Available Upgrades to Existing Stacker Reclaimers

STACKER RECLAIMERS
Forty-Six (46) Available Upgrades to Existing Equipment 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. 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 during 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.

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 indepth messages regarding machine status, operations, maintenance and safety. 7. Remote Condition Monitoring An enhanced service offered by Metso Bulk Materials Handling that allows Metso to assist your Maintenance Department through the periodic downloading and evaluation of selected equipment operating data, such as, motor current, 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 equipment 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.

3. Radio Modem Control System Replaces the existing control cable reel system and associated headaches. Benefit: Less maintenance, more reliable and no moving parts.

S/R 02.09 IMP

Metso Minerals Industries, Inc. Bulk Materials Handling

Available Upgrades to Existing Stacker Reclaimers

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.

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 9. Programmable Logic Controller Benefit: Corrosion resistant, esthetically pleasing. Complete automatic control or combination with manual. 15. CAT Chain for Scraper Reclaimers Benefit: Ease of adjustment of limits, rate selection, reduced maintenance, improves maintenance assistance - identification of problem areas. Upgrades standard engineered chain to CAT sealed chain. Benefit: Provides longer chain life and less maintenance.

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 components. 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.

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.

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-current, torque motor and hydraulic drives. Lower maintenance and fewer winter problems. Less components to provide increased availability.

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.

S/R 02.09 IMP

Metso Minerals Industries, Inc. Bulk Materials Handling

Available Upgrades to Existing Stacker Reclaimers

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.

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.

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.

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.)

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.

26. Hydraulic Assisted Conveyor Take-Ups Replaces screw type conveyor take-ups. Benefit: Easier to set up and better control of belt tension.

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.

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.

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.

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

Metso Minerals Industries, Inc. Bulk Materials Handling

Available Upgrades to Existing Stacker Reclaimers

29. Equalization System for Leveling Cylinders Automated machine leveling system installed on rail truck leveling cylinders. Benefit: Replaces the cumbersome hand pump.

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.

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.

36. Spring Set/Hydraulic Release Rail Clamps Benefit: Replaces the obsolete original rail clamps with new modular design.

37. Rail Clamp Modification 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. 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.

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.

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 33. Luffing Velocity Fuse Modules Benefit: Eliminates excess piping, increases reliability and safety. Benefit: Better reliability and reduced brake maintenance.

41. New Operator's Cab 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. Replaces the outdated existing operator's cab. Benefit: Better visibility and improved control layout and room.

S/R 02.09 IMP

Metso Minerals Industries, Inc. Bulk Materials Handling

Available Upgrades to Existing Stacker Reclaimers

42. Planetary Gear Reducer for Bucket Wheel Drive Replaces right angle helical/spur gear reducer. Benefit: Less weight and can provide 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

Metso Minerals Industries, Inc. Bulk Materials Handling