cths430-02_im_s223.855.en-01
TRANSCRIPT
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Installation Manual Doc. No. S 223.855.en
SANDVIK CTHS430:02
Tank unit
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1. Introduction
1.1 Equipment information.......................................................... 8
1.1.1 Document information............................................ 10
1.2 Operating principles............................................................ 11
1.2.1 Lubrication system................................................. 11
1.2.2 Description............................................................. 11
2. Safety precautions
2.1 Hazard information ............................................................. 14
2.1.1 Warning signs ....................................................... 14
2.1.2 Risk levels.............................................................. 15
2.1.3 Prohibition signs..................................................... 15
2.1.4 Mandatory signs..................................................... 15
2.1.5 Personnel............................................................... 16
2.1.6 Personal protection ................................................ 17
2.2 General safety precautions................................................. 18
2.2.1 Machine safety guards........................................... 19
2.2.2 Machine access ..................................................... 19
2.2.3 Electrical safety...................................................... 20
2.2.4 Welding .................................................................. 20
2.2.5 Hydraulic system.................................................... 21
2.2.6 Lubrication system................................................. 22
2.2.7 Lubricants and waste lubricants............................. 23
2.2.8 Diesel oil, white spirit and other cleaning agents ... 23
2.2.9 Lifting and moving loads ........................................ 24
2.3 Emissions ........................................................................... 24
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3. Installation preparations
3.1 General ............................................................................... 26
3.2 Installation preparations check list ...................................... 27
3.3 Placement........................................................................... 28
3.3.1 Electrical installation............................................... 29
3.3.2 Remote control system .......................................... 29
3.3.3 Guard ..................................................................... 29
3.4 Operating in low temperatures............................................ 30
3.4.1 Measures for easier starting and runningin cold climate ........................................................ 30
3.4.2 Low temperature problems symptoms and remedies..................................... 31
3.4.3 Heater set - cold climate ........................................ 32
3.4.4 Diesel heating system............................................ 33
3.4.5 Heating cables on oil lines ..................................... 33
3.4.6 Heating in the component sectionof the oil tank unit ................................................... 34
3.4.7 Synthetic oils .......................................................... 34
3.4.8 Mineral oil for the winter season ............................ 35
3.4.9 Blanking off the oil cooler radiator .......................... 36
3.4.10 Frequency converter .............................................. 36
3.4.11 Two-speed fan motor for oil cooler......................... 36
3.4.12 Insulation of the oil tank ......................................... 37
3.4.13 Continuous running of the lubrication oil pump ...... 37
4. Transport handling
4.1 Goods data ......................................................................... 40
4.1.1 Contents................................................................. 40
4.1.2 Loading and unloading goods signs....................... 41
4.2 Lifting equipment................................................................. 424.2.1 Overhead gantry or mobile crane........................... 43
4.2.2 Using a fork lift (only for goods on pallet) ............... 44
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4.3 Unloading the goods........................................................... 45
4.3.1 Unpacking area...................................................... 45
4.3.2 Inspection of goods................................................ 45
4.4 Moving and Storage............................................................ 46
4.4.1 Moving ................................................................... 464.4.2 Storage................................................................... 46
4.5 Unpacking the goods.......................................................... 48
4.6 Disposal/return of packaging material ................................ 49
5. Mechanical installation and connections
5.1 General requirements......................................................... 52
5.2 Foundation.......................................................................... 53
5.3 Hydroset and lubrication systems....................................... 53
5.4 Hoses and pipes General ................................................ 54
5.4.1 Oil tank unit ............................................................ 54
5.4.2 Air/oil cooler ........................................................... 56
5.4.3 Water/oil cooler (option)......................................... 57
5.5 Overpressure system.......................................................... 58
5.6 Lubricants ........................................................................... 60
6. Electrical installation
6.1 General requirements......................................................... 62
6.2 Overview............................................................................. 62
6.3 Motors and heating elements ............................................. 63
6.3.1 M2 Main lubrication pump................................... 63
6.3.2 M3 Oil cooler fan motor....................................... 63
6.3.3 M6 Hydroset pump.............................................. 63
6.3.4 E7 Oil heaters ..................................................... 63
6.3.5 M8 Overpressure fan .......................................... 63
6.4 Connection boxes............................................................... 64
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7. Final installation checks
7.1 Installation and connection checks ..................................... 66
7.1.1 Lubrication system and Hydroset checks............... 66
7.2 Electrical checks ................................................................. 66
7.2.1 Check the pressure switch PS2 ............................. 67
7.3 Safety checks...................................................................... 68
7.4 Start-up ............................................................................... 68
8. Preparations for commissioning
8.1 General ............................................................................... 70
8.2 Presence and correctness checks ...................................... 70
8.3 Supply value checks ........................................................... 70
8.4 Function checks .................................................................. 71
8.4.1 Preparation............................................................. 71
8.5 Health and safety checks.................................................... 71
8.6 Documentation.................................................................... 71
9. Disassembly, storage and removal
9.1 Moving and storage ............................................................ 74
9.1.1 Short moves and short-term storage...................... 749.1.2 Long moves and long-term storage ....................... 75
9.1.3 Regular inspection during storage ......................... 76
9.2 Return to the manufacturer ................................................. 76
9.3 Disposal .............................................................................. 77
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1. IntroductionTo ensure maximum safety, always readsection 2. Safety precautionsbefore
carrying out any work on the equipment or making any adjustments.
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1.1 Equipment information
Purpose
The purpose of this Sandvik equipment is to be an oil tank component in a
crushing and screening unit or site within an aggregate or mining process.This crusher component has been exclusively designed for this application. It
is not the responsibility of Sandvik secure the design and usage for the
complete aggregate, mining, or recycling process. Sandvik will not accept
any liability for damage to equipment or injury to personnel caused by
unauthorized or improper use or modification of this equipment.
Manufacturer
This Sandvik equipment has been manufactured by:
Sandvik SRP AB
SE-233 81 Svedala
Sweden
www.sandvik.com
For maintenance
Contact the nearest Sandvik company, agent or representative, or contact the
factory directly:
Sandvik SRP AB
Service Department
SE-233 81 Svedala
Sweden
Telephone +46 (0)40 40 90 00Telefax +46 (0)40 40 92 60
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Identification
The figure below shows the location and an example of the tank units
identification plate. The identification plate contains data needed when
contacting Sandvik concerning this specific equipment.
CE markingThis equipment complies with the basic health, environment and safetyregulations of the European Union and European Economic Area.
Sandvik will not take responsibility for this compliance when customers
modify any configuration of the oil tank unit.
6543
8
7
1
2
V10
1 Machine type
2 Serial number/PCR
3 Local manufacturer number
4 Mass (kg)
5 Order number
6 Manufacturer
7 Maximum operating speed
8 Year of manufacture
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1.1.1 Document information
Purpose of this Installation Manual
The purpose of this manual is to provide the installation personnel with
information on how to safely install this Sandvik equipment.
It is important to: keep the manual for the lifetime of the equipment
pass the manual on to any subsequent holder or user of the equipment.
Document Compliance
The instructions in this document are in accordance with the design and
construction of the equipment at the time it was delivered from the Sandvik
SRP AB manufacturing plant.
Technical Publications
Technical publications related to the installation of this equipment are:
IM - Installation Manual
IMA - Installation Manual Appendix
Technical publications related to the operation and maintenance of this
equipment are:
OMM - Operators and Maintenance Manual
SPC - Spare Parts Catalog
Read more about the document structure and accompanying work categories
insection 2.1.5 Personnel.
Feedback
If you have comments on this manual or problems connected to the
documentation, send an e-mail to: [email protected]
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1.2 Operating principles
1.2.1 Lubrication system
There are two separate lubrication systems the circulatory main lubrication
system and the pinionshaft oil bath lubrication. The main lubrication system
is described in Operators and Maintenance Manualfor the tank unit. The
pinionshaft lubrication is described in the Operators manualfor the crusher.
Setting adjustment
To control fragment size and to compensate for wear the crusher has a setting
control system, called the Hydroset system. It basically consists of a robust
hydraulic jack which supports the mainshaft and adjusts its position. Moving
the Hydroset piston up and down will change the discharge setting and the
size of the crushed material.
1.2.2 Description
The following figure shows an overview of the oil tank units nomenclature
and components.
123 4 5
1 Oil tank unit
2 Overpressure fan
3 Overpressure air regulator (option)
4 Air/oil cooler
5 Water/oil cooler (option)
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2. Safety precautionsTo ensure maximum safety, always read this section carefully before
operating, carrying out any work on the equipment or making anyadjustments.
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2.1 Hazard information
2.1.1 Warning signs
General danger Dangerous voltage Risk of crushing
Hanging load Skid risk Flying fragments
Rotating fan Irritant Hot surface
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2.1.2 Risk levels
Throughout the manual, risk levels are indicated with DANGER,
WARNING or CAUTION. The DANGER and WARNING levels
are accompanied by a warning sign, seesection 2.1.1 Warning signs.
CAUTION! Failure to observe information marked CAUTION! can result in minor
personal injury and/or damage to equipment!
2.1.3 Prohibition signs
2.1.4 Mandatory signs
DANGER!
Failure to observe information marked DANGER! can result in life-threatening injuries!
WARNING!
Failure to observe information marked WARNING! can result in
personal injury and/or serious damage to, or destruction of,
equipment!
Do not remove
guards
Disconnect current Read the manual
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2.1.5 Personnel
All work on the equipment must be carried out by trained personnel.
Trained means that the person in question has been given practical
instructions by Sandvik SRP AB personnel on how the various tasks
are carried out.
All expected work tasks on this production equipment have been defined by
Sandvik SRP AB as belonging to one of three categories:
Installation
Operation
Maintenance
Sandvik SRP AB provides technical documentation appropriate to the
categories:
Installation Manual and Installation Manual Appendix Operators and Maintenance Manual
Spare Parts Catalog
Adequate training can be provided, contact Sandvik SRP AB for further
information.
The technical documentation from Sandvik SRP AB only covers work on the
production equipment itself it does not cover work tasks associated with
other equipment or routines at the site.
It is the responsibility of the plant management to assign responsibility for:
The production equipment and the work area around the equipment
All personnel in the vicinity of the equipment
Compliance with national and local safety regulations
Checking that all safety devices are fully operational
Sandvik SRP AB declines all responsibility for injury or damage resulting
from non-compliance with the instructions in this manual.
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2.1.6 Personal protection
Sandvik SRP AB strongly recommends that personal protective equipment is
always worn when working in the vicinity of the equipment.
Sandvik SRP AB strongly recommends to use a safety harness when
working above, inside or under the equipment.
The Sandvik SRP AB recommendation for personal protective equipment
includes:
Ear protection Safety helmet Eye protection
Protective gloves Safety boots Mask or respirator
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2.2 General safety precautions
Always switch the power off and lock out the equipment (so that it cannot
inadvertently be switched on) before any maintenance work is started. Also
ensure that it is not possible for anyone else to switch the power on while
maintenance work is carried out.
Avoid staying on the equipment, unless necessary for maintenance work.
CAUTION! Sharp edges can appear on the equipment due to wear, please consider
sharp edges when handling worn parts. Remove any sharp edges.
WARNING!
Falling stones
Clear the feed arrangement and the crusher thoroughlyfrom process
material before any maintenance work is carried out inside or belowthe crusher, to prevent stones from falling down.
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2.2.1 Machine safety guards
Make sure all defective guards are checked, repaired and replaced before
starting the equipment.
2.2.2 Machine access
Every machine requires access for personnel who carry out inspections and/
or maintenance work. Suitable access platforms and guard rails must be
installed. Walkways, stairs and ladders must be designed in accordance with
applicable regulations.
These parts are not included in thetank units standard specification. For
advice, contact Sandvik SRP AB.
PROHIBITION!
Do not remove guardsMake sure that all guards are in place and functioning, to prevent
exposure to rotating parts. Only operate the equipment when all
guards are mounted.
WARNING!
Rotating partsExposure to rotating parts (pumps, fans etc.)must be prevented by
guards. Always attach the guards after maintenance work.
WARNING!
Flying fragments
Ejected fragments can fall down in the vicinity of the equipment.
Provide adequate guards and warning signs at appropriate places
around the danger zone.Sandvik SRP AB also recommends additional protection.
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2.2.3 Electrical safety
CAUTION! Only personnel working according to European Standard EN 50110 or
equivalent are permitted to perform electrical operations on theequipment.
Make sure all broken or damaged electrical cables and connectors are
checked, repaired and replaced before starting the equipment.
Control cabinets must be lockable.
2.2.4 Welding
CAUTION! Never weld the tank unit or parts attached to it.
DANGER!
Dangerous voltagePersonnel must regard all electrical equipment as live until it is proven
dead by proper testing procedures.
DANGER!
Risk of fire and explosionDue to the risk of leakage, open flames and hot surfaces (>200 C/>390 F) must be kept at a safe distance from the tank unit and the
lubrication pipe work.
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2.2.5 Hydraulic system
CAUTION! Only personnel certified in hydraulics are permitted to perform
maintenance on the hydraulic system (except bleeding air from the
Hydroset system).
CAUTION! Never adjust pressure relief valves beyond the recommended values.
CAUTION! Make sure all defective hoses, valves or fittings are checked, repaired
and replaced before starting the equipment.
WARNING!
Oil pressurePressurized oil is dangerous if released incorrectly. Relieve all
pressure before carrying out maintenance or repair work on the
hydraulic system.
WARNING!
Hot oil
Hydraulic oil can become very hot during operation. Allow the oil to
cool before working on the hydraulic system.
WARNING!
Hot surface
Equipment and hoses/pipes containing hydraulic oil can have hotsurfaces. Always wear protective gloves.
WARNING!
Skid risk
When filling, controlling or changing oil there is a risk of spillage thatcan cause a slippery surface. Always remove oil spillage and stains
to avoid skid risk.
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2.2.6 Lubrication system
When changing from mineral oil to synthetic oil, or if the oil has coked,
the tank unit must be thoroughly cleaned. Contact Sandvik SRP AB forfurther instructions.
CAUTION! Make sure all defective hoses, valves or fittings are checked, repairedand replaced before starting the equipment.
WARNING!
Oil pressure
Pressurized oil is dangerous if released incorrectly. Relieve allpressure before carrying out maintenance or repair work on the
hydraulic system.
WARNING!
Hot oilLubrication oil can become very hot during operation. Allow the oil to
cool before working on the lubrication system.
WARNING!
Hot surface
Equipment and hoses/pipes containing lubrication oil can have hotsurfaces. Always wear protective gloves.
WARNING!
Skid riskWhen filling, controlling or changing oil there is a risk of spillage that
can cause a slippery surface. Always remove oil spillage and stainsto avoid skid risk.
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2.2.7 Lubricants and waste lubricants
CAUTION! Handle all lubricants and waste lubricants with care and according to
the suppliers Material Safety Data Sheet (MSDS)and local regulations.
Collect waste lubricants in suitable containers and dispose asrecommended in the MSDSand according to local regulations.
2.2.8 Diesel oil, white spirit and other cleaning agents
It is recommended to clean the tank and the tank units parts with diesel oil.
Use white spirit only if it is necessary.
CAUTION! If white spirit is used for cleaning, wipe it off carefully and allow it toevaporate before pouring oil into the cleaned compartments.
CAUTION! Handle all cleaning agents and their waste with care and according tothe suppliers Material Safety Data Sheet (MSDS)and local regulations.
Collect the waste in suitable containers and dispose as recommendedin the MSDSand according to local regulations.
WARNING!
Toxic substances
Read the suppliers Material Safety Data Sheet (MSDS). Used and
contaminated oil can be a health hazard. Use protective gloves andgoggles.
WARNING!
Skid riskWhen filling, controlling or changing oil there is a risk of spillage thatcan cause a slippery surface. Always remove oil spillage and stains to
avoid skid risk.
WARNING!
Health hazardBefore you use a cleaning agent, read the suppliers Material Safety
Data Sheet (MSDS)and follow the instructions carefully. Risk ofserious injuries to eyes, skin, respiratory system etc. Use personalprotection and other safety measures as recommended in the MSDS.
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2.2.9 Lifting and moving loads
CAUTION! Only personnel with adequate lifting training are permitted to perform
lifting operations.
Make sure that the capacity of the lifting equipment (Working Load Limit,
WLL)is adequate and that the lifting equipment is in good working order.
If lifting tackle has to be made up by joining separate components, make sure
that the joints are secure and have the same lifting capacity (Working Load
Limit, WLL)as the rest of the tackle.
Always engage the safety clips on lifting hooks to prevent the tackle from
slipping off.
Use ropes or poles to steady and maneuver loads. Neveruse hands or feet.
Make sure that the route and the destination are free from obstacles before
moving a suspended load. It must be possible to quickly and safely lower the
load to the ground in case of an emergency.
When depositing loads, keep the lifting equipment in place until it has been
made sure that the load is stable.
2.3 Emissions
For emissions such as dust, noise and radioactivity in the tank units
environment, seesection 2. Safety precautions in the crushers manuals.
DANGER!
Hanging loadNever work or stand underneath a crane that is lifting material. Keep asafe distance to hanging loads.
NOTE! Always use lifting tackle certified in accordance with local conditions.
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3. Installation preparationsTo ensure maximum safety, always readsection 2. Safety precautionsbefore
carrying out any work on the equipment or making any adjustments.
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3.1 General
Check that the dimensions of the installation site and the positions of the
connections comply with the installation drawings in theInstallation Manual
Appendixand with any site-specific installation drawings. If the site does not
meet the specifications, please contact Sandvik SRPAB for guidance and
customizing.
Check that the oil tank unit meets the local legislation demands. In case of
doubt, please consult local authorities or local authorized personnel.
Prepare the installation site as much as possible by installing electricity and
water supply, foundation etc. before starting the main installation.Use the check list insection 3.2 Installation preparations check listas a
guide and for documenting the installation procedure.
NOTE! Make sure that the required service area at the site matches the requirements
in the installation drawings, and that the installation area is accessible for
spare and wear part delivery.
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3.2 Installation preparations check list
System Checks Remarks Date/sign
Placement Site access checked for oil tank unit
dimensions?
Smallest area that the oil tank unit
components must pass through?
(W H)
Available service area?
(L W H)
Available lifting device on site? Type:
Length of oil hoses and pipes?
Foundation
(if needed)
Foundation constructed according to
drawings?
Electrical system All necessary cables arranged to the
oil tank unit?Cable lengths?
All necessary switchgear installed?
All necessary connections to plant
control system arranged?
Electrical power available?
Guards Need for additional guards?
Platforms and
guard rails
Comply with local regulations?
Designed so they do not interfere with
crushers or tank units function?
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3.3 Placement
Place the tank unit as close to the cone crusher as possible. Excessively long
oil lines as well as many or sharp bends will increase the flow friction and
lower the performance.
Place the tank unit below the level of the cone crusher. Return oil must runback to the oil tank unit and be pumped to the cone crusher. Seesection
5.4.1 Oil tank unitand installation drawings in theInstallation Manual
Appendix.
Place the overpressure fan or air regulator for compressed air above the
connection to the pinionshaft housing. This to prevent oil from running into
the overpressure system. Seesection 5.5 Overpressure systemand
installation drawings in theInstallation Manual Appendix.
(Continued)
4
1 3
2
1 Crusher
2 Oil tank unit
3 Overpressure fan or regulator
for compressed air
4 Pinionshaft
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Place the oil tank unit so that it is easily accessible for operation, service and
maintenance but protected against damage and unauthorized access.
Make sure that there is sufficient room to drain out all oil.
Make sure that all requirements for the service area are met as shown in the
installation drawings in theInstallation Manual Appendix. If possible, mark
the limits of the service area with paint. Note the dimensions of the actual
service area in the check list.
Make sure that there is access to a lifting device meeting the requirements in
section 4. Transport handling. Note the available type of lifting device in the
check list.
3.3.1 Electrical installation
Make sure that all local and site-specific requirements for electrical
installations are fulfilled.
External cables, disconnecting switches and fuses must be ordered before
installation. Seesection 6. Electrical installationand the electrical drawings
in theInstallation Manual Appendix.
Contact Sandvik for further information about cables, switches and fuses.
3.3.2 Remote control system
At most sites a main control system is used to control the process. Make sure
that the control system is prepared for the addition of the tank.
3.3.3 Guard
The oil tank unit have two moving parts covered with guards, the pump P1
connected to the motorM2 and the fan connected to the motorM3 on the air/
oil cooler.
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3.4 Operating in low temperatures
The following section describes recommended methods for reliable
operation in low temperature.
The accompanying flow chart (section 3.4.2 Low temperature problems symptoms and remedies) can be used to determine which method to use.
3.4.1 Measures for easier starting and running in cold
climate
The following methods will increase the oil flow at low temperatures. The
order in which these methods are applied should be judged in each individualcase. A combination of several methods may be necessary.
Part numbers for ordering the modification kits are listed under the
respective methods.
Heating cables on oil lines
Additional oil heaters
Diesel heating system
Heating in the component section of the oil tank unit
Synthetic oils Mineral oil for the winter season
Blanking off the oil cooler radiator
Two-speed fan motor for oil cooler or a frequency converter
Insulation of the oil tank
Continuous running of the lubrication oil pump
A cone crusher that is fitted with low temperature equipment will normally
be equipped with:
Additional oil heaters
Insulated bottom in the component section of the oil tank unit
NOTE! If it is difficult to start the crusher even when the appropriate
recommendations have been followed, contact Sandvik for further
assistance.
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3.4.2 Low temperature problems
symptoms and remedies
Start
Oil returns to the tank, butnot in sufficient quantity.Wait 3.5 min. to drain thecrusher and then make anew attempt to start up.
Start the oil pump. Doesthe Crusher ready forstart signal appear within40 s?
There is a blockage in thereturn oil line. Clean out theblockage. If necessary,install heating cables on thereturn oil line. Does the oilflow back to the tank?
Has the crusher startedand continued to runnormally?
Start crushing when thecrusher has warmed up.
Stop the oil pump. Has oilrun back through the oil lineto the return oil flow switch?
Does the crusher stopdue to interruptions inreturn oil flow?
The ambient air tempera-ture is too low, whichmakes the oil cooler tooeffective. The oil isslowed down and blocksthe passages in the radi-ator coil!Blank off the radiator
completely or partially.Start with 50% blankedoff.
Alternatively, installa frequency converter ora two-speed motor to thecooling fan.
Has oil overflowed over thedust collar?
During long periods withvery low temperatures,the crusher should beheated during the nightto avoid excessivecooling. Position a fanheater beneath thecrusher and cover thefeed opening. In addition,the lubrication oil pumpshould be run continu-ously.
Under very low tempera-
tures the radiator coilcan be thawed out witha fan heater.
Install low temperatureequipment in the tank.(Heating in componentsection and insulated tankbottom.) Does oil flow backto the tank?
Change to synthetic oil.Does oil flow back to thetank?
Install heating cables on theoil lines. Does oil flow backto the tank?
Insulate the oil tank. Doesoil flow back to the tank?
Sometimes it can be advis-able to run the lubrication oilpump continuously to mini-mize starting problems
No
Yes
Alternatively, use an ISOVG 100 oil.
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3.4.3 Heater set - cold climate
In order to heat the oil to the correct temperature, it can be necessary to
install extra heaters. Installation is easiest if this equipment is ordered
together with a new crusher, but extra heaters can also be fitted in the tanks
of older crushers.
The component section of the oil tank unit is normally open at the bottom to
provide good ventilation and cooling of the oil pumps. In a cold climate it
might be necessary to insulate the tank to keep the oil at working temperature
and prevent pressure drop.
Modification kit
Modification kit Description Voltage (V) Rating (W) Connection
diagram
452.5370-901 Heaters and insulationfor a cold climate
Position number
1(2 )
Heater element 265/460240/415220/400
221902178521500
3.194.0191
2 Insulation3 Cable set - cold climate
1
132
1 Heater element - cold climate
2 Bottom plate insulated
3 Cable set - cold climate (not visible)
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3.4.4 Diesel heating system
In plants without 24-hour electrical power, a timer-controlled diesel heating
system can be used. The system starts heating the oil up to three hours before
electrical power is available.
The tank unit is prepared for diesel heating.
The diesel heating system uses a 12 V DC supply.
3.4.5 Heating cables on oil lines
See installation drawings in theInstallation Manual Appendix.
At low temperatures, the oil in the lines between the tank unit and the crusher
can solidify and block the lines. This problem can be minimized byinsulating the oil lines and installing heating cables.
It is preferable to use a heating cable of the self-regulating type which needs
no thermostat. The heating cable should have a rating of 810 W/m and
40 mm (1.6") insulation.
Install the heating cable on the underside of the oil line and use insulating
tape to keep the cable in place. If possible, increase the slope of the return oil
line before installing heating cables.
If the oil lines are >50 mm (2") in diameter, or if the oil need be heated to a
temperature 50 C (122 F) above the ambient temperature, the heating cablecan be led backwards and forwards on the same line.
Heating cables are in many countries considered as high voltage equipment
and must therefore be installed by an authorized electrician. The heating
cable can be purchased from a local supplier who can usually also install it.
Heating cable is normally supplied for 230 V.
Modification kit
452.5388-901
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3.4.6 Heating in the component section of the oil tank
unit
Extra heating in the tank unit can be provided by a standard fan heater with a
rating of about 600 W. The fan heater must have a thermostat which prevents
overheating.
CAUTION! Position the fan heater so that oil cannot drip onto it.
Sandvik does not supply modification kits with fan heaters. Select a suitable
fan heater from any supplier.
3.4.7 Synthetic oils
Synthetic oils will allow for trouble-free starting at about 10C lower
temperature than a mineral-based oil, and are in all respects superior to
mineral-based oils:
Longer change intervals due to high stability
Easier starting at low temperature
Lower energy consumption due to lower friction
Wider temperature range
No oxidation and coking
The synthetic oil shall meet the same requirements as for mineral oil. See the
text and the table for mineral oil in the Operators and Maintenance Manual
for the oil tank unit.
(Continued)
Skid risk
When filling, controlling or changing oil there is a risk of spillage thatcan cause a slippery surface. Always remove oil spillage and stains
to avoid skid risk.
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The following synthetic oils are recommended by Sandvik for the lubricating
system. Other brands can be used after consulting the supplier.
The recommended synthetic oils can be mixed with mineral-based oils, but
should be diluted as little as possible. Empty the crusher and oil tank
carefully before refilling with synthetic oil. For further information, see the
Operators and Maintenance Manualfor the tank unit.
To reduce the risk of dilution of a synthetic lubricating oil, the Hydroset oil
should also be synthetic. A grade with a viscosity down to 30 cSt at 40 C
can be selected for the Hydroset system.
CAUTION! It must be possible to mix the lubricating and Hydroset oils used in the
crusher. Consult the oil supplier if in doubt.
The following synthetic oils are recommended by Sandvik for the Hydroset
system. Other brands can be used after consulting the supplier.
3.4.8 Mineral oil for the winter season
In ambient temperatures below 0 C (32 F), an ISO VG 100 oil can be used.
CAUTION! Handle all oil and waste oil with care and according to the suppliersMaterial Safety Data Sheet (MSDS)and local regulations. Collect the
waste in suitable containers and dispose as recommended in the MSDSand according to local regulations.
Brand Type Minimum pour point Viscosity (cSt) at 40 C
Mobil oil SHC XMP 150 -48 C 150
Brand Type Minimum pour point Viscosity (cSt) at 40 C
Mobil oil SHC 626 -51 C 68
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3.4.9 Blanking off the oil cooler radiator
If the cooling fan on the air/oil cooler is started at low ambient temperature,
the pressure drop across the cooler will cause the by-pass valve CV4on the
cooler to open. The oil is then not cooled at all and can overheat.
The easiest way to avoid this is to blank off the radiator so that less air passesthrough the radiator matrix. The degree of blanking depends on the ambient
temperature and must be determined by trial-and-error.
3.4.10 Frequency converter
To reduce the air flow through the radiator, a frequency converter for the oil
cooling fan can be used.
For further information about the frequency converter, please contact
Sandvik
3.4.11 Two-speed fan motor for oil coolerAnother way to reduce the air flow through the radiator is to use a two-speed
motor on the cooling fan. The speed of the cooling fan is determined by the
oil temperature in the return line.
Examples of switching points with ISO VG 150 oil:
Return oil temperature Cooling fan
Rising oil temperature 43 C (109 F) The fan starts at low speed
4346 C (109-115 F) Runs at low speed
Over 46 C (115 F) Runs at high speed
Falling oil temperature Over 43 C (109 F) Runs at high speed
4340 C (109-104 F) Runs at low speed
40 C (104 F) The fan stops
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3.4.12 Insulation of the oil tank
Insulating the oil tank will reduce the overnight drop in oil temperature at
low ambient temperatures. In warmer weather the insulation should be
removed to prevent overheating.
Insulation can easily be installed by the plant personnel. A suitable materialis PAROC Pro Slab 35, 50 mm (2") thick. The insulation material must be
protected from moisture, as it will otherwise lose its insulating properties.
Insulation kits are not supplied by Sandvik.
3.4.13 Continuous running of the lubrication oil pump
Running the oil pump continuously while the cone crusher is stopped will
prevent the oil from solidifying in the lines and crusher.
Leave the oil tank heaters switched on. Cover the crushers feed opening to
prevent excessive cooling by cold air passing through the crusher chamber.
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4. Transport handlingTo ensure maximum safety, always readsection 2. Safety precautionsbefore
carrying out any work on the equipment or making any adjustments.
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4.1 Goods data
The oil tank unit is delivered as a complete assembled unit. Auxiliary and
optional equipment is delivered in separate packages.
Some basic measurements are given in the table below to indicate the spacerequired by the equipment during transportation. The number of packages
delivered may vary depending on the oil tank variant and equipment.
4.1.1 Contents
A Package Inventory List is attached to one of the packages in the delivery.
Part name Mass
kg (lbs)
Measurements L W H
mm (")
Tank unit 400 (800) 1350 950 900 (53.2 37.4 35.5)
Air/oil cooler 150(330) 1000 800 700 (40 27.6 23.6)
Water/oil cooler (option) 100 (220) 300 300 700 (20 11.9 27.6)
NOTE! If the tank is collected from the factory, check before transport that the
equipment corresponds with the items in the Package Inventory List.
If the tank is delivered by Sandvik either to a harbour or to the work site,
check immediately after arrival that the equipment corresponds with the
items in the Package Inventory List.
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4.1.2 Loading and unloading goods signs
Make sure that the handling personnel understand and follow the mandatory
and warning symbols used on the packages.
Use the forks here Overhead lifting point
Center of gravity Lifting point for chain
NOTE! Maximum load for both lifting eyes and lifting angles are shown in the
installation drawings in the Installation Manual Appendix.
885.0260-00
885.0250-00
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4.2 Lifting equipment
Different types of lifting equipment
The following types of equipment can be used to lift and move the goods:
overhead gantry
mobile crane
fork lift (use only for goods on pallet/platform)
Equipment specifications
Make sure that the lifting capacities of the equipment and tackle comply with
the minimum values given in the following table.
NOTE! Lifting with fork lift without a pallet or a platform may damage the goods.
NOTE! The lifting capacity of a mobile crane varies with the lifting radius. Make
sure that the lifting capacity is sufficient at the appropriate lifting radius.
Equipment or tackle Lifting capacity
kg (lbs)
Overhead gantry 500 (1200)
Mobile crane 500 (1200)
Lifting chains, cables, ropes or slings 500 (1200)
Fork lift (only for goods on pallet/platform) 500 (1200)
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4.2.1 Overhead gantry or mobile crane
The following instructions apply to this oil tank unit.
a) Make sure that the lifting chains, hooks and other equipment are in a
good state, and attended to according to instructions from the
manufacturer.
b) Make sure that the lifting chains have the correct lengths for the angle
from the vertical in which they are to be used.
c) Make sure that the lifting equipment has a sufficient WLL (Working
Load Limit) for the weight to be lifted and for the method of lifting.
d) Follow the applicable lifting standard for the equipment used.
e) Place the lifting equipment according to the symbols found insection
4.1.2 Loading and unloading goods signs
f) Check that the load lies against the saddles of the hooks. Never put load
on the tip of a hook.
g) Slowly take up the slack in the lifting chains. Make sure that the hooks
are secure in the lifting eyes of the component. If necessary, adjust the
chains to distribute the load evenly.
h) Check that the chains can straighten out correctly. Never lift with atwisted chain.
i) Make sure that the destination is clear and able to support the weight
before lifting.
j) Lift, move and lower the load carefully and calmly. Avoid twitches and
jerks.
k) Never use hands or feet to guide the load. Keep clear of the load.
DANGER!
Hanging load
Keep clear of hanging loads. Seesection 2. Safety precautions.Check the gross weight of the components to be lifted and make sure
the WLL (Working Load Limit) of the lifting equipment is sufficient forthe weight to be lifted.
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4.2.2 Using a fork lift (only for goods on pallet)
The following instructions apply to this oil tank unit.
CAUTION! Always use the lifting eyes mounted on the top of the oil tank unit and
a suitable lifting sling or similar when lifting the oil tank unit withoutpallet/platform, see the installation drawings in the Installation Manual
Appendix.
The oil tank unit must be placed on a pallet/platform when lifted with a fork
lift.
a) Make sure that the forks are of the correct length and lifting capacity for
the oil tank unit on its transport pallet/platform.
b) Set the lifting forks to the correct width for lifting the load from the side.
c) Make sure that the load is firmly attached to the transport pallet/
platform.
d) If the transport platform of the component is fitted with fork tubes,
manoeuvre the forks inside these to lift the component.
e) Make sure that the destination is clear and able to support the weight
before lifting.
f) Lift and move the load carefully and calmly.
g) Lower the load gently to the floor.
DANGER!
Hanging load
Keep clear of hanging loads. Seesection 2. Safety precautions.Check the gross weight of the components to be lifted and make sure
the WLL (Working Load Limit) of the lifting equipment is sufficient forthe weight to be lifted.
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4.3 Unloading the goods
4.3.1 Unpacking area
The unpacking area should have approximately 1.5 m (5 ft) of free space
around and above the tank.
4.3.2 Inspection of goods
Inspect the outside and wrapping of the packages before unloading. Report
any damage immediately to the person responsible for the installation.
If the damage is severe enough to prevent installation, submit a damage
claim to the transport company without delay. If possible, document thedamage with a camera.
Minimum recommended unpacking area L W H
CTHS430 3 2.5 2.5 m (10 8.2 8.2 ft)
NOTE! If damage has occurred during transport, report this immediately also to the
Sandvik shipping department. The address is found on thePackage
Inventory List.
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4.4 Moving and Storage
Important notes
If the oil tank must be stored before installation, make sure that the storage
area meets the requirements insection 4.4.2 Storage.If possible, place the oil tank unit at the installation site before unpacking.
Do not unpack the components until immediately before starting installation.
Position the packages on the installation site so that the oil tank unit can be
lifted out and installed without being turned around.
When lifting, follow the instructions insection 4.2 Lifting equipment.
4.4.1 Moving
a) Attach the lifting equipment according to the instructions insection
4.2 Lifting equipmentand the drawings in theInstallation Manual
Appendix.
b) Remove any screws holding the transport platform to the component.
c) Lift the component only enough to clear the floor.d) Make sure that the component remains stable on the lifting equipment.
e) Check that the transport platform has come loose from the oil tank unit.
f) Move the load into position.
g) Lower it gently to the floor. Leave enough room for access to all sides.
h) Make sure that the component is firmly supported.
i) Remove the lifting equipment.
4.4.2 Storage
CAUTION! Sandvik recommends storing the oil tank unit indoors. Long-term
exposure to moisture or very high or low temperatures may damage thetank.
WARNING!
Hanging loadKeep clear of hanging loads. Seesection 2. Safety precautions.Check the gross weight of the components to be lifted and make surethat the WLL (Working Load Limit) of the lifting equipment is sufficient
for the weight to be lifted.
WARNING!
Hanging load
Keep clear of hanging loads. Seesection 2. Safety precautions.Check the gross weight of the components to be lifted and make surethat the WLL (Working Load Limit) of the lifting equipment is sufficient
for the weight to be lifted.
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a) Prepare a storage area large enough to store the components with at least
1.5 m (5 ft) of free space around and above for access and ventilation.
b) Make sure that the storage area environment meets the conditions in the
table below:
c) Lift the components into position according to the instructions insection
4.4.1 Moving. If the ground/floor is uneven, place blocks or plates under
the components to provide a steady support.
d) Make sure that the components are stable before removing the lifting
equipment.
Characteristic Value Notes
Minmax temperatures 540 C (41104 F)
Max relative humidity 80% Non-condensing
NOTE! Before delivery from the factory, the oil tank unit is wrapped with rust
preventative materials sufficient for approximately one year of storage.
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4.5 Unpacking the goods
a) Remove any loose boxes and packages before unpacking the main
components.
b) Unpack and check each item against the Package Inventory List.
c) Check the unpacked components and accessories for damage. In case of
damage, send a transport damage report to Sandvik.
See alsosection 4.3.2 Inspection of goods.
d) Open the crushers tool box and take out the documentation.
e) Locate the Package Inventory List.
f) Check that the data on the oil tank unit identification plate corresponds
with the Package Inventory List. Seesection 1.1 Equipment
information.
g) Move spare and wear parts to the spare part store.
h) Dispose of the packaging material according to the instructions in
section 4.6 Disposal/return of packaging material.
WARNING!
Hanging load
Keep clear of hanging loads. Seesection 2. Safety precautions.
Check the gross weight of the components to be lifted and make surethat the WLL (Working Load Limit) of the lifting equipment is sufficient
for the weight to be lifted.
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4.6 Disposal/return of packaging material
The packaging material includes all pallets, crates, wrapping, boxes and
other protective material that are not part of the equipment. Packaging is
normally not returned to the manufacturer. Check if there is a special agreement for the return of the packaging to
the manufacturer.
If the packaging must be returned, prepare an area to store pallets,
transport racks and any other returnable packaging.
Check if there is a special arrangement for recycling packaging material.
If the packaging is not to be returned or recycled, check with the local
authorities how to separate and dispose of packaging material.
Dispose of pollutant waste (bubble wrapping, plastic bags, expanded
polystyrene, etc.) in accordance with local regulations.
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5. Mechanical installation and
connectionsTo ensure maximum safety, always readsection 2. Safety precautionsbefore
carrying out any work on the equipment or making any adjustments.
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5.1 General requirements
Personnel
Only qualified installation personnel are authorized to install the oil tank
unit. Seesection 2. Safety precautionsfor a definition of installationpersonnel.
The installation area
a) Clear the installation site. If necessary, clean the ground before starting
the installation.
b) Make sure that there is sufficient room to move safely around the
installation, for further information, see theInstallation Manual
Appendix.
If any adjacent machines on the site cannot be stopped, take measures to
prevent accidental contact.
c) Make sure that lighting on the installation site is adequate. Use
additional portable lights if necessary.
Lifting equipment, tools and materials
The equipment used for lifting and moving the components can also be used
for unpacking and installing the oil tank unit.
Seesection 4.2 Lifting equipment.
Packing
Leave wrapping and ties on the parts until they are ready for use.
Leave the plastic plugs in the oil line openings until they are ready to be
connected, but do not forgetto remove them before connecting the pipes.
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5.2 Foundation
The oil tank unit might need an adequately dimensioned foundation. Sandvik
recommends a steel supporting structure or a concrete foundation.
A steel supporting structure or a transportable frame must be mountedhorizontally and rest on a firm ground. If the oil tank unit is not sufficiently
stable the supporting structure will vibrate and be subjected to stresses.
For general information on placement, seesection 3.3 Placement.
5.3 Hydroset and lubrication systems
Oil is supplied to the crusher through two lines one two-way line from the
Hydroset cylinder and one to the main lubrication system.
The pinionshaft is lubricated in an oil bath in the pinionshaft housing.
The oil returns to the oil tank unit through two lines the Hydroset two-way
line and the main lubrication return oil line.
For general information on placement, seesection 3.3 Placement.
NOTE! The oil tank unit can be installed on either side of the crusher. This is
important to decide before the foundation is designed.
For further information, see the Installation Manual Appendix.
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5.4 Hoses and pipes General
Route all pipes and/or hoses to and from the crusher along the same path.
All pipes and/or hoses to and from the crusher must be carefully sealed and
tightened to avoid leakage and prevent the pipes/hoses to come loose from
the connections.
The inclination of return lines is critical. Seesection 5.4.1 Oil tank unit.
For a description of hoses, pipes and connections on the tank unit and
crusher, see theInstallation Manual Appendix.
5.4.1 Oil tank unit
a) Install the tank unit in a suitable location.
See alsosection 3.3 Placementandsection 4. Transport handling.
(Continued)
NOTE! Pipes are not supplied by Sandvik.
NOTE! When starting the pumps the first time, make sure there are no leakages.
If there are leakages, use a suitable compound to seal.
WARNING!
Hanging load
Keep clear of hanging loads. Seesection 2. Safety precautions.The oil tank unit without cooler weighs approx. 310 kg (700 lbs).
Make sure that the WLL (Working Load Limit) of the lifting equipmentis sufficient for the load.
NOTE! The tank unit must be placed below the level of the cone crusher.
L
L Return oil hose
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b) Connect the oil lines to the tank unit, see theInstallation Manual
Appendix.
Make sure that there are no kinks in the return oil hoses/pipes.
Avoid pipe elbows. Use large-radius pipe bends instead to reduce
resistance in the piping.
Run the piping so that it is protected against falling stones.
Make sure that the piping is securely supported to avoid vibration. Make sure that the piping is free from burrs, metal shavings and dirt
before it is connected to the crusher and tank unit.
Use normal water piping and hoses for lubrication oil lines.
c) Inspect and clean the lubrication oil tank.
Hydroset connections
a) Connect the Hydroset oil line to the oil tank unit with high-pressure
piping or hoses.
Minimum pressure rating: 8 MPa (1160 psi).
Make sure that there are no kinks in the oil hoses/pipes. If pipes are used, avoid pipe elbows. Use large-radius pipe bends
instead to reduce resistance in the piping.
Run the piping so that it is protected against falling stones.
Make sure that the piping is securely supported to avoid vibration.
Make sure that the piping is free from burrs, metal shavings and dirt
before it is connected to the crusher and tank unit.
b) Inspect and clean the Hydroset tank.
Distance tank crusher Inclination of return oil hose
< 3 m (10 ft) 5
> 3 m (10 ft) 10
NOTE! The connections are already fitted to the crusher. Pipes and pipe fittings are
not supplied by Sandvik.
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5.4.2 Air/oil cooler
For further information, see theInstallation Manual Appendix.
CAUTION! If the crusher is installed at high altitude and/or extremely high or low
ambient air temperature, a special cooling system is required.
The air/oil cooler can be installed directly on the oil tank unit or in a suitable
place close to it. Piping and hoses can be used to connect to the tank unit.
Hoses must always be fitted to the cooler.
If the ambient air contains a lot of dust, it is advisable to lead fresh air to the
cooler through a duct from a dust-free place. The duct must be correctly
dimensioned so that air flow is not restricted, and it must not be rigidly
connected to the air/oil cooler.
To reduce the amount of dust which settles in the radiator matrix, the air/oilcooler is best placed so that the fan blows towards the crusher.
A by-pass valve CV4is fitted on the air/oil cooler. Its duty is to limit the
pressure over the pump and coolers if the crusher is started at low
temperatures.
a) Install the air/oil cooler on or close to the tank unit.
b) Connect the hoses to the cooler.
c) Connect piping or hoses to the tank unit.
NOTE! The cooler and the piping must be shielded from direct sunlight.
NOTE! Pipes and pipe fittings are not supplied by Sandvik.
CV4
Air flow
CV4 By- pass valve
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5.4.3 Water/oil cooler (option)
See also the drawing in theInstallation Manual Appendix.
a) Connect water piping or hoses to the cooler. This must be arranged at the
site to suit local conditions.
b) Set the temperature switch TS2to the correct value.
For further information about temperature switches, see the Operators and
Maintenance Manual for the tank unit.
The supply of cooling water is controlled by temperature switch TS4.
The values on its scale correspond to the following oil temperatures:
c) Set the temperature switch TS4to 3 on the scale to keep the oil at
43 C (109 F).
NOTE! Pipes, water pump and pipe fittings are not supplied by Sandvik.
NOTE! Use clean fresh water. If only contaminated water is available, contact
Sandvik first!
NOTE! When a water/oil cooler is used, the temperature switches should be set atthe values for Normal Operating Conditions regardless of the ambient
temperature. For further information, see the Operators and Maintenance
Manual for the tank unit.
Value on scale Oil temperature
1 25 C (77 F)
2 32 C (90 F)
3 43 C (109 F)
4 57 C (135 F)
5 65 C (149 F)
TS2
J
O
V
U
TS4 TS4J Water in
O Water out
U Oil from tank
V Oil to crusher
TS2 Temperature
switch- return oil
TS4 Temperature switch
AVTA 25
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5.5 Overpressure system
The cone crusher and the tank unit are equipped with a common
overpressure system to prevent dust from entering the cone crusher or the oil
tank and contaminating the oil. A correctly functioning overpressure system
is important for the performance of the crusher.
(Continued)
Minimum and maximum length of hoses 215 m (750 ft)
Minimum and maximum pressure 6001000 Pa (0.0870.145psi)
Minimum blower capacity at 600 Pa0.3 m
3
/min (793 US gall./min)
NOTE! Hoses, pipes and pipe fittings are not supplied by Sandvik.
C C
C
PF
M8
FU5
1
1
2
2
1
1
P
P
C
C
FV6FU6
P
1 Hoses
2 Coupling to the air supplier
FU5Air filter
PF Fan
M8 Motor to fan
FV6Compressed air regulator
FU6Filter to air regulator
P Coupling to the oil tank unit
C Coupling to the pinionshaft housing
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Normally the system consists of two hoses and an air supplier. The air
supplier is a fan or a regulator with filter connected to a compressed air
system.
The hoses are joined in a T-connector on the pinionshaft housing. The length
of the hoses depends on the position of the air supplier and the tank.
For detailed drawings, see theInstallation Manual Appendix.
a) Install the fan or the regulator with filter
The fan can be mounted horizontally or vertically.
When the fan motor is connected, check that the direction of rotation is
the same as shown by the arrow on the fan housing. If the rotation isnt
correct, the output of the fan will be insufficient.
CAUTION! It is important to install the fan in a dust free environment. Dust willdamage the blower and result in malfunction of the cone crusher.
The regulator FV6with filter FU6must be mounted horizontally and if
it is possible, they should be installed in a heated space.
b) Measure the hose length between the air suppliers coupling (2) and the
T-connection Con the pinionshaft.
Measure the hose length between the T-connection Con the pinionshaft
and the tank overpressure coupling P.
c) Cut the appropriate lengths from the hose coil supplied with the oil tank
unit.
d) Connect one hose (1) between the air suppliers coupling (2) and the T-
connection C on the pinionshaft housing. Use hose clamps.
e) Connect the other hose (1) between the tank overpressure coupling P and
the T-coupling Con the pinionshaft housing. Use hose clamps.
NOTE! Air introduced into the crusher and the tank must be free from moisture and
dust.
NOTE! Install the fan or the regulator at least 0.5 m (20") above the tank and the
pinionshaft to prevent oil from running into them.
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5.6 Lubricants
Fill the required amount of oil into the tanks.
For further information about lubricants and lubrication, see the Operators
and Maintenance Manual.
Keep some extra oil within easy reach. It may be necessary to add some after
start-up due to the length of the hoses.
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6. Electrical installationTo ensure maximum safety, always readsection 2. Safety precautionsbefore
carrying out any work on the equipment or making any adjustments.
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IM Sandvik CTHS430:02 Tank unit 6. Electrical installation
6.1 General requirements
Electricians
Electricians should be certified according to local regulations and have
experience of similar types of installations, proven skills in reading andworking from drawings and cable lists, and knowledge of local safety
regulations regarding power and automation circuits. Work with electrical
equipment must be performed only by skilled or instructed technicians.
For further information, seesection 2. Safety precautions.
6.2 Overview
Electrical drawings are included in theInstallation Manual Appendix.
The purpose of the electrical system is to power the cone crusher with itsauxiliary systems and to control the operation.
If in any doubt about the connection, testing and operation of the electrical
equipment, please contact Sandvik SRP AB.
Connections for pump motors and other equipment are routed through
connection box L9 on the oil tank unit. The air/oil cooler fan and
overpressure air fan motors are connected directly.
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6.3 Motors and heating elements
Starting equipment for the oil tank pumps/motors and heating elements are
normally not part of the supply from Sandvik. Fuses, relays, motor protectors
and control units must be installed in the appropriate switch gear cabinets.
6.3.1 M2 Main lubrication pump
The power supply to the motor must incorporate the necessary fuse, relay
and motor protector, all installed in an electrical cabinet. Starting and
stopping can be made possible either by buttons or via software.
6.3.2 M3 Oil cooler fan motor
Every crusher has an air/oil or water/oil (option) cooler in the lubrication
system. The temperature is controlled by a temperature switch TS2. The
power supply to each air/oil cooler motor must incorporate the necessary
fuse, relay and motor protection built into an appropriate switch gear cabinet.
With a water/oil cooler it can be convenient to open/close the cooling water
supply with a magnetic valve.
For further information about temperature switches, see the Operators and
Maintenance Manualfor the tank unit.
6.3.3 M6 Hydroset pump
Starting and control equipment for the Hydroset pump is normally delivered
by Sandvik. The delivered electrical cabinet L3contains fuses, relays and
motor protection for operation of the Hydroset pump.
6.3.4 E7 Oil heaters
The power supply to the oil heaters must incorporate the necessary fuse,
relay and motor protection built into an appropriate switch gear cabinet.
The temperature is controlled by a temperature switch TS3.
6.3.5 M8 Overpressure fan
The power supply to the overpressure fan must incorporate the necessary
fuse, relay and motor protection built into an appropriate switch gear cabinet.
NOTE! The crusher drive motorsM1 relaymust be interlocked with the main
lubrication pump motorM2, so it is only possible to run the crusher when
the lubrication pumpM2is in operation.
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6.4 Connection boxes
L9
ASRi-
CBT
L9 Connection box, motor power ASRi-CBT ASRi connection box
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7. Final installation checksTo ensure maximum safety, always readsection 2. Safety precautionsbefore
carrying out any work on the equipment or making any adjustments.
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IM Sandvik CTHS430:02 Tank unit 7. Final installation checks
7.1 Installation and connection checks
Seesection 5. Mechanical installation and connectionsfor further details on
the following checks.
7.1.1 Lubrication system and Hydroset checks
7.2 Electrical checks
Seesection 5. Mechanical installation and connectionsfor further details on
the following checks.
(Continued)
No. Checks Done
1 Brand name and type of oil and grease are recorded.
2 The oil tank unit is placed in relation to cone crusher according to
instruction and is properly installed.
3 The Hydroset and lubrication systems are correctly installed.
4 Air/oil or water/oil (option) cooler is installed properly.
5 Piping and hosing has been installed according to the
recommendations in this manual.
No. Checks Done
1 All electric cables are correctly connected.
2 All motors have the correct rotation direction.
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7.2.1 Check the pressure switch PS2
The pressure switch PS2is of normally open (NO) type. This means that if
the pressure switch malfunction it will not indicate, the need for oil filter
exchange. Perform this check with the power on but pumps and crusher off.
a) Locate the pressure switch PS2.
b) Remove the clip (1) on top of the pressure switch.
c) Remove the pressure switch PS2by pulling it straight up from the oil
filter assembly FU1.
d) Turn the pressure switch PS2upside down and position the pressure
switch back on the tube. The pressure drop warning lamp H10 on the
front panel will light up if the pressure switch works.Turn the pressure
switch PS2back to its normal position.
e) Fit the clip (1) on top of the pressure switch PS2.
WARNING!
Hot oilLubrication oil can become very hot during operation. Allow the oil to
cool before working on the lubrication system.Always wear protective gloves.
PS2H10
FU1
1
1 Clip
PS2 Pressure switch - main lubrication
FU1 Filter unit - main lubrication
H10 Pressure drop warning lamp -
main lubrication
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IM Sandvik CTHS430:02 Tank unit 7. Final installation checks
7.3 Safety checks
7.4 Start-up
No. Checks Done
1 All threaded fasteners have been tightened to the correct torque.
No. Checks Done
1 Prepare the oil tank unit for production.
See the Operators and Maintenance Manualfor further details.
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8. Preparations for
commissioningTo ensure maximum safety, always readsection 2. Safety precautionsbefore
carrying out any work on the equipment or making any adjustments.
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IM Sandvik CTHS430:02 Tank unit 8. Preparations for commissioning
8.1 General
Perform the following checks even if an actual commissioning test is not
required.
8.2 Presence and correctness checks
8.3 Supply value checks
NOTE! Commissioning covers only the functioning of the individual machine.A line performance test is still required to check the functioning of the oil
tank unit as part of a complete production line. Contact the local service
organization about arrangements for a line performance test.
No. Checks Done
1 The data on the oil tank unit identification plate corresponds with
the machine specification document.2 The ordered wear and spare parts have been delivered and
deposited in the spare part store.
3 All the documents correspond to the specific oil tank unit:
- Operators and Maintenance Manual (OMM)
- Installation drawings (IMA)
- Spare part catalog (SPC)
- Factory acceptance test report (if relevant)
- Machine specification document (if relevant)
- Machine deviation report (if relevant)
4 Sufficient process material is available for commissioning
purposes.
No. Checks Done
1 Hydroset and lubrication systems:
- Systems have been thoroughly cleaned
- Lubricants of the correct types are available
2 Electrical power supply:
- Voltage
- Max voltage fluctuation within limits- Frequency
- Fuse rating
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8.4 Function checks
8.4.1 Preparation
Start the oil tank unit according to the Operators and Maintenance Manual.
8.5 Health and safety checks
8.6 Documentation
Compile the Installation report.
List all work, besides the installation work, that was performed to
ensure correct functioning.
The installation work covered by this manual is now complete.
No. Checks Done
1 No unusual noises which could indicate misaligned parts or faults.
2 Hydroset pressure within limits,
see the Operators and Maintenance Manual, Technical Data
4 Oil heating elements operate correctly.
5 Overpressure dust exclusion system functions correctly
6 Return lubrication oil temperature within limits for the chosen oil.
No. Checks Done
1 The oil tank unit stops when an Emergency stopbutton (if appli-
cable) is pressed. Test must be made with the cone crusher run-
ning.
2 The oil tank unit stops after a short delay when theStopbutton for
the cone crusher is pressed.
3 All necessary guards are in place.
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9. Disassembly, storage and
removalTo ensure maximum safety, always readsection 2. Safety precautionsbefore
carrying out any work on the equipment or making any adjustments.
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IM Sandvik CTHS430:02 Tank unit 9. Disassembly, storage and removal
9.1 Moving and storage
9.1.1 Short moves and short-term storage
CAUTION! Sandvik recommends storing of the oil tank unit indoors. Long-termexposure to moisture or very high or low temperatures may damage
the oil tank unit.
If the oil tank unit is to be taken out of operation and moved into storage,
carry out the following steps:
a) Shut off the cone crusher, see the Operators and Maintenance Manual
for the crusher.
b) Shut off and disconnect the electrical power, the compressed air supplies
and the cooling water if a water/oil cooler is used.
c) Drain the oil from the main lubricating system but leave the oil in the
pump.
See the Operators and Maintenance Manualfor the oil tank unit.
CAUTION! Handle all lubricants and waste lubricants with care and according to
the suppliers Material Safety Data Sheet (MSDS)and local regulations.Collect waste lubricants in suitable containers and dispose as
recommended in the MSDSand according to local regulations.
d) Drain the oil from the Hydroset system, but leave the oil in the pump.See the Operators and Maintenance Manualfor the oil tank unit
e) If a water/oil cooler is used (option): Drain the water circuit at the lowest
point. Make sure that no water remains in the water/oil cooler.
(Continued)
WARNING!
Hanging loadKeep clear of hanging loads. Seesection 2. Safety precautions.Check the weight of the components to be lifted and make sure that the
WLL (Working Load Limit) of the lifting equipment is sufficient for the
weight to be lifted.
WARNING!
Risk of electrocutionHigh voltage. Disconnect electrical power before disassembling the oil
tank unit.
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f) Plug or protect any open connections on the oil tank unit.
g) Check that the doors to the cabinet are closed and locked with the
handle.
h) Check that the main lubrication tank cover and the Hydroset tank cover
are fit to the tank, closed and the locking handles are fastened.
i) Prepare a storage area large enough to store the components with at least
1.5 m (5 ft) of free space around and above them for access and
ventilation. Make sure that the storage area environment meets the
conditions in the table below:
j) Disassemble the oil tank unit to the extent necessary for the planned
transport/storage. For further information on how to disassemble, see the
Operators and Maintenance Manual for the tank unit.
k) Move the oil tank unit to the storage area according to the instructions in
section 4.4 Moving and Storage.
l) Cover the oil tank unit with suitable covering if stored outdoors.
9.1.2 Long moves and long-term storage
If the oil tank unit is to be moved into storage for more than 30 days, the
following steps should be carried out.
a) Carry out the steps insection 9.1.1 Short moves and short-term storage.
b) Wrap any loose components in bubble wrap or other suitable wrapping
to prevent damage.
c) Pack the equipment using suitable packing, crates and transport
platforms. Use the original packing, crates and transport platforms if
possible. Make sure that all parts are adequately protected.
d) If there is no oil left in the pumps, fill with oil to keep all surfaces inside
lubricated.
Characteristic Value Notes
Minmax temperatures 540 C (41104 F)
Max relative humidity 80% Non-condensing
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9.1.3 Regular inspection during storage
The following checks should be carried out regularly during the storage
period:
Inspect the oil tank unit for damage and make sure that it is protected
from rust and contamination.
If the oil tank unit has not been in operation before being stored, check
that the rust prevention packing is undamaged, and renew it if necessary.
9.2 Return to the manufacturer
a) Prepare the equipment for transport according to the instructions in
section 9.1 Moving and storage.
b) Contact the local service organization for further instructions on
arranging transport.
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9.3 Disposal
CAUTION! If the oil tank unit is to be permanently disposed of, follow the sequence givenbelow.
a) Shut down and disconnect the oil tank unit according to the instructions
insection 9.1 Moving and storage.
(Continued)
DANGER!
Risk of fire and explosion
Due to the risk of leakage, open