Stacker Reclaimer Improvements 2.09

1. Control Upgrades with State-of-the-Art

Communications

Upgrade existing controls to reduce maintenance and

troubleshooting efforts.

Benefit: This upgrade reduces control wiring from

field devices to the electrical house PLC panel. The

upgrade eliminates long wiring runs for ease of

troubleshooting. The upgrade can be supplied in two

different methods:

Connect existing field devices, motor controllers,

operator consoles and other equipment to a common

communication link. Control wiring is eliminated from

the first connection box to the electrical house. The

equipment is connected to a DeviceNet platform.

This method places I/O modules out at the junction

boxes connected to field devices or "remote I/O."

Control wiring from the junction boxes to the electrical

house is drastically reduced. Trouble-shooting of

wiring is reduced to "device to I/O modules" local to

the device.

2. Man/Machine Interface (MMI)

Computer based device between the

operator and a PLC control system

that can provide beneficial information

to the operator.

Benefit:Ability to control virtually all

machine functions and

provide operator with in-

depth messages regarding

machine status, operations,

maintenance and safety.

3. Radio Modem Control System

Replaces the existing control cable reel system and

associated headaches.

Benefit: Less maintenance, more reliable and no

moving parts.

4. Laser Positioning System for Machine Travel

Laser distance measuring device used to

determine machine location.

Benefit: Eliminates moving parts. Also

eliminates slippage of the star wheel or fifth wheel dur-

ing inclement weather conditions and needs no

re-calibration.

5. Complete Machine Automation for Remote

Controlled Automatic or Manual Operation

Benefit: Allows

machine to be

completely controlled

from a remote location

in manual or automatic

mode.

6. Remote Troubleshooting Via Modem Interface

Benefit: Allows remote troubleshooting of PLC

controllers from our Pittsburgh office.

7. Remote Condition Monitoring

An enhanced service offered

by Metso Bulk Materials

Handling that allows Metso to

assist your Maintenance

Department through the period-

ic downloading and evaluation

of selected equipment operat-

ing data, such as, motor cur-

rent, speeds, and material

throughput on a monthly basis.

Benefit: The review of operating data will permit

Metso to identify potential equipment problems and to

recommend solutions to avoid consequential equip-

ment downtime. Identification of an equipment

problem by maintenance personnel, in advance of a

component failure, can result in significant cost savings

since measures can be taken to avoid costly

equipment downtime.

STACKER RECLAIMERSForty-Six (46) Available Upgrades to Existing Equipment

Available Upgrades to Existing

Stacker Reclaimers

S/R 02.09 IMP

Metso Minerals Industries, Inc.

Bulk Materials Handling

8. Single Point Scanning

Laser replaces the use of material probe and hoist.

Benefit: No moving parts.

Eliminates damage from recoil of

the hoist rope when probe arm

contacts the material pile.

9. Programmable Logic Controller

Complete automatic control or combination with

manual.

Benefit: Ease of adjustment

of limits, rate selection,

reduced maintenance,

improves maintenance

assistance - identification of

problem areas.

10. Flux Vector on Slew Drive

Addition of flux vector duty motor

and drive for AC slewing

operation.

Benefit: Smoother acceleration

and deceleration yielding less

wear and tear on the drive com-

ponents. Less maintenance.

11. Flux Vector Drive on Travel Drive

Addition of flux vector duty

motor and drive for machine

travel operation.

Benefit: Smoother

acceleration and deceleration

yielding less wear and tear

on the drive components. Less maintenance.

12. Flux Vector Drive on the Bucketwheel Drive

Addition of flux vector duty motor and drive for

bucketwheel drive function.

Benefit: Eliminates M.G. set on machines where the

bucketwheel is run by a M.G. set.

13. Flux Vector Drive for Boom Hoist

Replaces the contactor-based controls on machines

with cable hoists and wound rotor hoist motors.

Benefit: Eliminates the constant maintenance and

run-away problems common to wound rotor controls.

14. Stainless Steel Operator's Cab

Benefit: Corrosion resistant, esthetically pleasing.

15. CAT Chain for Scraper Reclaimers

Upgrades standard engineered chain to CAT sealed

chain.

Benefit: Provides longer chain life and less

maintenance.

16. Upgrade Feeders and Modify Chutes to

Improve Coal Flow That Will Meet Current

Plant Requirements

Benefit: Eliminates flow restrictions and reduces

spillage.

17. Replace Hydraulic Boom Conveyor Drive -

Electro/Mechanical Drive

Benefit: Less maintenance and improved

dependability. Hydraulic leaks are eliminated which

require less cleanup.

18. Monospiral Power Cable Reel Upgrade

Replaces existing bulk wrap and level wind reels. Also

provides replacement of existing monospiral torque

motor and hydraulic driven reels.

Benefit: New magnetic

coupling with standard

motor replaces eddy-cur-

rent, torque motor and

hydraulic drives. Lower

maintenance and fewer

winter problems. Less

components to provide

increased availability.

Available Upgrades to ExistingStacker Reclaimers

S/R 02.09 IMP



19. Rewind Wound Rotor Boom Hoist Motor for

Vector Duty

Allows the existing motor to be reused with a flux

vector drive.

Benefit: Eliminates the need for motor, motor base,

and brake changes. Cost is lower than a new Vector

duty motor.

20. Auto Adjust Slew Speed Based on

Bucketwheel Current

Automatically reduces slewing speed when high

bucketwheel current is detected.

Benefit: Eliminates bucketwheel drive trips, machine

stress and over-digging.

21. Automatic Pile Management

Allows the yard to be divided into sections for different

materials.

Benefit: Prevents intermixing of materials. Machine

automatically knows where each material is located in

the storage yard.

22. Microprocessor Based Field Control

Regulators

Allows the existing MG set to be reused.

Benefit: Eliminates the amplidynes or other outdated

controllers. Cost is lower than new SCR drives.

23. Higher Capacity Bearings and Improved Seals

for Bucket Wheel Shaft Main Bearings

Replaces the existing bearings with larger ones and

replaces the tube seals with lip seals.

Benefit: Longer life, better

lubricant retention, and better

contaminant exclusion.

24. Higher Load Capacity Slew Bearing

Employs larger

diameter ball

bearings.

Benefit:Longer service life.

Note: To be

considered at the time

the slew bearing needs

to be replaced.

25. Slew Drive Torque Control Coupling

Replaces the lubricated friction cone type control

coupling.

Benefit: Dry friction type is less likely to go solid than

the type used on earlier machines. Thus will provide

more predictable protection. (Must be used with

proper stalling protection.)

26. Hydraulic Assisted Conveyor Take-Ups

Replaces screw type conveyor take-ups.

Benefit: Easier to set up and better control of belt

tension.

27. Cell Less Bucket Wheel

Replaces the original

cell type wheel. Drive

modification is required.

Benefit: Provides better

discharge and increased

capacity for same

weight.

28. Shrink Disc Mounting for Bucket Wheel

Replaces taper fit method. Can also

be provided with a safety nut on end

of wheel shaft if required.

Benefit: Less complicated to apply

and with a straight shaft, less likely to lose the bucket

wheel due to improper mounting/overload.


S/R 02.09 IMP



29. Equalization System for Leveling Cylinders

Automated machine lev-

eling system installed on

rail truck leveling

cylinders.

Benefit: Replaces the

cumbersome hand

pump.

30. Shock Absorber Type Torque Link for Bucket

Wheel Drive

Replaces the solid link connection.

Benefit: Reduces shock loading and

wear on pins and links.

31. Flow Switch for Bucket Wheel Drive Reducer

Pressure Lube System

Benefit:Shuts down drive (in

sequence) if flow is lost -

saves bearings and

gearing.

32. Electrically Driven Lube

Pump for Bucket Wheel

Drive Reducer

Benefit: Can be set up to

start before main drive motor

to protect gearing and

bearings.

33. Luffing Velocity Fuse Modules

Benefit: Eliminates excess piping, increases reliability

and safety.

34. Luffing Cylinders Upgrade

Replaces existing with new style heavy duty mill type.

Benefit: Increased rod bearing area, improved piston

seals. Increased factor of safety. Decreased

maintenance.

35. Luffing Hydraulic System Upgrade

Modify the system to the load

sensing type for improved control

of acceleration, deceleration.

Note: Acceleration and

deceleration controlled electrically.

Benefit: Eliminates boom bounce and surge.

36. Spring Set/Hydraulic Release Rail Clamps

Benefit: Replaces the

obsolete original rail

clamps with new modular

design.

37. Rail Clamp Modification

Modify the hydraulic unit by installing the automatic

dump valve and eliminating the spool type valve.

Benefit: Avoids problems of spool valve silting up.

38. Slew Programmable Limit Switches

Replaces cam type limit switches.

Benefit: Ease of adjustment from cab by operator.

39. Roof Mounted A/C Units for Operator's Cab

Benefit: Better visibility and better cooling action.

40. Travel Drive Plugging and Over Speed Control

Benefit: Better reliability and reduced brake

maintenance.

41. New Operator's Cab

Replaces the outdated existing

operator's cab.

Benefit: Better visibility and

improved control layout

and room.


S/R 02.09 IMP



42. Planetary Gear Reducer for Bucket Wheel

Drive

Replaces right angle helical/spur

gear reducer.

Benefit: Less weight and can pro-

vide higher gearing service factor.

43. Retrofit Luffing and Slew Position Encoders

Replaces the cam type limit switches.

Benefit: More reliable position detection.

44. New SCR Slew Drives

Eliminates M-G sets. Provides better control than

earlier SCR drives.

Benefit: Provides accurate load sharing between

motors thus helping to prevent gear box damage.

45. Caliper Disc Brake with

Rotor (For Older Machines)

Replaces the brake band and

weight.

Benefit: Less parts,

better control of

operation and easier maintenance.

46. Install Dust Collection in Conveyor Transfers

and Feeder Discharge Areas

Benefit: Reduces dusting and cleanup of the transfer

areas.


S/R 02.09 IMP



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Stacker Reclaimer Improvements 2.09