Sie sind auf Seite 1von 76

METSO NW PORTABLE CRUSHING AND

SCREENING PLANT
INSTRUCTION MANUAL
MM0430841-EN

REV 1
METSO NW PORTABLE CRUSHING AND SCREENING PLANT CHAPTER 0
This instruction manual applies to Metso NW portable crushing and screening plant, manufactured by
Metso.

Because of the continuous development of the product, the manufacturer reserves a right to alter the
technical specifications written in this manual, without any advance information. In case of conflicts
between different language versions, the English version of this manual is the original and prevails.

Metso Minerals, Inc., Tampere Works


Lokomonkatu 3, P.O. Box 306
33101 Tampere
Finland
Phone: +358 204 84 142
Fax: +358-204-84 143

email: minerals.info.csr@metso.com
www.metso.com

Copyright © 2017 Metso. Printed in Tampere, Finland.

05/2017 MM0430841-EN NW PLANT INSTRUCTION MANUAL 0-1


METSO NW PORTABLE CRUSHING AND SCREENING PLANT

This Page Left Intentionally Blank.

0-2 NW PLANT INSTRUCTION MANUAL MM0430841-EN 05/2017


TABLE OF CONTENTS

METSO NW PORTABLE CRUSHING AND SCREENING PLANT

1 PREFACE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

2 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1 SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1.1 CONVEYOR SAFETY INSTRUCTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.1.2 WELDING THE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.1.3 RESTRICTED AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.1.4 EMERGENCY STOPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.1.5 WARNING SIGNS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.1.6 NOISE LEVELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

3 TECHNICAL SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1


3.1 PLANT INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 INTENDED USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3.3 COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
3.3.1 FEED HOPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
3.3.2 SURGE HOPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3.4 ELECTRIFICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

4 TRANSPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.1 GENERAL INFORMATION ABOUT THE TRANSPORTATION. . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 PREPARING THE PLANT FOR TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.2.1 TRANSPORTATION WITH THE TRAILER TRUCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.2.2 TRANSPORTATION IN THE CONTAINERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

5 OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1 PREPARING THE PLANT SITE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.2 UNLOADING THE PLANT FROM CONTAINERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
5.3 FEED HOPPER, SURGE HOPPER AND PLANT CONVEYOR SET-UP. . . . . . . . . . . . . . . . . 5-2
5.3.1 BASIC PROCEDURE FOR CONVEYOR INSTALLATION AFTER
CONTAINER TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.3.1.1 Assembly of conveyor frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
5.3.2 CONVEYOR TRANSPORTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
5.3.3 FEED HOPPER ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
5.3.4 SURGE HOPPER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
5.4 PLANT SET-UP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-29
5.5 MEASURES BEFORE STARTUP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
5.5.1 PROCESS SELECTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
5.5.1.1 Primary unit by-pass chute . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-33
5.5.1.2 Secondary unit dividing chute flap gates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34
5.5.2 CONNECTING SEVERAL UNITS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
5.6 MEASURES BEFORE STARTING THE PROCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
5.6.1 RESTRICTED AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
5.7 STARTING THE PROCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
5.7.1 PLANT WITHOUT SURGE HOPPER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
5.7.2 PLANT WITH SURGE HOPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38
5.8 OPERATING THE PLANT DURING THE PROCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
5.8.1 USING THE CONTROL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
5.8.2 LOADING THE UNIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
5.8.3 MONITORING PLANT INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
5.8.4 PARAMETERS AND SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
5.8.5 DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39
5.9 STOPPING THE PROCESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40
5.9.1 EMERGENCY STOP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-40

6 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.1 MAINTENANCE CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 CONVEYORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2.1 FOLDING THE CONVEYOR END . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.2.2 BELT TRACKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.2.2.1 Squaring the pulleys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.2.2.2 Adjusting the idlers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-5
6.2.3 BELT TENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.2.4 BELT SCRAPER ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
6.2.5 BEARING LUBRICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
6.3 PLANT STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9
PREFACE CHAPTER 1
This instruction manual is intended to assist owners and users of Metso products in the proper use of the
equipment.

It includes important references to safe, proper and economical operation of the equipment. Following
these instructions will help to avoid possible danger, reduce repair costs and breakdowns and to increase
the reliability and life of the equipment.

This manual must be complemented by those instructions necessary because of existing national
mandatory rules relating to accident prevention and environmental protection.

A copy of this manual must be kept at the equipment's location and made available to the operators as
required.

In addition to this manual and accident prevention regulations mandatory in the country of use and at the
equipment's place of operation, generally recognized rules for safe and professional operation must be
observed.

This instruction manual must be read and used by each person who works with the equipment, typically:

– operations, including installation, startup, operation, application engineering, materials handling,


site labour, environmental engineering and safety departments.
– maintenance, including inspection and repair.
– transport, materials handling and rigging.

Note that this instruction manual contains information and instructions on alternative and optional
equipment. Normally the machines have only some of them. Before maintaining and servicing, find out
which alternative and optional equipment your machine has.

See separate instruction manuals for more detailed instructions when servicing the main components.

There may be optional equipment which have separate instruction manuals. Those manuals must be read
and used by each person who works with the equipment.

Please refer to possible additional information included in the manuals from our sub-contractors and
suppliers. Such information may be used with the purpose to find out further details about sub-supplied
components in question. Please note that the Metso manuals are the governing documents for all other
purposes.

05/2017 MM0430841-EN NW PLANT INSTRUCTION MANUAL 1-1


PREFACE

This Page Left Intentionally Blank.

1-2 NW PLANT INSTRUCTION MANUAL MM0430841-EN 05/2017


SAFETY CHAPTER 2
2.1 SAFETY INSTRUCTIONS

2.1.1 CONVEYOR SAFETY INSTRUCTIONS

NOTE! Personnel shall not be allowed to operate, maintain or be near the conveyor without
receiving thorough conveyor safety training and reviewing this manual.

The operator must be acquainted with the following:

• Structure and operation of the conveyor


• Points of danger
• Safe working and moving near the conveyor
• Trip wire switch functions and the locations

The safety, operating, and maintenance instructions of the conveyor should always be easily available
near the conveyor.

The instructions on safety etc. must be observed.

Unauthorized persons are not allowed to be near the conveyor.

The conveyor should only be used for it’s purpose and in the conditions jointly agreed upon by the user
and the manufacturer.

The conveyor belt should not be used as an access or maintenance walkway.

No changes are allowed to be made on the conveyor without the manufacturer's written consent.

All those moving near the conveyor must use the marked walkways, service platforms, stairs, and ladders,
and these must always be kept clear.

The conveyor must not be used for carrying persons.

Caution must be observed when the conveyor is running.

The conveyor area must have sufficient lighting.

No safety device are allowed to be removed.

POINTS OF DANGER:

• Drive end
• Tensioning end
• Nip points of pulleys
• Nip points of idlers
• Loading and discharging locations
• Material flow
• Electric equipment and cables

05/2017 MM0430841-EN NW PLANT INSTRUCTION MANUAL 2-1


SAFETY

• Conveyor folding and raising mechanisms

Figure 2.1 Conveyor danger points

2.1.2 WELDING THE UNIT

Always take care to protect the control system, electric system and electric motor bearings when welding
the unit.

• Stop the process and disconnect the device (for example open the main switch)
• Fasten the grounding cable of the welding device as close to the part to be welded as possible. Make
sure that no welding current passes through any bearings or electrical equipment.

2-2 NW PLANT INSTRUCTION MANUAL MM0430841-EN 05/2017


SAFETY

2.1.3 RESTRICTED AREA

Before starting the operation, make sure that nobody is inside the device, on top of it or in the restricted
area. Everyone in the vicinity must be warned before the plant is started.

NOTE! Regulations concerning restricted areas may vary between different countries.

WARNING!
Only authorized persons are allowed to stay on the service platform of the NW unit
when it is operating!

WARNING!
Before starting the crushing process and during the crushing, make sure that the
restricted area is clear of people.

WARNING!
Do not climb on top of the plant devices when they are operating!

WARNING!
Do not go or stand below a running conveyor. Stay clear of any falling or
dropping materials or components. Wear a safety helmet and any other
appropriate personal safety equipment.

05/2017 MM0430841-EN NW PLANT INSTRUCTION MANUAL 2-3


SAFETY

WARNING!
If the crusher is equipped with the hydraulic breaker, make sure that there is no one
at the danger area, when using the breaker. Beware, that the hydraulic breaker or the
boom does not hit the hydraulic hoses, or the hydraulic hoses of the breaker or the
boom do not hit the other parts of the machine.

50 m
60 m

Figure 2.2 Restricted area during operation (example of the 2-phase plant)

2-4 NW PLANT INSTRUCTION MANUAL MM0430841-EN 05/2017


SAFETY

2.1.4 EMERGENCY STOPS

If a dangerous situation occurs, push the nearest emergency stop button. The emergency stop buttons
connected to the process control system stop the motor and the crushing process after the safety function
has been triggered by pressing the buttons. The trip wire switches in the conveyors only stop the conveyor
in question.

To reset an emergency stop button, pull the red button to its outer position. Before restarting the machine
ensure the area is clear around the unit and that no one will be endangered by your action.

CAUTION!
The operation of the emergency stop buttons must be checked weekly.

B
A
C

Callout Description
A Primary unit emergency stop circuit (the devices connected to the primary electric center)
B Secondary unit emergency stop circuit (the devices connected to the secondary electric center)
C Tertiary unit emergency stop circuit (the devices connected to the tertiary electric center)

Figure 2.3 Example of the emergency stop circuits in a typical 3-phase plant

For the location of the NW unit emergency stops, refer to the NW unit instruction manual.

Field conveyor trip wire switches are located on the side of each conveyor. Refer to the circuit diagrams for
more detailed information.

05/2017 MM0430841-EN NW PLANT INSTRUCTION MANUAL 2-5


SAFETY

2.1.5 WARNING SIGNS

The warning signs attached to the plant devices must always be kept readable and clean. Damaged or
loose signs must be replaced at once. If a component of the machine with an attached a warning sign is
replaced, always make sure that the required warning signs are included with the new component.

Figure 2.4 Warning and instruction signs

2-6 NW PLANT INSTRUCTION MANUAL MM0430841-EN 05/2017


SAFETY

2.1.6 NOISE LEVELS

DANGER!
The noise level in the plant area exceeds 85 dB(A).
Wear the appropriate ear protectors.

05/2017 MM0430841-EN NW PLANT INSTRUCTION MANUAL 2-7


SAFETY

This Page Left Intentionally Blank.

2-8 NW PLANT INSTRUCTION MANUAL MM0430841-EN 05/2017


TECHNICAL SPECIFICATION CHAPTER 3
3.1 PLANT INTRODUCTION

This Instruction Manual is valid for NW Plant manufactured by Metso.

2 PHASE PLANT

3 PHASE PLANT

The example NW Plant consists of:

• Metso NW-FH (Feed hopper)


• Primary unit
• Plant conveyors
• Metso NW-SH (Surge hopper)
• Secondary unit
• Tertiary unit

05/2017 MM0430841-EN NW PLANT INSTRUCTION MANUAL 3-1


TECHNICAL SPECIFICATION

3.2 INTENDED USE

The Metso NW plant is complete crushing and screening station that produces desired end products.

NOTE! Do not use the plant for any other purpose than those intended by the manufacturer.

WARNING!
Do not use this equipment in explosive duties or premises. It is highly forbidden to
crush explosive or flammable materials.

The Metso NW plant has been designed for safe operation when used by professional staff in the
operating situations specified in this instruction manual. All other service and repair procedures must be
performed by specially trained personnel or authorized Metso service staff.

The plant can be relocated with trailer trucks.

3-2 NW PLANT INSTRUCTION MANUAL MM0430841-EN 05/2017


TECHNICAL SPECIFICATION

3.3 COMPONENTS

3 5

5
1

5
5
4

Callout Description
1 Feed hopper (NW-FH)
2 Primary unit
3 Surge hopper (NW-SH)
4 Secondary unit
5 Plant conveyor

Figure 3.1 NW Plant components (example of the 2-phase plant)

05/2017 MM0430841-EN NW PLANT INSTRUCTION MANUAL 3-3


TECHNICAL SPECIFICATION

3.3.1 FEED HOPPER

The feed hopper enables the use of dump truck loading and also ensures even and continuous material
flow to the feeder. There are two feed hoppers available with different capacities.

1 5

7
2

Callout Description
1 Gap plate
2 Columns
3 Bracings
4 Skid
5 Bed plates
6 Side plates
7 Top frame
8 Chain curtain

Figure 3.2 Feed hopper components

• Feed hopper
– weight: 9000 kg
– 23 m3

3-4 NW PLANT INSTRUCTION MANUAL MM0430841-EN 05/2017


TECHNICAL SPECIFICATION

1 5

7
2

Callout Description
1 Gap plate
2 Columns
3 Bracings
4 Skid
5 Bed plates
6 Side plates
7 Top frame
8 Chain curtain

Figure 3.3 Feed hopper components

• Feed hopper
– weight: 12 950 kg
– capacity: 30 m3

05/2017 MM0430841-EN NW PLANT INSTRUCTION MANUAL 3-5


TECHNICAL SPECIFICATION

3.3.2 SURGE HOPPER

1 5

2 7

8
3

Callout Description
1 Extension plate
2 Columns
3 Bracings
4 Skid
5 Side panel
6 Cross beam
7 Chute
8 Support assembly for feeder mounting
9 Vibrating feeder

Figure 3.4 Surge hopper components

Capacity Weight (without feeder and feeder base)


3 3950 kg
20 m
3 3250 kg
option: 12 m
3 4600 kg
option: 32 m

• Vibrating feeder (located in the control panel of NW secondary or tertiary unit)


– electric variable frequency drive (VFD)

3-6 NW PLANT INSTRUCTION MANUAL MM0430841-EN 05/2017


TECHNICAL SPECIFICATION

3.4 ELECTRIFICATION

1
1

13

0
1

Callout Description
1 Primary unit electric center
2 Secondary unit electric center
3 Control panel is on the front door of the unit electric center

Figure 3.5 Control locations

All electric devices (plant conveyors, magnet separators etc.) are controlled from the NW unit's electric
center. The control panel is located on the door of the electric center.

05/2017 MM0430841-EN NW PLANT INSTRUCTION MANUAL 3-7


TECHNICAL SPECIFICATION

This Page Left Intentionally Blank.

3-8 NW PLANT INSTRUCTION MANUAL MM0430841-EN 05/2017


TRANSPORT CHAPTER 4
4.1 GENERAL INFORMATION ABOUT THE TRANSPORTATION

Because of the size and weight of the equipment, special attention must be paid when moving the NW
plant devices.

Use always approved lifting equipment with adequate capacity when preparing for a transport.

WARNING!
Make sure that the lighting is appropriate at the site.

WARNING!
Make sure that there is nobody in the vicinity when lifting/handling the plant
devices.

NOTE! Make sure that:


• the driving route is smooth enough
• differences in altitude or inclinations do not prevent driving

WARNING!
In case the surface is slippery or icy, make sure that the sanding is sufficient
enough to prevent the unpredictable movement of the NW, truck or trailer.

05/2017 MM0430841-EN NW PLANT INSTRUCTION MANUAL 4-1


TRANSPORT

4.2 PREPARING THE PLANT FOR TRANSPORTATION

4.2.1 TRANSPORTATION WITH THE TRAILER TRUCK

When the NW and plant devices are transported on public roads, note that it is a special transport which
may need transportation permits. Check the local regulations as they vary in each country.

Plant devices, like conveyors and hoppers, must be dismantled to pieces which can be placed on trailer
truck for transportation.

NOTE! Refer to the transport drawing for detailed transport dimensions!

Transport equipment needed:

• a trailer trucks for transporting the units and other devices


• correctly dimensioned fastening equipment

NOTE! PRIOR TO TRANSPORT ENSURE THE FOLLOWING:


• THE COMPONENTS THAT EXCEED THE FREE TRANSPORT HEIGHT AND WIDTH HAVE
BEEN REMOVED
• THE LOAD IS APPROPRIATELY FASTENED
• ALL HATCHES AND COVERS ARE LOCKED
• PROTECT COMPONENTS BEING TRANSPORTED USING APPROPRIATE SHIPPING
BRACES AND BLOCKING MATERIAL.
• BEFORE MOVING THE CRUSHING PLANT, CHECK ALL ROADWAYS AND BRIDGES ON
THE ROUTE FOR WEIGHT LIMITS.
• CHECK CLEARANCE OF BRIDGES, OVERHEAD LINES AND OTHER OVERHEAD
OBSTRUCTIONS.
• FOLLOW ALL APPLICABLE LAWS AND REGULATIONS.

4.2.2 TRANSPORTATION IN THE CONTAINERS

Container transport is for oversea transport. NW plant can be containerized in factory for oversea
transport.

For more details please contact Metso.

4-2 NW PLANT INSTRUCTION MANUAL MM0430841-EN 05/2017


OPERATION CHAPTER 5
5.1 PREPARING THE PLANT SITE

Metso NW Plant consist of different devices like feeders, crushers, screens, conveyors and hoppers.

Figure 5.1 General arrangement on the site

The place where the Metso NW units, conveyors and hoppers are to be located must be even and
load-bearing. The surface needs to be evened out. Refer to the layout and general arrangement drawings
for equipment load towards the ground. The ground needs to be levelled.

Typical foundations are made out of concrete or steel. The devices must not be allowed to sway. Spread
some fine-grained material on the ground, distributing it evenly. It is a customer decision to create concrete
foundations and, if necessary, use the separate concrete elements as a foundation under the devices.
When units are placed on compacted soil, spreader plates are recommended.

Figure 5.2 Spread some fine-grained material on the ground and even it out

05/2017 MM0430841-EN NW PLANT INSTRUCTION MANUAL 5-1


OPERATION

5.2 UNLOADING THE PLANT FROM CONTAINERS

Refer to separate unloading instructions.

5.3 FEED HOPPER, SURGE HOPPER AND PLANT CONVEYOR SET-UP

Figure 5.3 NW-FH (feed hopper)

Figure 5.4 NW-SH (surge hopper)

5-2 NW PLANT INSTRUCTION MANUAL MM0430841-EN 05/2017


OPERATION

Figure 5.5 Plant conveyor

During the first installation the hoppers and conveyors need to be assembled. Later when moving the plant
to a new location, the conveyors can be folded to transportation position to minimize the needed
re-assembly work.

Refer to the elevation drawing or conveyor specification in the order confirmation to find the exact angle
and height of the tail drum. This is needed when adjusting the conveyor supports to match the feed and
discharge points. Refer to the same documents for additional equipment such as skirt rubbers, foldable
head for crusher feed conveyors and discharge chute types.

5.3.1 BASIC PROCEDURE FOR CONVEYOR INSTALLATION AFTER CONTAINER


TRANSPORTATION

NOTE! This procedure should only be performed under qualified supervision.

5.3.1.1 Assembly of conveyor frame

The conveyor frame is an assembly of different modules namely:

1. Drive end module (5 m & 2.5 m)

05/2017 MM0430841-EN NW PLANT INSTRUCTION MANUAL 5-3


OPERATION

2. Intermediate module (5 m & 3 m)


3. Tail end or Non-drive end module (5 m only)

Each module consists of left & right side plates & combination of cross members.

All these modules are further joined to make different length combination using splice plates.

Typically a conveyor is available in following lengths: 7.5 m, 10 m, 13 m, 15 m, 18 m, 21 m, 23 m and 25 m.

Begin with individual modules, i.e any one module whether it is drive, or non-drive or intermediate module.

1. Place all the corresponding side plates and cross members in position, for instance the left hand
side plate of drive end in front of the right hand side plate and the cross-members at their place.

2. Bolt the cross members. Please note that the bolts for cross-members should not be fully
tightened at this stage.
3. Place the splice plates and fasten all the bolts. Do not tighten these bolts fully.
4. Once the complete frame is ready, check both the diagonals of the compete frame and then
tighten all the bolts.

5-4 NW PLANT INSTRUCTION MANUAL MM0430841-EN 05/2017


OPERATION

5. Assemble the end brackets on the drive end side.

05/2017 MM0430841-EN NW PLANT INSTRUCTION MANUAL 5-5


OPERATION

6. Install the brackets for transition idlers. The transition from 0 deg to 45 deg happens in three steps:
i.e 15 deg > 25 deg > 35 deg > 45 deg. These idlers are generally impact idlers.

5-6 NW PLANT INSTRUCTION MANUAL MM0430841-EN 05/2017


OPERATION

5.3.1.1.1 Drive assembly

In any conveyor, the drive i.e. geared motor mounting can be on the right or left side depending on the
layout. The default position for drive is left hand side.

For larger conveyors, there are also dual drive pulleys, i.e. geared motor mounted on both the sides.

5.3.1.1.2 Non-drive end assembly

05/2017 MM0430841-EN NW PLANT INSTRUCTION MANUAL 5-7


OPERATION

Once the frame is ready, drive and non-drive assemblies are installed, the carrying rollers are installed.

Generally the spacing between the carrying rollers is 1000 mm for all the conveyors. However due to
assembly constraints the spacing may sometimes be 500 mm.

5.3.1.1.3 Tail end skirt rubbers

After the rollers are installed, the skirt rubbers on the tail end are installed.

The skirt rubbers are generally 3 m long for normal conveyors. However there is a provision of putting the
skirt rubber along the length of conveyor.

Then the skirt board extensions are installed. There are various types of extensions available depending
upon the feeding method.

5-8 NW PLANT INSTRUCTION MANUAL MM0430841-EN 05/2017


OPERATION

5.3.1.1.4 Trip wire switch and junction box mounting plate

05/2017 MM0430841-EN NW PLANT INSTRUCTION MANUAL 5-9


OPERATION

5.3.1.1.5 Installation of discharge chute

5-10 NW PLANT INSTRUCTION MANUAL MM0430841-EN 05/2017


OPERATION

5.3.1.1.6 Installation of optional equipment

Figure 5.6 Installation of dust covers

Figure 5.7 Installation of walkways

05/2017 MM0430841-EN NW PLANT INSTRUCTION MANUAL 5-11


OPERATION

5.3.1.1.7 Typical installation of supports

4
4

Callout Description
1 Straight vertical members
2 Middle cross members
3 Bottom cross member
4 Ground supports
5 Lower hinge point

Only the middle cross-members changes as per the conveyor width.

The included angle in between the lower hinge point should be 25 to 40 degrees.

5-12 NW PLANT INSTRUCTION MANUAL MM0430841-EN 05/2017


OPERATION

5.3.2 CONVEYOR TRANSPORTATION

Between the sites conveyors can be folded for transportation.

1. Lift the conveyor with proper lifting equipment.


2. Turn the legs away.
3. Lower the conveyor on ground, support the structure to avoid twisting and bending.
4. If needed, loosen the belt and open bolted joints between drive end, intermediate and tail end
modules.
5. Use support between the modules and lift them on top of each other.

NOTE! Typically conveyors are transported in unfolded condition between the sites.

Figure 5.8 Folding the conveyor legs

05/2017 MM0430841-EN NW PLANT INSTRUCTION MANUAL 5-13


OPERATION

5.3.3 FEED HOPPER ASSEMBLY

1. Start the hopper assembly by preparing the support structure. Ensure that the support structure is
levelled and fits properly on the foundations.

Figure 5.9 Feed hopper foundation details

5-14 NW PLANT INSTRUCTION MANUAL MM0430841-EN 05/2017


OPERATION

2. Assemble vertical columns.

3. Complete the bracing assembly.

05/2017 MM0430841-EN NW PLANT INSTRUCTION MANUAL 5-15


OPERATION

4. Install the bracings to the columns.

5. Install one of the side bracings to the columns.

5-16 NW PLANT INSTRUCTION MANUAL MM0430841-EN 05/2017


OPERATION

6. Assemble the top frame.

7. Install taper plates on the top frame.

8. Install the bed plates over the top frame.

05/2017 MM0430841-EN NW PLANT INSTRUCTION MANUAL 5-17


OPERATION

9. Assemble the top box side plates on the ground.

10.Lift the top box over the top frame.

5-18 NW PLANT INSTRUCTION MANUAL MM0430841-EN 05/2017


OPERATION

11.Fasten the top box on the top frame.

12.Install the top part on the columns.

05/2017 MM0430841-EN NW PLANT INSTRUCTION MANUAL 5-19


OPERATION

13.Assemble the remaining bracings.

5-20 NW PLANT INSTRUCTION MANUAL MM0430841-EN 05/2017


OPERATION

14.Install the chain curtain.

05/2017 MM0430841-EN NW PLANT INSTRUCTION MANUAL 5-21


OPERATION

15.Install the gap plate.

16.Once the conveyors and the NW unit have been installed, check that there is enough clearance.
After the run-in period tighten all bolts and nuts.

5-22 NW PLANT INSTRUCTION MANUAL MM0430841-EN 05/2017


OPERATION

5.3.4 SURGE HOPPER ASSEMBLY

1. Start the hopper assembly by preparing the support structure. Ensure that the support structure is
levelled and fits properly on the foundations.

Figure 5.10 Surge hopper foundation details

2. Assemble the columns.

05/2017 MM0430841-EN NW PLANT INSTRUCTION MANUAL 5-23


OPERATION

3. Install the bracings on the columns.

4. Install a tie between the bracings.

5-24 NW PLANT INSTRUCTION MANUAL MM0430841-EN 05/2017


OPERATION

5. Assemble the cross beam.

6. Install the brackets for mounting the side panels.

05/2017 MM0430841-EN NW PLANT INSTRUCTION MANUAL 5-25


OPERATION

7. Install the feeder.

8. Assemble the side panels.

5-26 NW PLANT INSTRUCTION MANUAL MM0430841-EN 05/2017


OPERATION

9. Lift the side panel assembly using the assigned lifting hooks.

10.Mount the side panel assembly on the columns.

05/2017 MM0430841-EN NW PLANT INSTRUCTION MANUAL 5-27


OPERATION

11.Install the chute.

12.Install the top panels.

13.Once the conveyors and the NW unit have been installed, check that there is enough clearance.
After the run-in period tighten all bolts and nuts.

5-28 NW PLANT INSTRUCTION MANUAL MM0430841-EN 05/2017


OPERATION

5.4 PLANT SET-UP

Figure 5.11 Typical NW plant layout, page 1

05/2017 MM0430841-EN NW PLANT INSTRUCTION MANUAL 5-29


OPERATION

Figure 5.12 Typical plant layout, page 2

Refer to the layout or foundation drawing and elevation drawing for the detailed position of the NW units
and plant equipment. An example of foundation drawing shown below in Figure 5.13.

5-30 NW PLANT INSTRUCTION MANUAL MM0430841-EN 05/2017


OPERATION

Metso Minerals (India) Pvt. Ltd. TITLE NW PLANT EQUIPMENT No.


01 AGI PSI 2016-11-21 2-STAGE NW PLANT
DRN: AGI
1st Floor, DLF Building No. 10
Tower A, DLF Cybercity,
DATE: 2016-11-21
MATERIAL No.:
DLF Phase II, Gurgaon FOUNDATION COORDINATES CKD: PSI MATERIAL Spec.:
Haryana, India - 122002 MATERIAL Wt.: Wt. Unit:
NW106 + NW220GPD DATE: 2016-11-21
The inf ormation in this document/drawing was prepared using Intellectual Property owned SCALE: RELEASE
by METSO MINERALS (India) Pvt. Ltd. This is conf idential proprietary information and
r emains the exclusive property of METSO. The document/drawing is f or use solely in APPD: PSI ISO DRAWING NO SHEET REV

DO NOT SCALE FIRST ANGLE


BY DATE connection with the performance of Metso's Contract .
2016 DATE: 2016-11-21 A1 2-C17032-05-002 1 01
PROJECTION This drawing is the copyright of Metso Minerals . OF 1

Figure 5.13 Example of a foundation drawing

1. Check that the foundations are levelled and evened out. It is important that especially the
horizontal level is correct in order to have proper contact between the equipment legs and
foundations.
2. Mark the exact position of the legs on the foundations. Use a tape measure or digital laser
measure.
3. Set up the NW feed hopper if applicable. Then tow the NW primary unit underneath it and follow
the NW primary unit instruction manual to prepare it for operation.
4. Place other NW units such as the secondary and tertiary units. Refer to their operating manuals to
prepare them for operation.
5. Place the surge hoppers and vibrating feeders in position if applicable.
6. Lift the conveyors into their place. Pay special attention that transfer points are correct. Feed is
guided into the feed box and middle of the conveyor belt.
7. Remember that crushers and screens need sufficient clearance for operation. Also electric panels
and lubrication units should be isolated from the NW chassis, whenever possible.
8. Check levelling of the all equipment. NW unit level to be checked at crusher support legs and
separately underneath the feeder and screen. Laser level or transparent hose filled with water to
be used.
9. Ensure that all legs are evenly loaded and no gap can be seen between the legs and foundations
or between the fixed and extension part of the legs. If not correct, level the foundations by
grinding. Fine tuning can be done by using a rubber plate (max 5 mm thick) or flat steel shim
plates.

05/2017 MM0430841-EN NW PLANT INSTRUCTION MANUAL 5-31


OPERATION

10.Once all the equipment is mechanically installed and in correct position, the electrical connections
are made. Only an authorized electrician is allowed to perform any electrical work.

Plant conveyors are powered from the NW unit electrical panels. During the first installation the cables
need to be cut to correct length and plugs prepared. Connect also safety trip wires and zero speed
switches if applicable.

Main feed cables are to be connected directly on NW units (main feed cables are not part of the Metso
supply). NW panels are to be grounded according to local legislation. Cables are recommended to be
buried underground and protected with external cable protection, according to local legislation.

Figure 5.14 Plant set-up diagram

5-32 NW PLANT INSTRUCTION MANUAL MM0430841-EN 05/2017


OPERATION

5.5 MEASURES BEFORE STARTUP

Refer to the NW units’ own manuals for detailed information.

5.5.1 PROCESS SELECTIONS

Before starting the machine and process there are few mechanical adjustments and automation system
pre-selections to be made depending on the application.

5.5.1.1 Primary unit by-pass chute

The material flow that passes below the feeder grizzlies can be directed towards the main conveyor or
towards the optional side conveyor. With the optional screen deck, materials larger than the mesh
openings can be directed towards the main conveyor. Turn the lever to change the direction of the material
flow. When using the centre position, lock the lever in place using a bolt.

1 2 3

Callout Description
Screened with optional screen deck and divided as undersized to side
1
conveyor and oversized to main conveyor
2 Directed all to side conveyor
3 Directed all to main conveyor
Figure 5.15 By-pass chute

05/2017 MM0430841-EN NW PLANT INSTRUCTION MANUAL 5-33


OPERATION

WARNING!
Make sure that the machine is stopped (feeder, crusher, conveyors) before entering
to chute. Ensure that it can not be started during cleaning operation.

NOTE! Do not use excessive power if the by-pass chute lever is jammed.

5.5.1.2 Secondary unit dividing chute flap gates

Callout Description
1 First deck
2 Second deck
3 Third deck
4 Fourth deck
5 Undersize from the fourth deck
Figure 5.16 Dividing chute and flap gates

The chute has following possibilities.

1. deck:

5-34 NW PLANT INSTRUCTION MANUAL MM0430841-EN 05/2017


OPERATION

– to crusher

2. deck:

– as a product
– to the crusher (possibility to split 4x25%)
– mix to 3rd deck product (possibility to split 4x25%)

3. deck:

– as a product

4. deck:

– as a product
– mix to 3rd deck product (possibility to split 4x25%)

Fines (bottom deck undersize):

– as a product

5.5.2 CONNECTING SEVERAL UNITS

Consecutively operating NW crushing units can be interlocked with connection cables. In that case the
interlocked NW’s are transmitting information between units. E.g. an overload, a material level alarm or a
malfunction stops the feeder of the previous machine.

The primary unit feeder stop delay can be adjusted. By delaying the primary unit stop request the primary
unit keeps feeding the secondary unit but with less tonnage as the feeder is set to its minimum speed when
the secondary unit pause request is active. If the stop is delayed too much it might lead to overflow in the
secondary crusher chamber.

05/2017 MM0430841-EN NW PLANT INSTRUCTION MANUAL 5-35


OPERATION

5.6 MEASURES BEFORE STARTING THE PROCESS

Ensure that all units and equipments of the plant are in operation position and are adjusted according to
the process.

5.6.1 RESTRICTED AREA

Before starting the operation, make sure that nobody is inside the device, on top of it or in the restricted
area. Everyone in the vicinity must be warned before the plant is started.

NOTE! Regulations concerning restricted areas may vary between different countries.

WARNING!
Only authorized persons are allowed to stay on the service platform of the NW unit
when it is operating!

WARNING!
Before starting the crushing process and during the crushing, make sure that the
restricted area is clear of people.

WARNING!
Do not climb on top of the plant devices when they are operating!

WARNING!
Do not go or stand below a running conveyor. Stay clear of any falling or
dropping materials or components. Wear a safety helmet and any other
appropriate personal safety equipment.

5-36 NW PLANT INSTRUCTION MANUAL MM0430841-EN 05/2017


OPERATION

WARNING!
If the crusher is equipped with the hydraulic breaker, make sure that there is no one
at the danger area, when using the breaker. Beware, that the hydraulic breaker or the
boom does not hit the hydraulic hoses, or the hydraulic hoses of the breaker or the
boom do not hit the other parts of the machine.

50 m
60 m

Figure 5.17 Restricted area during crushing (example of the 2-phase plant)

05/2017 MM0430841-EN NW PLANT INSTRUCTION MANUAL 5-37


OPERATION

5.7 STARTING THE PROCESS

5.7.1 PLANT WITHOUT SURGE HOPPER

When the plant does not include surge hopper, the plant is operated as one process. Devices of the whole
plant can be started in certain starting order.

With relay controlled units start all devices separately using start push buttons.

With automation system start process from each NW unit control system.

There is start/stop sequence so process devices are interlocked and can be started in certain sequence.

When the crusher and following process is running, the feeder can be started. Feeder speed can be
adjusted using separate potentiometer or IC control system.

5.7.2 PLANT WITH SURGE HOPPER

When the plant includes the surge hopper, the plant is divided to separate phases like primary, secondary
and tertiary.

Automation system is controlling the safe and effective operation of NW Plant phases separately. Actual
values of the unit and process as well as diagrams can be seen on the display.

With relay controlled units start devices of the phase separately using start push buttons. Devices inside
each phase can be started in certain starting order.

With automation system each phase will start by pushing Process Start push button. Automation system
will start process automatically.

The process start sequence starts the devices of the unit in a specific order. Optional equipment that are
not in use are ignored on start sequence. The sequence ensures that the devices are started in the correct
order.

Automation will start and adjust the feeder automatically.

5-38 NW PLANT INSTRUCTION MANUAL MM0430841-EN 05/2017


OPERATION

5.8 OPERATING THE PLANT DURING THE PROCESS

5.8.1 USING THE CONTROL SYSTEM

With relay controlled unit the feeder speed is controlled from potentiometer.

With IC automation controlled unit the feeder speed is controlled from IC display or from service platform
control box (primary unit).

Keep feeder speed suitable for choke feed of crushers. Try to keep phases and whole plant in balance. Too
high speed will stop feeding and then reduce capacity.

5.8.2 LOADING THE UNIT

Jaw crusher setting can be adjusted manually, or optionally, with hydraulic setting adjustment.

Keep setting suitable for process targets. Also pay attention for material properties.

5.8.3 MONITORING PLANT INFORMATION

With IC automation system the NW unit process values can be monitored from the display. Refer to the IC
instruction manual.

5.8.4 PARAMETERS AND SETTINGS

With IC automation system NW process parameters can be adjusted. Refer to the IC instruction manual.

5.8.5 DIAGNOSTICS

With IC automation system alarms and events can be monitored from the display.

05/2017 MM0430841-EN NW PLANT INSTRUCTION MANUAL 5-39


OPERATION

5.9 STOPPING THE PROCESS

Before stopping the process stop feeding material and allow all material to pass through the process. Start
the stopping procedure from the feeding end and continue to product conveyors.

With relay controlled units stop all devices separately using stop push buttons in the control panels of NW
units. It is recommended to use plant or phase stopping order (feeder first, product conveyors last).

Automation system will stop the devices in a specific stopping order.

5.9.1 EMERGENCY STOP

To activate the emergency stop safety function press the emergency stop button. For locations of the
emergency stops, see Safety section.

The emergency stop must be used when there is an

• Immediate risk of injury to the humans


• Immediate risk of mechanical damage to the equipment

Emergency stop provides a mechanical means of quickly stopping all the equipment on the machine. The
emergency stop does not switch off the automation system display but all electric controls are made dead.

NOTE! The emergency stop does not stop the other NW units even when they are connected with
interlock cable. Other units have separate emergency stops.

NOTE! Do not stop the unit with emergency stops in daily operations.

5-40 NW PLANT INSTRUCTION MANUAL MM0430841-EN 05/2017


MAINTENANCE CHAPTER 6
Continuous and regular maintenance is one of the prerequisites for profitable operation.

With that in mind, the maintenance instructions have been grouped into different categories:

• preventive, daily maintenance and checking procedures


• running-in maintenance
• periodically performed servicing and inspection procedures

Follow the machine specific maintenance programs and instructions.

NOTE! Update maintenance log book daily!

If any deviation from the recommendations is detected during the check, necessary measures must be
taken immediately. In the long run, this kind of procedure will produce the best results for all parties.

The equipment must be serviced and repaired by professional personnel that is adequately acquainted
with the equipment. The safety manual instructions, the startup and shutdown instructions in the instruction
manual and all possible servicing instructions must be followed in all proceedings concerning the
operations of the equipment and its safety devices, as well as inspecting, servicing and repairing the
equipment.

NOTE! Any person working on elevated areas not protected by railings, or on hazardous places
must wear suitable safety equipment, including safety harnesses, if there is a risk of falling.

6.1 MAINTENANCE CHART

This chart presents the schedule for periodic maintenance of the equipment. If more than one time limit is
indicated, the maintenance must be carried out when the first limit is reached (such as 2,000 h / once a
year). The time limits for maintenance procedures must be specified according to the operating conditions.
For example, in extremely dusty operating conditions (or if the dust is very fine), special attention must be
paid to the maintenance of air filters and breathers, and they must be replaced as soon as the minimum
limit for operating hours is reached. In cold conditions and in case of continuous temperature changes, it is
important to drain any condensate waters.
Weekly/

1000 h

2000 h
250 h
Daily

50 h

GENERAL
Check visually for any ice or frost build up in the motor ventilator X
Check the running clearance of the feeders X
Tension the bolts and nuts X
Observe that there are not any cracks X
Check the welded structures X
Check all electric boxes for water or excess moisture X

CONVEYORS
Check the run and tension of the conveyor belt X

05/2017 MM0430841-EN NW PLANT INSTRUCTION MANUAL 6-1


MAINTENANCE

Weekly/

1000 h

2000 h
250 h
Daily

50 h
Check the trouble-free operation of the tail- and drive drums X
Check the operation of the supporting and return rolls (rotation
of rolls) X
Lubricate the tail- and drive drum bearings and the magnetic
separator X
Check the safety and control devices X
Check the condition of scrapers, guiders and brushes X
Lubricate the threads of the belt tightening screws X
Check the skirt rubbers X
Lubricate conveyor pivot points X
Check the condition of the impact bars X

6.2 CONVEYORS

6.2.1 FOLDING THE CONVEYOR END

Before replacing the crusher parts, the conveyor end needs to be folded. The conveyor end is folded by
the lifting lugs using a crane, exceeding 90 degrees to prevent it from unfolding during maintenance
procedures.

After maintenance, the conveyor end is unfolded back to its place in a controlled manner by the lifting lugs
using a crane.

6-2 NW PLANT INSTRUCTION MANUAL MM0430841-EN 05/2017


MAINTENANCE

6.2.2 BELT TRACKING

A properly trained conveyor belt will travel over the center of the troughing rolls, pulleys and return rolls,
resulting in lower maintenance costs and improved operation. Conveyor belts can be trained to track
properly, unless they are warped or curved from improper manufacture, use or storage.

Before any belt adjustment is done, make sure that the unit is in level. Also make sure that the material
flow is even. For example the stuck object in the crusher cavity may cause uneven material flow. To inspect
that the conveyor is levelled correctly, refer to the unit level indicator for the unit straightness.

When adjusting the belt, the following items can be used to control the belt tracking:

– Drive drum position


– Return roller position
– Carrying rollers
– Tail pulley position

Before adjustment, make sure that the conveyor belt is undamaged. A damaged belt will not track properly.

6.2.2.1 Squaring the pulleys

In short conveyors the belt tracking is heavily affected by the position of the drive drum and tail pulley.
Before making tracking adjustments, check that the drive and tail pulleys are both square to the conveyor
frame.

Squaring the tail pulley - Mark the frame member close to the tail pulley (Point A). Use a large square (1) to
mark (Point B) on the opposite frame member so that a line between the two points is at a 90° angle to the
imaginary centerline of the frame. Adjust tail pulley bearing blocks so that the distance C (the distance
between marks A and B and the ends of the tail pulley shaft) is equal on both sides of the frame.

If the belt starts moving sideways on the tail pulley check the condition of the pulley.

05/2017 MM0430841-EN NW PLANT INSTRUCTION MANUAL 6-3


MAINTENANCE

Figure 6.1 Squaring the tail pulley

Squaring the drive pulley - When adjusting the drive drum location, remember always to loosen the slide
beam locking bolts and the joint bolts of the subframe assembly on both sides of the conveyor. This
function allows the parts to move without causing any torsion on the drive motor. Adjust until the belt is
properly tensioned and the drive pulley is square to the conveyor frame.

Tighten the slide beam locking bolts slightly on both sides of the conveyor to the proper torque (30 Nm).

Figure 6.2 Loosen the slide beam locking bolts on both sides of the conveyor

6-4 NW PLANT INSTRUCTION MANUAL MM0430841-EN 05/2017


MAINTENANCE

6.2.2.2 Adjusting the idlers

WARNING!
MOVING PARTS HAZARD
Moving parts can cause death or serious injury
Do not attempt to adjust idlers when the conveyor is running. Stop the conveyors
and perform the appropriate lock out tage out procedures before making any
adjustments.

Adjust for run off by finding the point of maximum run off (D) and adjusting the idler or idlers (E) "ahead" of
it. "Ahead" means those idlers which the belt contacts before the point of run off. Roller position
exaggerated for illustration purposes in figure below.

Figure 6.3 Eliminating run off. 1) Before adjustment, 2) After adjustment

Loosen bolts and pivot roll (E) around its mid point the way you would turn a steering wheel to bring a car
back into the center of its lane. Make small adjustments, retighten bolts and test for run off after each
adjustment. If point of creep changes, adjust idler ahead of the new creep point.

Do not attempt to adjust idlers with the conveyor running. Lock out and tag controls while making
adjustments.

1. Return roller adjustment is used to center the belt on the tail pulley. Run the conveyor with the belt
empty. Loosen the bolts and displace the roller assembly (see the arrows in Figure 6.2). Tighten
bolts and test for run off again.

05/2017 MM0430841-EN NW PLANT INSTRUCTION MANUAL 6-5


MAINTENANCE

Figure 6.4 Return idler adjustment

NOTE! Protection plate must adjusted separately. Distance to the roller must not be more than 5
mm.

If the gap between protection plate and roller cannot be adjust smaller than 5 mm roller must be replaced.

2. Carrying idler adjustment is used when the belt does not center with material.

Each end of the carrying idler fits into an elongated hole that provides two mounting locations. See
Figure 6.5. Determine which direction the idler must turn and turn the idler accordingly.

Figure 6.5 Carrying roller adjustment

3. If the belt adjustment method 1 and 2 have not corrected the belt tracking completely, adjust the
tail pulley slightly to make the final correction.

Figure 6.6 Tail pulley adjustment

6-6 NW PLANT INSTRUCTION MANUAL MM0430841-EN 05/2017


MAINTENANCE

6.2.3 BELT TENSION

The conveyor belt tension is adjusted by relocating the drive pulley position. When adjusting the drive
drum location, remember always to release the slide beam locking bolts from both side of the conveyor.
This function allows the parts to move without causing any torsion to the drive motor.

A belt is properly tensioned when the sag of the loaded belt between two adjacent return rollers is 0,5 - 3%
of the distance between the rollers when an empty belt is operating.

Sag can be difficult to measure accurately, because of the small distances involved. The practical rule of
thumb is, "The proper tension is the lowest possible tension that will prevent drive pulley slippage and belt
misalignment."

If the conveyor has a vertical curve, the conveyor belt should remain touching all carrying rollers with
material. Without material in the vertical curve the gap between the belt and carrying roller must not be
more than 30 mm.

6.2.4 BELT SCRAPER ADJUSTMENT

The scraping force is done by spring force. Rubber, steel or gas springs are generally used methods.

Belt scraper tension and condition must be checked daily.

1. Observe the scraper wear daily and replace the scraping element when necessary.

The tension mechanism can be jammed or frozen in muddy/icy conditions and due to this the scraper
operation must be checked in the beginning of every shift or daily.

Figure 6.7 Steel spring type pre-cleaner (not available with all conveyors)

2. Adjust the spring to set the scraper’s pressing force so that the belt becomes properly cleaned.

05/2017 MM0430841-EN NW PLANT INSTRUCTION MANUAL 6-7


MAINTENANCE

Figure 6.8 Adjusting the rubber spring type pre-cleaner

3. Use tensioning screw Z to adjust the scraper with a rubber element tensioner.

Figure 6.9 Scraper with rubber strap tensioning

The belt scraper in the picture above is adjusted by a rubber strap.

6-8 NW PLANT INSTRUCTION MANUAL MM0430841-EN 05/2017


MAINTENANCE

6.2.5 BEARING LUBRICATION

The bearing size will affect the needed grease amount. In the following table the amount of grease (in
grams) is proportioned to shaft diameter (in millimeters).

Notice that same lubrication instructions are valid for magnetic separator as well.

Shaft diameter Amount of grease (g / 40-50 h)


40 4
55 6
60 6
80 9

In practice an appropriate amount of grease to each bearing is about 5-10 grams (0.17....0.35 ounces) in
every 40 - 50 hours.

Use a multipurpose grease with an NLGI-class 2 rating and a good resistance to water, cold (-30 °C/ - 22
°F) and hot (continuous operating temperature +100 °C/ 212 °F).

The grease must have rust and oxidation (RO) inhibitors and it must contain EP-additives. Do not use
grease containing molybdenum.

The minimum viscosity of the base oil must be 160 mm 2/s ( cSt ) in 40 °C/ 104 °F and minimum viscosity
index 80.

6.3 PLANT STORAGE

If the plant is not used for long periods at a time, start up the plant monthly to ensure proper functioning.
Otherwise, contact Metso for instructions for proper protection and storage.

05/2017 MM0430841-EN NW PLANT INSTRUCTION MANUAL 6-9


MAINTENANCE

This Page Left Intentionally Blank.

6-10 NW PLANT INSTRUCTION MANUAL MM0430841-EN 05/2017