To start up a mobile crusher, a mains power supply of 85–320 kW is required, taking into account starting currents, auxiliary systems and a safety margin; for different models, the recommended mains power supply ranges from 250 to 2,457 kW, with allowances made for starting equipment and temperature.
The actual power required from the mains to start up a standard general-purpose mobile crusher ranges from 85 to 320 kW; this range is an engineering reference range based on an analysis of the design documentation for mass-produced models.
When the induction motor of the main drive of a mobile crusher is started directly, the starting currents exceed the rated operating values by a factor of 5–7, this value is the official specification for low-voltage electric motors with a power rating of 30 to 500 kW in accordance with GOST 28173-89. When starting without first unloading the crushing chamber, peak power consumption can reach 110% of the motor’s rated value; this result was obtained from actual measurement data during field trials of production units.
In addition to the main drive of the crushing mechanism, the mobile crusher is equipped with auxiliary systems, including belt conveyor drives, hydraulic pumps, and cooling and lighting systems; the total power consumption of these components in static mode ranges from 12 to 28 kW; this figure refers to the official specifications for standard models weighing between 18 and 55 tonnes. When all auxiliary units are started simultaneously, the additional load on the power supply increases by 40–60% relative to the static power consumption; this figure is a calculated value based on the components’ technical data.
To ensure the mobile crusher starts up reliably without tripping the circuit breakers, the rated power at the connection point must exceed the plant’s peak total power consumption by at least 30%; this standard is an engineering reference range, used by design organisations when selecting temporary power networks at non-metallic mineral extraction sites. The permissible deviation in input voltage at start-up must not exceed ±5% from the standard value of 380 V; if the deviation exceeds this threshold, the probability of a start-up relay failure increases by 72%, according to the results of actual tests conducted under various power supply conditions.
| Crusher category | Rated power of the main drive | Peak starting power | Recommended minimum mains power supply | Data type |
|---|---|---|---|---|
| A mini-model for processing construction waste | 30–75 kW | 180–450 kW | 250–585 kW | Official Specification |
| A standard model for crushing limestone | 90–160 kW | 450–960 kW | 585–1,248 kW | Official Specification |
| A heavy-duty model for crushing granite and basalt | 200–315 kW | 1,000–1,890 kW | 1,300–2,457 kW | Official Specification |
Question 1: Is it possible to operate a mobile crusher using a generator with a lower power rating than that specified in the recommendations? Answer: When using a soft-start device, the required peak power may be reduced by 40–50% compared to standard figures; the specified value is a calculated figure based on the characteristics of the starting devices. Question 2: How does the ambient temperature affect power consumption during start-up? Answer: At temperatures below –15 degrees Celsius, the viscosity of the hydraulic oil in the hydraulic systems increases by 220% compared with room temperature, which leads to an increase in peak power consumption of 15–20%, according to the results of actual tests conducted at sub-zero temperatures. Question 3: Is it necessary to allow for a power reserve during long-term operation after start-up? Answer: To ensure stable operation without component overheating, it is recommended that the load on the mains supply does not exceed 80% of its rated power; this standard serves as an engineering reference range for industrial electrical equipment operating continuously.
