HP & MP - Crusher Comparisons

(1)

Cone Crusher Comparisons Presentation

METSO MINERALS ROCK CRUSHERS

Metso Minerals Industries, Inc.

The popular HP Series Cone Crusher & MP Series Cone Crusher are sold in

different a variety of different sizes. There are some differences between the

smaller cone crushers and the larger cone crushers. This presentation will

explain some of those differences.

(2)

Crusher Pivot Points

+

HP200, HP300 (original), HP500, HP700, HP800, MP800, MP1000 HP200, HP300 (original), HP500, HP700, HP800, MP800, MP1000 HP100, HP300 (current), HP400 HP100, HP300 (current), HP400 è Higher pivot point machines

è Results in increased upper head movement è Larger volumetric area between the liners

è Normal pivot point machines

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

(3)

Crusher Technical Information

Crusher Model Head Diameter Ø Connected Horsepower Countershaft Speed Capacity @ 3/4" (STPH) Crusher Weight (LBS) HP100 28" 125 750-1200 85-105 11,900 HP200 37" 200 750-1200 165-210 23,000 HP300 44" 300 700-1200 220-265 33,500 HP400 52" 400 700-1000 280-355 50,600 HP500 60" 500 700-950 355-440 73,000 HP700 70" 600 700-950 136,500 HP800 70" 800 700-950 480-600 141,200 MP800 80" 800 685-800 640-760 266,000 MP1000 90" 1000 700-850 794-992 338,000

è Lower speed = higher capacity but coarser product (standards) è Higher speed = lower capacity and finer product (short heads)

(4)

Countershaft Rotation

MP800, MP1000 MP800, MP1000 HP100, HP200, HP300, HP400, HP500, HP700, HP800 HP100, HP200, HP300, HP400, HP500, HP700, HP800 è Clockwise rotation of the countershaft.

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

è Head rotates clockwise when crushing. è Left hand thread locking bolt.

è Counter-clockwise rotation of the countershaft. è Crusher setting increases (bowl turns out) with

insufficient bowl clamping pressure.

è Head rotates counter-clockwise when crushing. è Right hand thread locking nut.

(5)

Jack Shaft Arrangement

è The jack shaft arrangement is being used on most large cone crushers.

è The motor sheave is fitted between two jack shaft bearings.

è The drive motor is connected to the jack shaft with a coupling.

Motor Sheave Coupling Drive Motor

Jack Shaft Bearing Crusher Sheave

(6)

Drive Belt Tensioning Device

è Crusher drive belt tensioning devices are being used on most large cone crushers. è When using this device, the drive motor

never moves, the belts stay in proper tension as a tensioning drum is pushed against the back of the belts under spring pressure. è The unit being used is called an ACS system

named after the company that makes it (Appleton Control Systems).

(7)

Crusher Mounting Arrangement

è At some crusher installations (predominately large crushers), you will find that the main frame is grouted into position.

è In past years, you would find that the crusher was shimmed up under each corner to

compensate for foundation irregularities, then the entire crusher base flange was grouted into position.

è In the recent past, you will find that crusher mounting pads (sole plates) are shimmed and grouted into position.

è You will seldom see smaller cone crushers grouted into position.

è Metso Deep Pour Grout (up to 8”) or HP Grout (up to 1/2”).

Fully Grouted

(8)

Main Frame Liner Arrangement

HP700, HP800, MP800, MP1000

HP100, HP200, HP300, HP400, HP500

Note: Original main frame liners are made of mild steel, optional wear resistant steel liners and rubber coated liners are available, see your RPTD’s for details.

(9)

Main Frame “U” Seals

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

HP100

Two Plastic Strips One Full “U” Seal

(10)

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

(11)

Tramp Release Arrangement

MP1000

Adjustment Ring

Main Frame

Accumulator Clearing Jack

Adjustment Ring

(12)

Tramp Release Arrangement

Adjustment Ring

Main Frame

Accumulator Clearing Jack

Adjustment Ring

MP800

(13)

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)

(14)

Bowl Clamping Arrangement

Dust Shell Adjustment Ring Clamping Ring Clamping Cylinder Dust Shell Adjustment Ring Clamping Ring Support Tube HP100 HP100 HP200, HP300, HP400, HP500, HP700, HP800 HP200, HP300, HP400, HP500, HP700, HP800

(15)

Bowl Clamping Arrangement

MP1000

Pump on @ 2400PSI Pump off @ 2800PSI

Dust Shell Dust Shell

Adjustment Ring Clamping

Cylinder

Clamping Ring Clamping Ring

Clamping Cylinder Adjustment Ring MP800 MP800

(16)

Main Frame Pin

Main Frame Pin Arrangement

Main Frame Pin

Main Frame Adjustment Ring Pin Bushing Adjustment Ring Main Frame HP100, HP400, HP500, HP700, HP800 HP100, HP400, HP500, HP700, HP800 HP200, HP300 HP200, HP300

(17)

Main Frame Pin Arrangement

MP800

MP800 MP1000MP1000

Pin Bushing

Main Frame Pin Adjustment Ring

Main Frame Pin Bushing

Main Frame Pin Adjustment Ring

(18)

Hydraulic Motor Adjusting System

- One hydraulic motor

HP100, HP200, HP300, HP400, HP500, HP700

HP800, MP800

- Two hydraulic motors - dual speed - Slow speed = setting adjustment - High speed = bowl removal

MP1000

- Four hydraulic motors - dual speed - Slow speed = setting adjustment - High speed = bowl removal

(19)

Adjust Under Load Feature

è The HP200, HP300, HP400, HP500,

HP700, HP800, MP800 and MP1000 are all designed and sold with “Adjust Under Load” capabilities.

è The HP100 is the only crusher that we do not adjust under load, this is due to the bowl clamping arrangement.

è The two most important items that come into play if the customer is using the adjusting under load feature is; 1) using the proper grease on the threads and 2) making sure that the adjust under load relief valve is set correctly (see service alert #122).

è Power units are supplied with the adjust under load relief valve set at zero.

(20)

Power Unit Push Button Station

“On / Off” Push Button “Run / Adjust” Selector Switch “Open Setting” Push Button “Close Setting” Push Button “Pressurize” Push Button “Power On” Lamp “Low Clamping Pressure” Lamp “Clear” Push Button “Low Release Pressure” Lamp HP100, HP200, HP300, HP400, HP500, HP700 HP100, HP200, HP300, HP400, HP500, HP700

(21)

Power Unit Push Button Station

HP800

Power On Lamp Power On / Off

Push Button

Low Release Pressure Lamp

Low Clamping Pressure Lamp

High Oil Temp Low Oil Level

Dirty Filter

Open / Close

Bowl Removal / Run

Clear

Local / Remote

Remote Lamp

Pressurize Reset

(22)

Power Unit Push Button Station

Power On Lamp

Power On / Off Push Button

Manual / Run Selector Switch

Bowl Removal / Run Selector Switch Low Release Pressure

Lamp

Low Clamping Pressure Lamp

High Oil Temp

Open Setting Push Button Closed Setting Pressure Reset Push Button Tramp Release Pressure Gauge Bowl Clamping

Low Oil Level

Clear / Release

Selector Switch Clamping Cylinder

Pressurize

MP800, MP1000

(23)

Bowl Liner Retention Arrangement

Bowl Liner Bowl Hopper Bowl Liner Bolt Backing Material Bowl Liner Bowl

Liner Wedge Bolt Assembly

Backing Material

HP700 (original)

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

(24)

MP800, MP1000

Bowl Liner Retention Arrangement

Bowl Wedge Bowl Ring (MP1000 only) Shims Bowl Liner

Wedge Retainer Wedge Bolt

Special Nut & Retainer Shims

è The MP800 wedges fit into a slot.

è Shims are added or removed from under the wedge to obtain proper midpoint contact on the incline surface of the wedges..

(25)

Crusher Liner Metallurgy

Crusher XT520 XT610 XT710 XT720 HP100 X X HP200 X X HP300 X X HP400 X X HP500 X X HP700 X X X HP800 X X X MP800 X X X MP1000 X X X Bowl Liner Mantle XT520 = 14% Manganese w/Molybdenum XT610 = 14% Manganese (formerly 510) XT710 = 18% Manganese XT720 = 22% Manganese

(26)

Thread Pitch

è 1-1/2” Thread Pitch / 45° è Left Hand Thread

è Template part number 4660 0101

HP100

HP300, HP400, HP500, HP700, HP800

è 2” Tread Pitch / 45° è Right Hand Thread

MP800

è 4” Tread Pitch / 45° - Double Lead (looks like 2” thread) è Right Hand Thread

è Template part number 7962 4000 è 1-1/2” Thread Pitch / 45°

è Right Hand Thread

HP200

MP1000

è 75mm Tread Pitch è Right Hand Thread

(27)

Bowl Turning Pins

HP700, HP800, MP800, MP1000

Bowl

Cable & Clevis Cable & Clevis

(28)

Bowl Installation Procedure

è Due to the weight of the larger cone crusher bowl assemblies, the installation procedure will be slightly different then with the smaller cones. è Prior to bowl installation (new machine or

reworked bowl), the bowl, adjustment ring and clamping ring threads are to be coated with a Dry Film Lubricant, two coats are required and a four hour cure time must be given.

è After the dry film lube has cured, a special High Content Molybdenum Based Anti-seize (25%) is applied to the threads.

è This kit is part number 10 04810822.

HP700, 800, MP800, 1000

(29)

Backing Material Requirement

Standard Epoxy Backing Material

Metso Minerals “Standard Epoxy Backing” is a general purpose backing material used in cone crushers undernormal operating conditions. This backing material has a compressive strength of 16,000 PSI and a cure time of 6 hours at 70°F.

HP Epoxy Backing Material

Metso Minerals “HP Epoxy Backing” is an intermediate strength backing material used in cone crushers operating intougher applications. This backing material has a compressive strength of 16,500 PSI and a cure time of 5 hours at 70°F.

WF Epoxy Backing Material

Metso Minerals “WF Epoxy Backing” is an ultra performance backing material used in such crushers as the HP700, HP800, MP800 and MP1000 in highly demanding applications. This backing has a

compressive strength of 18,000 PSI and a cure time of 7 hours at 70°F.

Note 1) Nordbak (former name of our backing material), is no longer a trade name of Metso Minerals, it is now a trade name and product of the Loctite company.

Note 2) Zinc should not be used as a liner backing material with the HP or MP Crushers as the high temperature may dimensionally damage the head bore!

(30)

Head Bushing Arrangement

HP100

Head Ball (bronze) Upper & Lower

Head Bushing (one-piece)

(31)

Head Bushing Arrangement

HP100, HP400, HP700 (current), HP800, MP800, MP1000 HP100, HP400, HP700 (current), HP800, MP800, MP1000 HP200, HP300, HP500, HP700 (original) HP200, HP300, HP500, HP700 (original)

(32)

Anti-spin Mechanism

Universal Joint Spline Shaft

è The newer MP800 and MP1000 Cone Crushers

are using an anti-spin mechanism or bachstop clutch arrangement.

è The anti-spin mechanism reduces shock loads when initiating the feed.

è The anti-spin mechanism reduces dynamic

loads during operation.

è See service bulletin #425266 or service alert #167 for lube spec.

(33)

Head Turning Plate

MP1000

Head Turning Plate Eye Bolt

Two Eye Bolts 180° Apart Lifting Cables

(34)

Socket Arrangement

HP200, HP300, HP400, HP500, HP700, HP800, MP800, MP1000 HP200, HP300, HP400, HP500, HP700, HP800, MP800, MP1000 HP100 HP100

- One piece socket / socket liner - Made of steel

- Two piece socket / socket liner - Socket made of steel.

(35)

Counterweight Guard Arrangement

WELD ON BOLT ON WELD ON BOLT ON

HP100 X X HP200 X X HP300 X X HP400 X X HP500 X X HP700 X X HP800 X X MP800 X X MP1000 X X CRUSHER MODEL ORIGINALLY CURRENTLY

Counterweight Guard History

(36)

Counterweight Guard Arrangement

Welded On CWT Guard

Bolted On CWT Guard

(37)

Counterweight “T” & “U” Seals

è The HP100, HP200, HP300, HP400, HP500

use integral counterweight “T” & “U” seals.

è The HP700, HP800, MP800 & MP100 use

plastic “T” & “U” seals.

è Regarding the large crusher “T” & “U” seal, you will find that the upper “T” & “U” seal is a different color then the lower “T” & “U” seal (orange and blue).

Counterweight “U” Seal

“T” Seal Counterweight

(38)

Stationary Counterweight Shields

Stationary Counterweight Guard

è Stationary counterweight guards are a popular option with the larger crushers. è Stationary counterweight guards

prevents crushed material from contacting the counterweight guard.

(39)

Crusher Gears & Pinions

è The HP100, HP200, HP300, HP400,

HP500, HP700, HP800 (original), MP800 (original) and MP1000

(original) all use a straight tooth bevel gear and pinion.

è The newer HP800, MP800 and

MP1000 all use a spiral bevel gear and pinion for a quieter operation.

è Backlash for the new gear and pinion checked at the crusher sheave.

Gear Pinion

Eccentric

Countershaft

(40)

Lube Oil Pump Flow Rates

Crusher Capacity (Liters) HP 100 25-30 (95-114) HP 200 25-30 (95-114) HP 300 30-35 (114-132) HP 400 50-55 (189-208) HP 500 60-65 (227-246) HP 700 125-130 (473-492) HP 800 125-130 (473-492) MP800 200 (757) MP1000 200 (757)

è The function of the lube pump oil flow is to keep the crusher bronze bushings cool and lubricated.

è The effect of poor oil flow is lower oil pressure, higher oil temperature, wider temperature differential and a continuous running oil cooler.

è Larger crushers have higher flow rates, smaller crushers have lower flow rates.

(41)

Lube Oil Pump Arrangement

HP800, MP800, MP1000

HP100, HP200, HP300, HP400, HP500, HP700

(42)

ADVANTAGES

• Two moving parts (rotor & Idler) • Two bushings operate in the oil • Flexible design

Lube Oil Pump Arrangement

HP800, MP800, MP1000

HP100, HP200, HP300, HP400, HP500, HP700

Internal Gear Pump (Viking) External Gear Pump (Permco)

DISADVANTAGES

• Low speed pump (speed reducer required) • Has an overhung bearing load

• Can utilize a leaking pump shaft seal • Can be a loud pump

• Considered a medium pressure pump

ADVANTAGES • High speed pump

• No overhung bearing load • No speed reducer needed • No leaking pump seal • Quiet

DISADVANTAGES

• Four bushings operate in the oil • Considered a medium pressure pump

(43)

Main Relief Valve Setting

è The function of the main relief valve is to limit the amount of oil pressure that enters the crusher and to protect the pump.

è It should be mounted vertically and

positioned right next to the countershaft box. è * Indicates mounted at the pump.

Crusher PSI (Bar) HP100 35 (2.4) HP200 35 (2.4) HP300 35 (2.4) HP400 50 (3.4) HP500 50 (3.4) HP700 150 (10.3) * HP800 150 (10.3) * MP800 200 (13.8) * MP1000 200 (13.8) *

(44)

Main Relief Valve Position

HP700, HP800, MP800, MP1000

HP100, HP200, HP300, HP400, HP500

(45)

Lube Oil Filter Arrangement

HP400, HP500

HP100, HP200, HP300

HP100, HP200, HP300 HP700, HP800, MP800, MP1000HP700, HP800, MP800, MP1000

(46)

Lube Oil Filter Element

HP100, HP200, HP300, HP400, HP500, HP700

HP100, HP200, HP300, HP400, HP500, HP700 HP800, MP800, MP1000HP800, MP800, MP1000

(47)

Lube Oil Tank Breather

HP100, HP200, HP300

All (original)

All (original) HP700, HP800, MP800, MP1000HP700, HP800, MP800, MP1000

(48)

Countershaft Box Blower Unit

è A countershaft box blower unit is used on the some HP500, all HP700, all HP800, all MP800 & all MP1000

crushers due to their slower countershaft speeds (used at countershaft speeds less then 800RPM).

è The blower unit forces air into the crusher which allows the crusher, drain line and oil tank to maintain

atmospheric conditions.

è This blower unit air filter breather should be checked every week and replaced as required.

è Should turn on with under crusher belt.

(49)

Lube Oil Cooler (radiator type)

HP400, HP500, HP700, HP800

HP400, HP500, HP700, HP800 HP100, HP200, HP300HP100, HP200, HP300 - Young - OCS1000 (and larger)

- Oil in the bottom two ports - Oil out the one top port

- Young - OCS600 (and smaller) - Oil in the one bottom port - Oil out the two top ports

(50)

Lube Oil Cooler

MP800, MP1000

è Fan #1 turns on at 120°F (49°C) and off at 115°F (46°C)

è Fan #2 turns on at 125°F (52°C) and off at 110°F (43°C).

è 50PSI (3.4 Bar) bypass valve. è Oil in the bottom two ports. è Oil out the top one port.

(51)

Lube Oil Tank Temperature

è The temperature of the oil in the oil tank should be proper prior to starting the oil pump.

è Oil immersion heaters fitted into the tank should be energized 24/7.

è Proper oil tank temperature prevents over-loading the pump motor.

è Once the pump is running, drain line oil temperature must be higher then 60ºF (16ºC).

- Should be 80ºF (27ºC) or higher

HP100, HP200, HP300, HP400, HP500

HP700, HP800, MP800, MP1000

(52)

Lube Oil Temperature

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

HP100, 200, 300, 400, 500

Preferred Temperature 100F to 130F

HP700, 800, MP800, 1000

Preferred Temperature 100F to 130F

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

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

(53)

Temperature Sensors

è Remote temperature devices are used to convert oil temperature to a digital readout. è At times the digital readout is simply

displayed in the operators room.

è At other times the temperature signal is routed to an automation program, where the program will display warnings, alarms or will automatically take a corrective action step based on abnormal operating temperature.

Remote Temperature Device (RTD)

(54)

Lube Oil Pressure

- Normal Oil Pressure: 20PSI to 40PSI - ISO 150 (EP4)

HP100, HP200, HP300, HP400, HP500,

HP700, HP800

MP800, MP1000

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

(55)

Lube Oil Pressure Switch Setting

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

Crusher PSI (Bar)

HP100 12 (0.8) HP200 12 (0.8) HP300 12 (0.8) HP400 12 (0.8) HP500 12 (0.8) HP700 15 (1.0) HP800 15 (1.0) MP800 15 (1.0) MP1000 15 (1.0)

(56)

Pressure Sensors

è Pressure transducers are used to convert countershaft box oil pressure to a digital readout.

è At times the digital readout is simply displayed in the operators room.

è At other times the pressure signal is routed to an automation program, where the program will display warnings, alarms or will automatically take a corrective action step based on abnormal operating

pressure.

(57)

TC Automation System

è The Metso Minerals TC Automation package

is being used on may large cone crusher. è The TC500 is used on the HP500 and smaller

machines, the TC1000 is used on the HP700 and larger machines.

è Can run in power, setting or manual modes.

è See TD7-275 for mechanical logic.

- uses pressure, temperature & current sensors - uses vibration sensors (accelerometers)

- automatic or operator activated setting control - improved productivity due to maximizing the

cavity level & optimal setting - overload warnings & protection - liner wear detection

- auto calibrate feature

(58)

SKF Accelerometers

è Accelerometers are being used

predominately on large crushers to electronically monitor adjustment ring movement.

è At times, the signal from the

accelerometer is used to simply turn on a warning lamp in the operators room indicating ring movement.

è At other times the vibration signal is routed to an automation program, where the program will display warnings, alarms or will automatically take a corrective action step based on abnormal vibration levels.

è See TD7-049 for set-up procedures. Accelerometer

(59)

Power Transducers

è Power transducers are used to convert drive motor power draw to a digital readout.

è At times the digital readout is simply displayed in the operators room.

è At other times the power signal is routed to an automation program, where the program will display warnings, alarms or will automatically take a corrective action step based on abnormal operating power.

Current Transformer (CT)

(60)

Tooth Counters

è Two tooth counters are used in conjunction with an automation program.

è As the pinion gear moves, the proximity switches are used to determine direction of rotation and to count teeth.

è The tooth count is translated into crusher setting.

(61)

Eccentric Bushing Temperature

è The Crusher eccentric bushing

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

è If the bushing temperature reaches 60°F (33°C) above the crusher drain line oil temperature, activate a “high eccentric bushing oil temperature alarm” and stop the feed.

Temperature is Measured Here

(62)

Socket Liner Temperature

è The Crusher socket liner oil temperature is measured using a thermocouple

located in one of the oil grooves near the center of the socket liner which provides a 4-20 mA analog signal. è If the socket liner oil temperature

reaches 60°F (33°C) above the Crusher drain line oil temperature, activate a “high socket liner oil temperature alarm” and stop the feed.

(63)

Countershaft Bushing Temperature

è The Crusher outer countershaft box bushing temperature is measured using a temperature sensor mounted in the

countershaft box with it’s probe contacting the outer countershaft box bushing.

è If the outer box bushing temperature reaches 130°F (54°C), activate a “high countershaft box bushing temperature warning” and recheck the Crusher drive belt tension.

è It is recommended to evaluate the operating temperature after several months and then reset the warning to 10°F (6°C) above the normal high temperature.

(64)

Countershaft Speed Sensor

è Countershaft speed sensors are used with many large cone crushers.

è At times, the signal from the sensor is used to simply turn on a warning lamp in the operators room indicating a slowing crusher.

è At other times, the signal is routed to an automation program, where the program will display warnings, alarms or will automatically stop the crusher feed based on abnormal operating speed.

è Speed sensors prevent downtime

associated with stall outs and extends drive belt life.

(65)

Crusher Coast Down Time

è Coast down time is the amount of time in seconds that it takes the crusher sheave to come to a stop after the crusher drive motor has been turned off.

è Check the crusher coast down time at the end of each shift.

è The operator should compare crusher coast down from one day to another looking for changes from the normal coast down time.

- Should be over 30 seconds

HP100, HP200, HP300, HP400, HP500

HP700, HP800

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

- Should be between 60 to 90 seconds

MP800, MP1000

(66)

Read Your Instruction Manual

è Do you understand the crusher that you are working on?

è A crusher instruction manual is readily available for any cone crusher you work on.

è Whenever in question, read the manual for the crusher you will be working on to learn its operating and maintenance

(67)