BG01654786 Sandvik Crusher Level Sensor - Genuine VEGAPULS Radar - CH440 / CH660 / Metso HP400 - Pre-Configured

Crusher Level Sensor for Sandvik CH440 / CH660 — Replaces BG01654786

Your crusher's auto-feed system is down because the level sensor failed. Production has stopped. The unmasked truth: this is a Genuine VEGAPULS radar sensor, the same unit Sandvik and Metso install in their crushers — pre-configured for aggregate applications. Replaces Sandvik BG01654786 and EN9504. Don't pay $3,500 for a rebranded sensor. Get the real thing.

The Problem

Your cone crusher's auto-feed system has shut down. The level sensor — the device that tells the control system how full the crushing chamber is — has failed. Without it, the automated feed system goes into fault, and your entire crushing circuit stops. Every hour of downtime at a quarry or mine site costs thousands in lost production. Sandvik quotes $2,800–$3,500 for a replacement sensor and their lead time can stretch to weeks.

The Solution

Sandvik and Metso don't manufacture sensors. They buy them from VEGA, the world's leading German manufacturer of industrial level measurement instruments. This is a genuine VEGAPULS radar sensor — the exact same unit, from the same factory — pre-configured for aggregate crushing applications. Radar technology provides superior performance over older ultrasonic sensors — it cuts through the heavy dust, noise, and vibration inside a crushing chamber where ultrasonic sensors struggle.

Why Radar Beats Ultrasonic

• Dust Immunity: Crushing generates massive dust clouds. Ultrasonic sensors bounce sound waves that scatter in dust — radar punches straight through it
• Vibration Resistance: Cone crushers vibrate intensely. Radar sensors are unaffected; ultrasonic sensors can give false readings from vibration
• Temperature Stability: Crushing generates heat. Ultrasonic accuracy drifts with temperature changes; radar does not
• No False Alarms: The #1 complaint with ultrasonic sensors is false "Bin Full" readings. Radar eliminates this problem

Specifications

• Sandvik OEM Part Number: BG01654786 / EN9504
• Manufacturer: VEGA (Germany)
• Model: VEGAPULS Series — Radar Level Sensor
• Technology: Radar (non-contact, continuous level measurement)
• Housing: Bright yellow — the signature VEGA color
• Application: Pre-configured for aggregate / rock crushing
• Output: 4-20 mA (standard process signal)
• Rating: IP66/IP67 — sealed for outdoor quarry/mine environments
• Connection: Process thread connection (verify size against your crusher)
• Made In: Germany
• Condition: Brand New

Identification

• Visual ID: Bright yellow, round housing — if it's yellow and round on your crusher, it's a VEGA
• Location: Mounted above the crushing chamber — pointing down into the bowl
• Label: VEGA branding on the sensor body (Sandvik may have an overlay sticker)

Compatible Equipment

The BG01654786 / EN9504 level sensor fits the following crushers:

Sandvik Cone Crushers

• Sandvik CH430 Cone Crusher
• Sandvik CH440 Cone Crusher
• Sandvik CH660 Cone Crusher
• Sandvik CH870 Cone Crusher
• Sandvik CS430 Cone Crusher
• Sandvik CS440 Cone Crusher
• Sandvik CS660 Cone Crusher

Metso / Metso Outotec Cone Crushers

• Metso HP300 Cone Crusher
• Metso HP400 Cone Crusher
• Metso HP500 Cone Crusher
• Metso GP300 Gyratory Crusher
• Metso GP500 Gyratory Crusher

Applications

• Aggregate Quarries (Limestone, Granite, Basalt)
• Hard Rock Mining (Gold, Copper, Iron Ore)
• Sand & Gravel Operations
• Recycled Concrete / Asphalt Crushing
• Mobile Crushing Plants

VEGA sensors are configured per application (measurement range, output signal, process connection size). Verify your existing sensor's configuration against your crusher parts manual before ordering. Contact us with your crusher model and serial number for exact match confirmation.

Why Buy From Trenchwell?

• Save $800–$1,500: Sandvik and Metso charge $2,800–$3,500 for a rebranded VEGA sensor. We offer the genuine VEGA at $1,995 — same German sensor, same factory, no OEM markup.
• Genuine VEGA Quality: This is NOT a cheap knockoff. This is the authentic VEGAPULS, manufactured in Germany by VEGA — the global leader in process level measurement. VEGA sensors are certified to SIL2 safety integrity levels and trusted in the most demanding industrial applications on earth.
• Pre-Configured: Configured for aggregate/crushing applications out of the box. Measurement range, signal output, and damping are set for the crushing chamber environment.
• Upgrade Path: If your crusher currently uses an ultrasonic sensor (VEGASON 61), upgrading to the VEGAPULS radar eliminates false alarms caused by dust and vibration. Ask us about ultrasonic-to-radar upgrade compatibility.
• Expert Support: VEGA instrumentation requires proper configuration. Contact us with your crusher model and serial number — we'll confirm the correct sensor variant, process connection, and configuration settings before shipping.
• Fast Shipping: In stock and ready to ship. A crusher sitting idle costs a quarry $5,000–$20,000+ per day in lost aggregate production. We ship fast.

Symptoms of a Failed Level Sensor

• Auto-feed system shuts down or goes into fault
• False "Bin Full" or "Chamber Full" alarms when the chamber is not full
• Erratic feed rates — crusher surges and starves alternately
• Level reading stuck at 0% or 100% (sensor frozen)
• Level reading jumps randomly (signal interference or sensor failure)
• Crusher control screen showing sensor communication errors

Installation Notes

• Lock out/tag out the crusher and all feed conveyors before working above the chamber
• The sensor is mounted above the crushing chamber — you will need fall protection/scaffolding
• Photograph the existing sensor wiring and process connection before removal
• Remove the process connection (threaded or flanged) and disconnect the signal cable
• Install the new VEGAPULS sensor in the same mounting position and orientation
• Connect the 4-20 mA signal wiring per the VEGA wiring diagram
• Power up the sensor and verify the level reading on your crusher control system
• Perform an empty chamber and full chamber calibration check
• Run the crusher at normal feed rates and verify auto-feed tracks correctly
• If upgrading from ultrasonic to radar, the control system may need the input range reconfigured

Frequently Asked Questions

Is this really the same sensor Sandvik sells for $3,500?
Yes. Sandvik and Metso do not manufacture level sensors. They purchase VEGA instruments from VEGA (Germany), apply their own part number (BG01654786), and sell them at a significant markup. We source the identical VEGA sensor through authorized process automation distributors. Same factory, same product, same quality — without the crusher OEM's premium.

What's the difference between VEGAPULS (radar) and VEGASON (ultrasonic)?
VEGAPULS uses radar technology — electromagnetic waves that are unaffected by dust, temperature, or vibration. VEGASON uses ultrasonic technology — sound waves that can scatter in dusty environments and drift with temperature changes. If your crusher currently uses an ultrasonic sensor and you're experiencing false alarms, upgrading to the radar VEGAPULS will solve the problem. Contact us to confirm compatibility.

Will this work with my Sandvik ASRi automation system?
Yes. The sensor outputs a standard 4-20 mA process signal that is compatible with Sandvik's ASRi and ASR automation systems. The signal range and configuration are pre-set for crushing applications. If your system uses a different protocol (HART, Profibus), let us know and we'll source the correct interface variant.

How do I know if my sensor is a VEGA?
Look at the sensor mounted above your crushing chamber. If it has a bright yellow, round housing, it is a VEGA. Sandvik may have placed a label over the VEGA branding, but the yellow housing is unmistakable. You can also check the data plate on the sensor body for the VEGA model number (VEGAPULS 69 or VEGASON 61).

My sensor is ultrasonic — can I upgrade to radar?
In most cases, yes. The radar VEGAPULS uses the same mounting and process connection as the ultrasonic VEGASON. The signal output (4-20 mA) is the same. You may need to adjust the measurement range in your crusher control system. Contact us with your crusher model and current sensor part number — we'll confirm the upgrade path.