Installation Instructions for Mineral Sizer

What is Mineral Sizer?

The Mineral Sizer uses a dual toothed roller mechanism that moves in opposite directions, continuously crushing the material entering the crushing chamber. The machine consists of two crushing rollers, which are mounted horizontally and parallel to the frame. The motor is connected to the toothed rollers via a hydraulic coupling, gearbox, and coupling. Materials are crushed through the impact, shear, and compression of the rollers. A crushing beam can be installed at the discharge port to further crush the material, improving the crushing efficiency. The Mineral Sizer is most suitable for breaking various brittle materials such as coal, coke, slag, and limestone.

Installation and Commissioning

Technical Requirements

• The allowable deviation in the horizontal alignment of the Mineral Sizer main shaft is ≤2mm.
• The allowable deviation in the vertical direction of the main shaft is ≤1mm/m.
• The allowable concentricity deviation between the main shaft and the motor shaft is ≤1mm.
• The angular deviation between the coupling and the motor coupling should not exceed 40°.

Installation

The installation of the Mineral Sizer should be done after the foundation platform is firmly secured. First, check the positions of the reserved holes and the installation elevation on the foundation to ensure they match the installation layout.

Then, lift the machine body and motor separately onto the foundation, aligning them with the pre-drawn centerline. Use wedge-shaped shims to adjust the base to meet the technical installation requirements, and secure the anchor nuts. Fine-tune the Mineral Sizer to meet the installation requirements and tighten the anchor nuts.

Next, adjust the motor according to the installation technical requirements and tighten the motor’s anchor nuts. After completing the installation, manually rotate the toothed rollers; the main shaft must rotate smoothly and easily. If there is any resistance, adjustments must be made until the required conditions are met.

Commissioning

No-load Test

The no-load test should be carried out without feeding material. The following requirements must be met:

• Follow the start-up and shut-down procedures, and the electrical interlocking system should meet design requirements.
• All fasteners must be secure and reliable, with no looseness.
• Gears must rotate smoothly.
• Bearing temperature must not exceed 75°
• Bearing lubrication must be normal, with no oil leakage.

Load Test

The load test should be performed after the no-load test is successfully completed. In addition to meeting the no-load test requirements, the following must also be satisfied:

• There should be no significant vibrations or abnormal noises.
• The feed position should be correct, and discharge should be normal.
• Material must not be pre-fed before starting the machine.
• After starting, the machine should run smoothly before material is fed.
• The machine should only be stopped after all material in the Mineral Sizer is discharged.
• After 5-6 hours of load testing, stop the machine and check the operation of each part, tightening any loose bolts.

Operating Procedures

Start-up

Before starting, check if there is an adequate amount of lubricant in the bearing housing; check the clearance between the toothed rollers and both comb plates and the lower crushing anvil; check for any foreign objects in the crushing chamber; check the tightness of machine bolts and the connection between the machine and the installation platform; rotate the rollers by hand 2-3 times to ensure there is no jamming; ensure the Mineral Sizer is running in the correct direction, which can be selected via the locked knob on the control panel.

Operation

After 12 minutes of no-load operation, if everything is normal, material can be fed in. The feeding should be continuous and uniform through the feed inlet into the crushing chamber. It is strictly prohibited to feed uncrushable material into the machine to avoid damage and accidents. While the Mineral Sizer is operating, operators must not stand within the rotor’s inertia force line, and no cleaning, adjusting, or checking should be done during operation to avoid danger. The maximum bearing temperature should not exceed 75°C. If it exceeds this limit, the machine must be stopped immediately, and the cause must be investigated and dealt with properly.

Shut-down

The following shutdown sequence should be followed:

• Stop the discharge conveyor.
• Stop the Mineral Sizer.
• After stopping the feeding, allow the Mineral Sizer to continue running until the material in the crushing chamber is processed.

Reverse Operation

The direction of rotation (forward or reverse) of the Mineral Sizer can be selected using the locked knob on the control panel. This knob must only be used when the machine is stopped, and it should never be operated while the machine is running.

Safety Precautions

• No maintenance work should be performed while the machine is running.
• No personnel or parts should enter the crushing chamber while the machine is operating.
• Reverse operation is prohibited before the equipment has completely stopped.

Common Failures and Solutions

Vibration

Causes:

• When the Mineral Sizer and motor are misaligned, their motion paths do not match, causing extra force and vibration.
• Large feed material blocks can cause the Mineral Sizer to bear large impact loads, and uneven feeding can lead to unstable force distribution, both of which can cause vibration.
• Loose bearing housings or anchor nuts can cause gaps at the connection points, leading to vibration under the forces exerted by the Mineral Sizer.
• Loosened connections between the tooth caps and the tooth seats may cause the two parts to move out of sync, resulting in relative displacement and vibration.

Solutions:

• For misalignment issues, correct the alignment of the Mineral Sizer and motor using precise measuring tools like a dial indicator or level to ensure the shafts are on the same axis.
• Control the feed size to ensure it does not exceed the specified range and adjust the feeding system to ensure uniform material flow into the crushing chamber.
• Regularly inspect the bearing housing and anchor nuts. Tighten any loose components promptly to ensure stable connections.
• Regularly check the connection between the tooth cap and seat. Tighten any loose connections to ensure they remain firmly fixed.

Reduced Output

Causes:

• The tooth cap, which directly contacts and crushes the material, may wear down over time, reducing its crushing capacity and output.
• Too much clearance between the toothed rollers, comb plates, and bottom anvil causes incomplete crushing, allowing some material to escape without being sufficiently crushed, reducing output.

Solutions:

• If the tooth cap has worn down significantly, it must be repaired or replaced to restore crushing capacity.
• Regularly check the clearance between the toothed rollers, comb plates, and bottom anvil. If the clearance is too large, replace the comb plates or bottom anvil, or adjust the relevant components to restore proper clearance for efficient material crushing.

Abnormal Noise Inside

Causes:

• Hard materials, such as uncrushable objects or metals, entering the crushing chamber may cause intense collisions inside the machine, producing abnormal noises.
• Loose internal parts may cause relative movement and collisions between components, generating strange sounds.
• Parts may crack due to prolonged stress or material aging, and fractured components may cause friction or collision inside the machine, producing abnormal sounds.

Solutions:

• If abnormal noise is detected, immediately stop the machine and check the internal situation. If uncrushable materials or metals are found, remove them to prevent further damage.
• Perform a comprehensive inspection of the machine, tightening any loose parts to ensure all components are securely connected.
• If fractured internal parts are found, identify the broken parts and replace them to ensure the machine operates smoothly and the noise is eliminated.

Conclusion

The efficient operation of the Mineral Sizer depends on correct installation, standardized operation, and regular maintenance. Strictly following the installation requirements, commissioning procedures, and operating guidelines will effectively reduce the occurrence of faults, extend the equipment’s lifespan, and ensure safe and efficient crushing operations. Regular monitoring and timely resolution of any abnormalities will guarantee smooth production.