release Pressure Lamp

Low Clamping Pressure Lamp

Pressure Reset Push Button Low Oil Level

Power On / Off Push Button

High Oil Temp Clear / Release Selector Switch

Clamping Cylinder Pressurize

Manual / Run Selector Switch Bowl Removal / Run Selector Switch Open Setting Push Button MP800, MP1000 Bowl Clamping Pressure Gauge

Closed Setting Push Button 22 © Metso Corporation

May 2005

Crusher Comparison's

Tramp Release Pressure Gauge

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Bowl Liner Retention Arrangement Liner Wedge Bolt Assembly

Bowl

Bowl Hopper

Bowl

Backing Material

Liner Bolt Backing Material

Bowl Liner

HP200, HP300, HP400, HP500, HP700 (current), HP800

23 © Metso Corporation

May 2005

Crusher Comparison's

Bowl Liner

HP700 (original)

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Bowl Liner Retention Arrangement Wedge Retainer

Wedge Bolt

Shims

è è

Wedge

Shims

Bowl Ring (MP1000 only)

Special Nut & Retainer

Bowl Liner

Bowl

MP800, MP1000

24 © Metso Corporation

May 2005

Crusher Comparison's

The MP800 wedges fit into a slot. Shims are added or removed from under the wedge to obtain proper midpoint contact on the incline surface of the wedges..

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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

XT520 = 14% Manganese w/Molybdenum XT610 = 14% Manganese (formerly 510) XT710 = 18% Manganese XT720 = 22% Manganese 25 © Metso Corporation

May 2005

Crusher Comparison's

Bowl Liner

Mantle

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Thread Pitch HP100 è è è

1-1/2”Thread Pitch / 45° Left Hand Thread Template part number 4660 0101

HP200 è è è

1-1/2”Thread Pitch / 45° Right Hand Thread Template part number 4660 0101

HP300, HP400, HP500, HP700, HP800 è è è

2”Tread Pitch / 45° Right Hand Thread Template part number 7962 4000

MP800 è è è

4”Tread Pitch / 45° - Double Lead (looks like 2”thread) Right Hand Thread Template part number 7962 4000

MP1000 è è è 26 © Metso Corporation

May 2005

Crusher Comparison's

75mm Tread Pitch Right Hand Thread Template part number 7962 4001

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Bowl Turning Pins Cable & Clevis

Cable & Clevis

Turning Pin

Bowl

HP700, HP800, MP800, MP1000

27 © Metso Corporation

May 2005

Crusher Comparison's

Turning Pin

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Bowl Installation Procedure è

è

è

è

HP700, 800, MP800, 1000

28 © Metso Corporation

May 2005

Crusher Comparison's

Due to the weight of the larger cone crusher bowl assemblies, the installation procedure will be slightly different then with the smaller cones. 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. After the dry film lube has cured, a special High Content Molybdenum Based Anti-seize (25%) is applied to the threads. This kit is part number 10 04810822.

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Backing Material Requirement Standard Epoxy Backing Material Metso Minerals “Standard Epoxy Backing”is a general purpose backing material used in cone crushers under normal 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 in tougher 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. Note 4) The HP100 crusher does not use backing material. 29 © Metso Corporation

May 2005

Crusher Comparison's

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Head Bushing Arrangement Upper & Lower Head Bushing (one-piece)

Head Ball (bronze)

HP100

30 © Metso Corporation

May 2005

Crusher Comparison's

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Head Bushing Arrangement

HP200, HP300, HP500, HP700 (original) - Tight fit, no flange and set screws

31 © Metso Corporation

May 2005

Crusher Comparison's

HP100, HP400, HP700 (current), HP800, MP800, MP1000 - Tight fit, flange and cap screws

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Anti-spin Mechanism Universal Joint

Spline Shaft è

è è è

Socket

Anti-spin

32 © Metso Corporation

May 2005

Crusher Comparison's

The newer MP800 and MP1000 Cone Crushers are using an anti-spin mechanism or bachstop clutch arrangement. The anti-spin mechanism reduces shock loads when initiating the feed. The anti-spin mechanism reduces dynamic loads during operation. See service bulletin #425266 or service alert #167 for lube spec.

Slip Clutch Device

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Head Turning Plate Lifting Cables

Eye Bolt

Blocking

Head Turning Plate

Two Eye Bolts 180° Apart MP1000

33 © Metso Corporation

May 2005

Crusher Comparison's

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Socket Arrangement

HP100

HP200, HP300, HP400, HP500, HP700, HP800, MP800, MP1000

- One piece socket / socket liner

- Two piece socket / socket liner

- Made of steel

- Socket made of steel. - Socket liner made of bronze.

34 © Metso Corporation

May 2005

Crusher Comparison's

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Counterweight Guard Arrangement Counterweight Guard History CRUSHER MODEL

ORIGINALLY WELD ON

HP100

CURRENTLY

BOLT ON X

BOLT ON X

HP200

X

X

HP300

X

X

HP400

X

X

HP500

X

X

HP700

X

X

HP800

X

X

MP800

X

X

MP1000

X

Note: All counterweight guards are made of a wear resistant steel.

35 © Metso Corporation

WELD ON

May 2005

Crusher Comparison's

X

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Counterweight Guard Arrangement

Bolted On CWT Guard

36 © Metso Corporation

May 2005

Crusher Comparison's

Welded On CWT Guard

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Counterweight “T”& “U”Seals Counterweight Guard

è è è

The HP100, HP200, HP300, HP400, HP500 use integral counterweight “T”& “U”seals. The HP700, HP800, MP800 & MP100 use plastic “T”& “U”seals. 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).

“U”Seal

Counterweight

“T”Seal 37 © Metso Corporation

May 2005

Crusher Comparison's

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Stationary Counterweight Shields è è

Stationary Counterweight Guard

38 © Metso Corporation

May 2005

Crusher Comparison's

Stationary counterweight guards are a popular option with the larger crushers. Stationary counterweight guards prevents crushed material from contacting the counterweight guard.

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Crusher Gears & Pinions Eccentric è

è

è

The HP100, HP200, HP300, HP400, HP500, HP700, HP800 (original), MP800 (original) and MP1000 (original) all use a straight tooth bevel gear and pinion. The newer HP800, MP800 and MP1000 all use a spiral bevel gear and pinion for a quieter operation. Backlash for the new gear and pinion checked at the crusher sheave.

Countershaft

Gear

Thrust Bearings

39 © Metso Corporation

May 2005

Crusher Comparison's

Pinion

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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)

40 © Metso Corporation

May 2005

Crusher Comparison's

è

è

è

The function of the lube pump oil flow is to keep the crusher bronze bushings cool and lubricated. The effect of poor oil flow is lower oil pressure, higher oil temperature, wider temperature differential and a continuous running oil cooler. Larger crushers have higher flow rates, smaller crushers have lower flow rates.

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Lube Oil Pump Arrangement

HP100, HP200, HP300, HP400, HP500, HP700

HP800, MP800, MP1000

Internal Gear Pump - Viking

External Gear Pump - Permco

41 © Metso Corporation

May 2005

Crusher Comparison's

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Lube Oil Pump Arrangement

HP100, HP200, HP300, HP400, HP500, HP700 Internal Gear Pump (Viking)

ADVANTAGES •Two moving parts (rotor & Idler) •Two bushings operate in the oil •Flexible design 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 42 © Metso Corporation

May 2005

Crusher Comparison's

HP800, MP800, MP1000 External Gear Pump (Permco)

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

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Main Relief Valve Setting 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) *

43 © Metso Corporation

May 2005

Crusher Comparison's

è

è 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. It should be mounted vertically and positioned right next to the countershaft box. * Indicates mounted at the pump.

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Main Relief Valve Position

HP100, HP200, HP300, HP400, HP500 Mounted at the Countershaft Box

44 © Metso Corporation

May 2005

Crusher Comparison's

HP700, HP800, MP800, MP1000 Mounted at the Pump

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Lube Oil Filter Arrangement

HP100, HP200, HP300 Farley Arlon

Nugent

45 © Metso Corporation

May 2005

HP400, HP500

Crusher Comparison's

HP700, HP800, MP800, MP1000

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Lube Oil Filter Element

HP100, HP200, HP300, HP400, HP500, HP700 50 Micron - Bag

46 © Metso Corporation

May 2005

Crusher Comparison's

HP800, MP800, MP1000 25 Micron - Pleated

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Lube Oil Tank Breather

All (original)

HP100, HP200, HP300

HP700, HP800, MP800, MP1000

Airmaze - Oil Bath

Donaldson - Dry

Stauff - Dry

47 © Metso Corporation

May 2005

Crusher Comparison's

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Countershaft Box Blower Unit è

è

è

è

Air Filter

Blower Unit

48 © Metso Corporation

May 2005

Crusher Comparison's

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). The blower unit forces air into the crusher which allows the crusher, drain line and oil tank to maintain atmospheric conditions. This blower unit air filter breather should be checked every week and replaced as required. Should turn on with under crusher belt.

Air Line to Crusher

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Lube Oil Cooler (radiator type)

HP400, HP500, HP700, HP800

HP100, HP200, HP300

- Young - OCS1000 (and larger)

- Young - OCS600 (and smaller)

- Oil in the bottom two ports

- Oil in the one bottom port

- Oil out the one top port

- Oil out the two top ports

Note: Fan on @ 125°F (52°C), fan off @ 115°F (46°C), 50PSI (3.4 Bar) bypass valve. 49 © Metso Corporation

May 2005

Crusher Comparison's

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Lube Oil Cooler è è è è è

MP800, MP1000

50 © Metso Corporation

May 2005

Crusher Comparison's

Fan #1 turns on at 120°F (49°C) and off at 115°F (46°C) Fan #2 turns on at 125°F (52°C) and off at 110°F (43°C). 50PSI (3.4 Bar) bypass valve. Oil in the bottom two ports. Oil out the top one port.

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Lube Oil Tank Temperature è

è è è

The temperature of the oil in the oil tank should be proper prior to starting the oil pump. Oil immersion heaters fitted into the tank should be energized 24/7. Proper oil tank temperature prevents over-loading the pump motor. Once the pump is running, drain line oil temperature must be higher then 60ºF (16ºC).

51 © Metso Corporation

May 2005

Crusher Comparison's

HP100, HP200, HP300, HP400, HP500 - Should be 80ºF (27ºC) or higher

HP700, HP800, MP800, MP1000 - Should be 90ºF (32ºC) or higher

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Lube Oil Temperature HP100, 200, 300, 400, 500

Preferred Temperature 100F to 130F

- Maximum of 9ºF (5ºC) with radiator type oil cooler fan off - Maximum of 15ºF (8ºC) with radiator type oil cooler fan on

HP700, 800, MP800, 1000

Preferred Temperature 100F to 130F

- Maximum of 12ºF (7ºC) with radiator type oil cooler fan off - Maximum of 20ºF (11ºC) with radiator type oil cooler fan on

Note: If the maximum temperature differential is exceeded, most likely the bushings within the crusher have closed in due to abnormal operating conditions.

52 © Metso Corporation

May 2005

Crusher Comparison's

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Temperature Sensors è è è

Remote temperature devices are used to convert oil temperature to a digital readout. At times the digital readout is simply displayed in the operators room. 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)

53 © Metso Corporation

May 2005

Crusher Comparison's

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Lube Oil Pressure HP100, HP200, HP300, HP400, HP500, HP700, HP800 - Normal Oil Pressure: 20PSI to 40PSI - ISO 150 (EP4)

MP800, MP1000 - Normal Oil Pressure: 20PSI to 70PSI - ISO 150 (EP4)

54 © Metso Corporation

May 2005

Crusher Comparison's

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Lube Oil Pressure Switch Setting

è

55 © Metso Corporation

May 2005

Crusher Comparison's

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)

The low oil pressure switch should be mounted near the crusher and at the same elevation as the countershaft box.

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Pressure Sensors è

è è

Pressure Transducer

56 © Metso Corporation

May 2005

Crusher Comparison's

Pressure transducers are used to convert countershaft box oil pressure to a digital readout. At times the digital readout is simply displayed in the operators room. 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.

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TC Automation System è è

è è -

57 © Metso Corporation

May 2005

Crusher Comparison's

The Metso Minerals TC Automation package is being used on may large cone crusher. The TC500 is used on the HP500 and smaller machines, the TC1000 is used on the HP700 and larger machines. Can run in power, setting or manual modes. 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

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SKF Accelerometers è

è

è

è Accelerometer

58 © Metso Corporation

May 2005

Crusher Comparison's

Accelerometers are being used predominately on large crushers to electronically monitor adjustment ring movement. At times, the signal from the accelerometer is used to simply turn on a warning lamp in the operators room indicating ring movement. 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. See TD7-049 for set-up procedures.

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Power Transducers è è è

Power transducers are used to convert drive motor power draw to a digital readout. At times the digital readout is simply displayed in the operators room. 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

59 © Metso Corporation

May 2005

Crusher Comparison's

TTM-31017-A

Tooth Counters è è

è

Tooth Counters

60 © Metso Corporation

May 2005

Crusher Comparison's

Two tooth counters are used in conjunction with an automation program. As the pinion gear moves, the proximity switches are used to determine direction of rotation and to count teeth. The tooth count is translated into crusher setting.

TTM-31017-A

Eccentric Bushing Temperature è

è

The Crusher eccentric bushing temperature is measured using an RTD located directly below the bushing which provides a 4-20 mA analog signal. 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

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Crusher Comparison's

TTM-31017-A

Socket Liner Temperature è

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. 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

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Crusher Comparison's

TTM-31017-A

Countershaft Bushing Temperature è

è

è

Temperature is Measured Here 63 © Metso Corporation

May 2005

Crusher Comparison's

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. 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. 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.

TTM-31017-A

Countershaft Speed Sensor è è

è

è

Countershaft speed sensors are used with many large cone crushers. At times, the signal from the sensor is used to simply turn on a warning lamp in the operators room indicating a slowing crusher. 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. Speed sensors prevent downtime associated with stall outs and extends drive belt life.

Speed Sensor

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Crusher Comparison's

TTM-31017-A

Crusher Coast Down Time è

è 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. Check the crusher coast down time at the end of each shift. The operator should compare crusher coast down from one day to another looking for changes from the normal coast down time.

HP100, HP200, HP300, HP400, HP500 - Should be over 30 seconds

HP700, HP800 - Should be between 60 to 90 seconds

MP800, MP1000 - Should be between 60 to 120 seconds

Note: A decrease in coast down time may indicate that the bushings within the crusher have closed in due to abnormal operating conditions.

65 © Metso Corporation

May 2005

Crusher Comparison's

TTM-31017-A

Read Your Instruction Manual è è

è

66 © Metso Corporation

May 2005

Crusher Comparison's

Do you understand the crusher that you are working on? A crusher instruction manual is readily available for any cone crusher you work on. Whenever in question, read the manual for the crusher you will be working on to learn its operating and maintenance characteristics, pressures, and limitations.

TTM-31017-A

67 © Metso Corporation

May 2005

Crusher Comparison's