Nordberg GP series cone crushers

Wear parts application guide

Wear parts application guide - Nordberg GP series cone crusher

GP cone crusher and basic concepts

GP cone crusher is a compressive
crusher where feed material is
crushed between a fixed concave
and a movable mantle. Bigger
rock particles are crushed against
the mantle and concave. This is
called single-layer crushing.
Smaller rock particles are crushed
between other rock particles,
which is called multi-layer crushing. multi-layer crushing plays a
significant role in the GP cavity.
This improves the end product
shape and reduces wear in wear
parts.

Closed side setting (CSS)

The closed side setting defines the reduction
ratio in GP cone crusher and has significant
bearing on product gradation, capacity and
power draw.
The closed side setting is measured from
the bottom of the mantle to the bottom of
the concave at their closest coincidence during the gyrating cycle.
Nip angle
The nip angle is the the angle between the
mantle and the concave. Too large nip angle
reduces the capacity and increases the wear
due to feed material is bouncing upwards in
the cavity.
Product

Feed opening
The feed opening defines the maximum feed
size to the crusher. In GP cone, the closed
side feed opening is measured from the top
of the concave to the top of the mantle
when the mantle is at the closed side setting
position.
The maximum feed size in GP cone is the
same as closed side feed opening. maximum
feed sizes are also stated in cavity configuration tables later in the guide.
Reduction ratio = F80 /
P80

Reduction ratio
The reduction ratio means the reduction factor between feed and a product. This ratio is
usually taken from the 80% point of the feed
and product curve. A typical reduction ratio
for the GP secondary crusher is 3-5 and, for
the GP fine crusher, 1.5-3.

Feed

Feed
Good feed level and distribution

How to operate a GP cone crusher

In order to get optimum capacity
and maximum lifetime of wear
parts, consider the following
points:
1. Check the feed arrangement:
The crusher should be choke fed so that
the crushing chamber is full all the time.
This is important, especially in fine crushing.
Choke feeding maximizes the amount of
multi-layer crushing, and improves wear
shape and crushing efficiency.
1.

Choke feed level for GP secondary

crusher is at the level of the mantle
fixing nut
2. Choke feed level for GP fine crusher
is max 1 meter above the top bearing
arrangement
The feed must be distributed evenly 360
across the crushing chamber. Uneven feed
distribution may cause unbalanced crushing
forces and uneven wearing in the GP concave.
Feed should not be segregated (for example finer material in other side of cavity).
The flow of the feed should be stable and
continuous. (However GP cone crusher can
be used in pulse fed applications as the
head spin is minimized.)
Circulation is needed when producing high
quality products.

Too big feed material

Too small feed material

2. Check the feed size and gradation:

Oversize feed material decreases capacity
and can cause unnecessary loads to the
crusher.
Too small feed size for the cavity increases
wearing at the bottom part of liners and
may cause poor utilization rate of wear parts.
Fines (0-4) should be screened away before
the crusher as they may cause packing. (GP
secondary is not sensitive to fines)
Feed gradation should be stable (no gaps
in feed).

Note: Feed material characteristics

such as gradation, bulk density, moisture, clay content and crushability
have significant impact on crusher
capacity.

Feed material characteristics

Easy
crushability

High specific gravity

Operating parameters
Stroke
increase

Setting
increase

Speed
increase

Choke feed

Shape of < C.S.S. in product

Capacity
Cubicity of product
Power consumption
Energy consumption kWh/ton
Indicative table

3. Check the setting. It should be close to

required product
Setting increases -> Product size increases
Setting increases -> Capacity increases
Setting increases -> Power draw decreases

6. Check the wear profile of the liners: A

distorted wear profile may decrease
capacity, increase wearing and increase
crushing forces

4. Check the stroke

Stroke increases -> Capacity increases
Stroke increases -> Power draw increases

Example of bad wearing. Cupping has occurred.

5. Check the cavity in use

Based on feed size
Based on required end product size which
gives required setting range
Check the crushing ratio.

Example of normal wear. Obtained with correct

feed arrangements, feed gradation and parameters
for the cavity.

EC

GP100S M / GP200S C / GP300S C / GP500S C / GP7 C

GP100S C / GP200S EC / GP300S EC / GP500S EC / GP7 EC

GP secondary cone crusher

cavity selection
Each GP secondary cone crusher has two cavity options with different feed openings and setting ranges.
The correct cavity can be selected based on feed size and setting.
GP Secondary
XT510 / XT610
XT710
XT720 / XT810
Can be used

Difficult and Difficult and non Medium and Medium and non Easy and
Easy and non
abrasive rock abrasive rock abrasive rock abrasive rock abrasive rock abrasive rock

Definitions for different rock types are presented

Good choice
Recommended

The minimum setting is limited by

either the power requirement or
adjusting pressure. Depending on
rock characteristics, the minimum
closed side setting can change.

in Wear and materials application

guide, page 4.

Maximum feed size and setting ranges min-max, mm (in)

GP100S

GP200S

Max Feed size

16 mm ( 0.63 in) stroke

M
(7.83)
199

GP300S
C

(9.29)
236

GP500S
EC

C
212
(8.35)

286
(11.3)

EC

237
(9.33)

320
(12.6)

GP7
C
340
(13.4)

EC
423
(16.65)

EC

EC-TR
(15.87)

(12.76)
324

(15.87)
403

(1.06-3.23)

(1.34-3.66)

(1.34-5.47)

27-82

34-93

34-139

403

20-43
24-48
(0.79-1.69) (0.94-1.89)
24-46
26-52
(0.94-1.81) (1.02-2.05)

25-47
28-53
(0.98-1.85) (1.10-2.09)

30-67
35-77
(1.18-2.64) (1.38-3.03)

27-43
29-49
(1.06-1.69) (1.14-1.93)

29-44
32-50
(1.14-1.73) (1.26-1.97)

35-63
40-74
(1.38-2.48) (1.57-2.91)

28 mm ( 1.10 in) stroke

28.5-41
30.5-47
(1.12-1.61) (1.20-1.85)

31-42
34-48
(1.22-1.65) (1.34-1.89)

37-62
42-72
(1.46-2.44) (1.65-2.83)

28-80
32-92
36-138
(1.10-3.15) (1.26-3.62) (1.42-5.43)

32 mm ( 1.26 in) stroke

30-39
32-45
(1.18-1.54) (1.26-1.77)

33-40
36-46
(1.30-1.57) (1.42-1.81)

40-60
45-70
(1.57-2.36) (1.77-2.76)

30-78
38-90
38-136
(1.18-3.07) (1.50-3.54) (1.50-5.35)

36 mm ( 1.42 in) stroke

31.5-37
33.5-43
(1.24-1.46) (1.32-1.69)

35-38
(1.38-1.5)

43-57
48-67
(1.69-2.24) (1.89-2.64)

32-76
40-88
40-134
(1.26-2.99) (1.57-3.46) (1.57-5.28)

45-55
50-65
(1.77-2.17) (1.97-2.56)

34-74
43-86
43-132
(1.34-2.91) (1.69-3.39) (1.69-5.20)

18 mm ( 0.71 in) stroke

20 mm ( 0.79 in) stroke
25 mm ( 0.98 in) stroke

(1.10-1.54) (1.34-1.73)
24-41
29-46
(0.94-1.61) (1.14-1.81)
28-39
34-44

40 mm ( 1.57 in) stroke

36-72
45-83
45-129
(1.42-2.83) (1.77-3.27) (1.77-5.08)

45 mm (1.77 in) stroke

50 mm (1.97 in) stroke

m = medium

38-44
(1.5-1.73)

C = Coarse

EC = Extra coarse

36-69
48-81
48-126
(1.54-2.72) (1.89-3.19) (1.89-4.96)

ECTR = Extra coarse - tramp release

--"'

7
~

..

~ ......

...

. ..

.."

., ,

~~

-.

:,

'

'-

...

8
~

GP fine cone crusher cavity selection

Each GP fine cone crusher has several cavity options with different feed openings and setting ranges.
The correct cavity can be selected based on feed size and setting.
EF

GP100 EF, GP11F EF, GP200 EF, GP220 EF, GP300 EF, GP330
EF, GP550 EF

GP100 M, GP11F M, GP200 M, GP220 M, GP300 M, GP330 M,

GP550 m

GP100 F, GP11F F, GP200 F, GP220 F, GP300 F, GP330 F, GP550

F

GP100 C, GP11F C, GP11M C, GP200 C, GP220 C, GP300 C, GP330 C,

GP550 C

MF

GP100 MF, GP220 MF, GP300 MF, GP330 MF, GP550 MF

EC

GP11m EC, GP200 EC, GP220 EC, GP300 EC, GP330 EC, GP550 EC

GP Fine

Difficult and

Definitions for different rock types

are presented in Wear and materials

Difficult and non Medium and Medium and non Easy and
Easy and non
abrasive rock abrasive rock abrasive rock abrasive rock abrasive rock

*
*
*
*
Good choice
Recommended
*coarse feed

abrasive rock

XT510 / XT610
XT710
XT720 / XT810
Can be used

application guide, page 4.

Maximum feed size and setting ranges min-max, mm (in)

GP100

Max Feed size

16 mm (0.63 in)
stroke

GP11F

GP11M

GP200

EF

MF

EF

EC

ECLS

EF

EC

32
(1.26)

46
(1.81)

87
(3.43)

133
(5.24)

135
(5.31)

35
(1.38)

70
(2.76)

113
(4.45)

152
(5.98)

112
(4.41)

194
(7.64)

206
(8.11)

35
(1.38)

64
(2.52)

104
(4.09)

168
(6.61)

5-18
5-17
7-20
10-20
13-24
(0.20-0.71) (0.20-0.67) (0.28-0.79) (0.39-0.79) (0.51-0.94)

18 mm (0.71 in)
stroke

8-27
7-29
10-29
12-35
(0.31-1.06) (0.28-1.14) (0.39-1.14) (0.47-1.38)

20 mm (0.79 in)
stroke

6-16
6-15
9-18
11-18
15-22
5-23
7-24
14-28
15-29
15-29
18-32
20-51
(0.24-0.63) (0.24-0.59) (0.35-0.71) (0.43-0.71) (0.59-0.87) (0.20-0.91) (0.28-0.94) (0.55-1.10) (0.59-1.14) (0.59-1.14) (0.71-1.26) (0.79-2.01)

25 mm (0.98 in)
stroke

7-14
7-12
11-15
12-15
17-19
7-21
9-21
16-26
17-27
17-27
20-30
25-49
11-24
10-26
13-26
17-32
(0.28-0.55) (0.28-0.47) (0.43-0.59) (0.47-0.59) (0.67-0.75) (0.28-0.83) (0.35-0.83) (0.63-1.02) (0.67-1.06) (0.67-1.06) (0.79-1.18) (0.98-1.93) (0.43-0.94) (0.39-1.02) (0.51-1.02) (0.67-1.26)

28 mm (1.10 in)
stroke

12.5-22
11.5-24
14-24
20-30
(0.49-0.87) (0.45-0.94) (0.55-0.94) (0.79-1.18)

30 mm (1.18 in)
stroke

9-18
11-19
18-23
19-24
19-24
22-27
30-46
(0.35-0.71) (0.43-0.75) (0.71-0.91) (0.75-0.94) (0.75-0.94) (0.87-1.06) (1.18-1.81)

32 mm (1.26 in)
stroke

14-20
13-22
15-22
24-28
(0.55-0.79) (0.51-0.87) (0.59-0.87) (0.94-1.10)

36 mm (1.42 in)
stroke

15.5-18
14.5-20
16.5-20
(0.61-0.71) (0.57-0.79) (0.65-0.79)

GP220

Max Feed size

GP300

EF

MF

EC

EC-LS

EF

MF

EC

35
(1.38)

70
(2.76)

83
(3.27)

106
(4.17)

168
(6.61)

204
(8.03)

204
(8.03)

32
(1.26)

50
(1.97)

106
(4.17)

126
(4.96)

150
(5.90)

192
(7.56)

18 mm (0.71 in)
stroke

4-30
5-32
5-31
6-32
8-37
9-42
13-52
(0.16-1.18) (0.20-1.26) (0.20-1.22) (0.24-1.26) (0.31-1.46) (0.35-1.65) (0.51-2.05)

25 mm (0.98 in)
stroke

5-27
7-28
8-27
8-28
11-33
13-39
17-49
6-22
8-28
13-24
15-29
18-32
22-41
(0.20-1.06) (0.28-1.10) (0.31-1.06) (0.31-1.10) (0.43-1.30) (0.51-1.54) (0.67-1.93) (0.24-0.87) (0.31-1.10) (0.51-0.94) (0.59-1.14) (0.71-1.26) (0.87-1.61)

28 mm (1.10 in)
stroke

7-25
8-27
9-25
10-27
13-31
15-37
19-47
7-21
9.5-27
14-23
16-28
19.5-31
23.5-39
(0.28-0.98) (0.31-1.06) (0.35-0.98) (0.39-1.06) (0.51-1.22) (0.59-1.46) (0.75-1.85) (0.28-0.83) (0.37-1.06) (0.55-0.91) (0.63-1.10) (0.77-1.22) (0.93-1.54)

32 mm (1.26 in)
stroke

8-23
9-25
10-23
11-25
14-29
18-35
22-45
8-19
11-25
15-21
17-26
21-29
26-37
(0.31-0.91) (0.35-0.98) (0.39-0.91) (0.43-0.98) (0.55-1.14) (0.71-1.38) (0.87-1.77) (0.31-0.75) (0.43-0.98) (0.59-0.83) (0.67-1.02) (0.83-1.14) (1.02-1.46)

36 mm (1.42 in)
stroke

10-21
11-23
11-21
12-23
16-27
20-33
23-43
9-17
12.5-23
16-19
18-24
22.5-27
28-35
(0.39-0.83) (0.43-0.91) (0.43-0.83) (0.47-0.91) (0.63-1.06) (0.79-1.30) (0.91-1.69) (0.35-0.67) (0.49-0.91) (0.63-0.75) (0.71-0.94) (0.89-1.06) (1.10-1.38)

40 mm (1.57 in)
stroke

11-19
12-21
13-19
14-21
17-25
21-31
25-41
10-15
14-21
(0.43-0.75) (0.47-0.83) (0.51-0.75) (0.55-0.83) (0.67-0.98) (0.83-1.22) (0.98-1.61) (0.39-0.59) (0.55-0.83)

GP330

Max Feed size

GP550

MF

EC

EC-TR

EF

MF

EC

72
(2.83)

93
(3.66)

129
(5.08)

174
(6.85)

215
(8.46)

215
(8.46)

50
(1.97)

73
(2.87)

94
(3.70)

137
(5.39)

177
(6.97)

235
(9.25)

18 mm (0.71 in)
stroke

5-31
6-31
7-37
8-42
10-49
10-68
(0.20-1.22) (0.24-1.22) (0.28-1.46) (0.31-1.65) (0.39-1.93) (0.39-2.68)

22 mm (0.87 in)
stroke

6-29
7-29
8-36
9-41
11-48
11-67
(0.24-1.14) (0.28-1.14) (0.31-1.42) (0.35-1.61) (0.43-1.89) (0.43-2.64)

25 mm (0.98 in)
stroke

8-28
9-35
10-39
12-46
12-65
8-29
11-35
12-38
16-41
18-43
22-46
(0.31-1.10) (0.35-1.38) (0.39-1.54) (0.47-1.81) (0.47-2.56) (0.31-1.14) (0.43-1.38) (0.47-1.50) (0.63-1.61) (0.71-1.69) (0.87-1.81)

28 mm (1.10 in)
stroke

8-27
9-27
10-33
11-38
13-45
13-64
9-28
12-34
13.5-37
18-40
20-41
23.5-45
(0.31-1.06) (0.35-1.06) (0.39-1.30) (0.43-1.50) (0.51-1.77) (0.51-2.52) (0.35-1.10) (0.47-1.34) (0.53-1.46) (0.71-1.57) (0.79-1.61) (0.93-1.77)

32 mm (1.26 in)
stroke

9-25
10-25
11-31
12-36
14-43
14-62
10-26
13-32
15-35
20-38
22-39
25-43
(0.35-0.98) (0.39-0.98) (0.43-1.22) (0.47-1.42) (0.55-1.69) (0.55-2.44) (0.39-1.02) (0.51-1.26) (0.59-1.38) (0.79-1.50) (0.87-1.54) (0.98-1.69)

36 mm (1.42 in)
stroke

10-23
11-23
12-29
13-34
15-41
15-60
11-24
14-29
16.5-32
22-35
23.5-37
26.5-41
(0.39-0.91) (0.43-0.91) (0.47-1.14) (0.51-1.34) (0.59-1.61) (0.59-2.36) (0.43-0.94) (0.55-1.14) (0.65-1.26) (0.87-1.38) (0.93-1.46) (1.04-1.61)

40 mm (1.57 in)
stroke

11-20
12-20
13-27
14-32
16-38
16-58
12-22
15-26
18-29
24-32
25-35
28-39
(0.43-0.79) (0.47-0.79) (0.51-1.06) (0.55-1.26) (0.63-1.50) (0.63-2.28) (0.47-0.87) (0.59-1.02) (0.71-1.14) (0.94-1.26) (0.98-1.38) (1.10-1.54)

EF

19-22
24-25
30-33
(0.75-0.87) (0.94-0.98) (1.18-1.30)

= Extra fine

= Fine

MF = Medium fine

The minimum setting is

limited by either the
power requirement or
adjusting pressure.
Depending on rock
characteristics, the
minimum closed side
setting can change.

= Medium

10

= Coarse

EC

= Extra coarse

ECLS = Extra coarse large setting

ECTR = Extra coarse - tramp release

10

When to change liners

Liners must be changed before
they are worn through in order to
prevent damage to frame or
head. Liners should be changed
no later than when the A dimension is 10-15 mm depending on
crusher model.
Production aspects may sometimes favour
changing of wear parts before they are
fully utilized. Hourly capacity or product
quality may decrease towards the end of
liner life- time and it may be economical to
change the liner before the end of its
lifetime.
A distorted wear profile typically causes a
reduction in capacity. Other symptoms of
distorted wear profiles are high power and
pressure and short lifetime of wear parts. A
distorted wear profile may lead to liners
having to be replaced before they are fully
worn.

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Expect results is our promise to our customers and

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