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Sandvik
Stationsplan, SE-233 81 Svedala, Sweden
Tel: +46 (0)40 409000, Fax: +46 (0)40 409260
www.sandvik.com
OM Sandvik ASRi 2.0 Table of Contents
Table of Contents
1. Introduction
1.1 Equipment information.......................................................... 6
1.1.1 Document information.............................................. 7
1.2 Operating principles of a cone crusher ................................. 8
1.3 Function and benefits of the ASRi ...................................... 10
1.3.1 ASRi system description ........................................ 11
1.3.2 Hydroset pressure definitions ................................ 14
1.4 Information levels................................................................ 15
2. Safety precautions
2.1 Hazard information ............................................................. 18
2.1.1 Warning signs ........................................................ 18
2.1.2 Risk levels.............................................................. 18
2.1.3 Prohibition signs..................................................... 19
2.1.4 Mandatory signs..................................................... 19
2.2 Personnel............................................................................ 19
2.2.1 Personal protection ................................................ 20
2.3 General safety precautions................................................. 21
2.3.1 Machine safety guards........................................... 22
2.3.2 Machine access ..................................................... 22
2.3.3 Electrical safety...................................................... 22
2.3.4 Welding .................................................................. 23
2.3.5 Hydraulic system.................................................... 23
2.3.6 Lubrication system ................................................. 23
2.3.7 Lifting and moving loads ........................................ 24
2.3.8 Feed and jams ....................................................... 25
2.4 Emissions ........................................................................... 26
2.4.1 Dust........................................................................ 26
2.4.2 Noise...................................................................... 27
2.4.3 Radioactivity........................................................... 27
3. Set-up: Operation
3.1 Starting up........................................................................... 30
3.2 Display ................................................................................ 30
3.3 Service ................................................................................ 32
3.3.1 Connections ........................................................... 33
4. Main picture
4.1 General ............................................................................... 36
4.2 The Main picture layout....................................................... 36
4.2.1 Menu bar ................................................................ 37
4.2.2 Hydroset pressure indicator ................................... 38
4.2.3 Motor power indicator............................................. 38
4.2.4 CSS indicator ......................................................... 39
4.2.5 Status bar ............................................................... 39
4.2.6 Crusher symbol ...................................................... 40
4.2.7 A-dimension indicator............................................. 40
4.2.8 Start/Stop buttons................................................... 41
4.2.9 Operating mode selector........................................ 41
4.2.10 Mainshaft control buttons ....................................... 41
4.2.11 Program/Calibration selector buttons ..................... 41
4.3 Calibration........................................................................... 42
4.3.1 Calibration: metal-to-metal ..................................... 43
4.3.2 Calibration: with lead.............................................. 45
4.4 Program .............................................................................. 47
4.4.1 Adding new programs ............................................ 47
4.4.2 Edit Program .......................................................... 50
4.4.3 Selecting programs ................................................ 53
4.4.4 Auto-CSS regulation mode .................................... 54
4.4.5 Multi-CSS regulation mode .................................... 55
4.4.6 Auto-Load regulation mode.................................... 57
5. Operating data
5.1 Operating data .................................................................... 60
5.1.1 Motor power ........................................................... 60
5.1.2 Pressure................................................................. 62
5.1.3 CSS........................................................................ 64
5.1.4 Lubrication oil temperature .................................... 65
5.1.5 A-dimension ........................................................... 66
5.1.6 Overview ................................................................ 68
5.1.7 Event list ................................................................ 69
6. Alarms
6.1 Alarms................................................................................. 72
6.1.1 Alarm severity levels .............................................. 72
6.1.2 Alarm status ........................................................... 73
6.1.3 Alarm list ................................................................ 74
6.1.4 Alarm log................................................................ 75
6.1.5 A-alarms................................................................. 78
6.1.6 B-alarms................................................................. 79
6.1.7 C-alarms ................................................................ 81
7. History
7.1 Historical data—general ..................................................... 84
7.1.1 Motor power ........................................................... 86
7.1.2 Pressure................................................................. 87
7.1.3 CSS........................................................................ 88
7.1.4 Temperature........................................................... 89
7.1.5 A-dimension ........................................................... 89
7.1.6 Overview ................................................................ 90
7.1.7 Liner wear .............................................................. 91
Identification
The ASRi serial number decal is located on the side of the ASRi control unit.
The serial number is needed when contacting Sandvik concerning this
specific equipment and when ordering spare parts.
Please enter the ASRi serial number in the intended field on the first page of
this document (the copyright page).
1 Serial number decal
Design modifications
The instructions in this document are in accordance with the design and
construction of the equipment at the time it was delivered from the Sandvik
manufacturing plant.
Technical publications
The technical publications available for this equipment are:
• Installation manual (IM)
• Operator’s manual (OM)
• Spare parts catalog (SPC)
When ordering technical publications, always specify the language and state
the ASRi serial number.
Number of pages
This document contains a total of 92 numbered pages.
Feedback
If you have comments on this Operator’s manual or problems connected to
the ASRi 2.0 documentation, send an e-mail to: manuals.srp@sandvik.com.
1
2
3
4
1 Spider bearing
5
2 Topshell 6
3 Concave ring
4 Mantle
5 Eccentric assembly
6 Mainshaft
(Continued)
Setting adjustment
Due to the need to compensate for wear and the need to produce different
product sizes the crusher has a control system, named the Hydroset system. It
basically consists of a robust hydraulic jack, which supports the mainshaft
and adjusts its position. By moving the mainshaft up and down, the discharge
setting can be changed and the size of the crushed material can thereby be
changed. Read more in your cone crusher’s Operator’s manual.
= =
– The distance A (mm or in.) between the underside of the spider hub
and the top of the headnut. This is also referred to as the A-dimension,
and is used to describe the position of the mainshaft. The A-
dimension is also used to calculate the cone crusher’s setting, also
referred to as the CSS, and the wear on the manganese. If the mantle
is raised in order to reduce the setting or compensate for wear, the A-
dimension will decrease.
Regulation of the crusher’s performance can be carried out in accordance
with two basic principles:
– maintaining a constant, predetermined setting
– maintaining a constant, predetermined crusher load.
The system checks the input information and compares it with the permitted
levels. The system detects and registers repetitive pressure peaks and reacts
by running the Hydroset pump in order to increase or decrease the setting.
The system will also give warnings and alarms of different kinds, such as an
indication that the manganese is nearing the end of its life or that a sensor is
faulty.
The figure below shows an example of how the system can be arranged.
-PS -OP
=PM =OT/HT
NOTE! The power supply unit (PS) must be installed close to the control unit (OP).
The other units can be installed in the most convenient positions as they are
connected by a bus system.
The signals from these transducers are fed to a distributed I/O unit
designated as HT-CBT. This distributed I/O unit forwards the measurements
to the control unit via a serial bus, also referred to as the ASRi bus.
There is a second I/O unit:
– A power transducer with an associated current transformer and if
necessary, a voltage transformer, that measures the power drawn by
the crusher’s drive motor.
The signal from the power transducer is forwarded to the control unit via the
ASRi bus. If the motor is of the high-voltage type, the voltage measurements
needed by the power transducer are made via appropriate high voltage
transformers.
In addition to the analog transducer signals, the system incorporates the
following digital inputs:
– Hydroset pump contactor status signals that tell the system that the
pump motor is pumping the mainshaft up or down.
– An overload protector signal that trips out if the Hydroset pump
motor is overloaded.
and the following digital outputs:
– A signal to other equipment that the crusher is able to receive feed
material.
– Hydroset pump contactor control signals. The contactors open and
close to provide power to the pump motor that moves the mainshaft
(and the mantle) up and down.
– An alarm signal that indicates that the system has detected an alarm
condition.
All of the digital signals are routed through a third distributed I/O unit in the
L3 cabinet and forwarded to or sent from the control unit via the ASRi bus.
1 Peak Hydroset
pressure
2 Average peak
Hydroset pressure
3 Average Hydroset
pressure 1 2 3
The ASRi uses a measurement principle that permits observation of cyclic
variations in Hydroset pressure caused by an uneven feed, segregation, and
packing, etc. The ASRi system uses this information to analyse the operating
conditions by mathematically processing the pressure signal, providing a
value called the average peak Hydroset pressure (2). The Hydroset pressure
setpoint is set in accordance with the average peak Hydroset pressure, thus
the crusher can generally be run with higher average Hydroset pressure (3)
than would otherwise be possible.
The ASRi displays the amplitude of the Hydroset pressure variations. This is
done with a sector in the Hydroset pressure indicator in the main picture, see
also section 4.2.2 Hydroset pressure indicator. The wider the sector shown in
the Hydroset pressure indicator, the larger the amplitude of the pressure
variations. Ideally, the sector should be reduced to a single line, which would
correspond to a constant Hydroset pressure throughout the revolution of the
eccentric. In practice, there are often variations in the crushing pressure
around the crushing chamber and this shows up as a sector in the Hydroset
pressure indicator. The Hydroset pressure can also be studied in the History:
Pressure picture, see section 7.1.2 Pressure. These pictures can be used to
analyse the crusher’s operating conditions and thus help to optimize the
performance of the machine.
DANGER!
Failure to observe information marked “WARNING!” can result in
personal injury and/or serious damage to, or destruction of,
equipment!
WARNING!
CAUTION! Failure to observe information marked “Caution!” can result in damage
to equipment!
Do not remove
guards
2.2 Personnel
All work on the equipment is to be carried out only by trained or authorized
personnel.
– “Trained” means that the person in question has been given practical
instruction by an authorized person on how the various tasks are to be
carried out.
– “Authorized” means that a person has undergone a theoretical and
practical test of knowledge, organized by Sandvik SRP AB. He/she is
therefore judged to have the knowledge and competence to carry out
the tasks assigned to the appropriate role.
All expected work tasks on this production equipment have been defined by
Sandvik SRP AB as belonging to one of three categories – work roles –
based on different competence profiles. These three work roles are:
• Installation
• Operation
• Maintenance
Always switch off power and lock out the equipment (so that it cannot
inadvertently be switched on) before any maintenance work is started. Also
ensure that it is not possible for anyone else to switch the power on while
maintenance work is being carried out.
Avoid staying on the crusher, unless necessary for maintenance work.
Risk of crushing
Never remain on the crusher while crushing. Moving parts constitute a
risk of crushing. Falling into the crusher implies danger of being
DANGER! crushed.
Risk of crushing
If the crusher is mounted on rubber dampers, there is a risk of
crushing between the oscillating parts of the crusher and the
WARNING! stationary frame.
Ejection
Never look into the crusher while crushing. Fragments and possibly
harmful matter fed to the crusher may be ejected.
WARNING!
Rotating parts
Exposure to rotating parts of the equipment shall be prevented by
guards. Always attach guards after maintenance work.
WARNING!
Flying fragments
Fragments ejected upwards may fall down in the vicinity of the
crusher. Provide adequate guards and warning signs at appropriate
WARNING! places around the danger zone.
Upwardly ejected fragments may fall down in the vicinity of the crusher.
Therefore Sandvik SRP AB recommends additional protection.
Make sure all defective guards and dust sealing components are checked,
repaired and replaced before starting the equipment.
Dangerous voltage
Personnel must regard all electrical equipment as live until it is proven
dead by proper testing procedures.
DANGER!
Make sure all broken or damaged electrical cables and connectors are
checked, repaired and replaced before starting the equipment.
Control cabinets must be lockable.
2.3.4 Welding
CAUTION! Welding on the crusher is only permitted when and as described in the
manual. For all other welding operations on the crusher local service
personnel must be consulted.
If welding an item to the crusher, the grounding cable must be attached to the
item itself. If a crusher component is to be welded, the grounding cable
should be attached as near to the welding area as possible.
Toxic gases
Inhalation of welding fumes can be dangerous to health. Always follow
instructions provided by the welding equipment supplier.
WARNING! Some parts of the crusher are made of manganese steel. Long-term
exposure to manganese oxide can affect the nervous system.
Oil pressure
Pressurized oil is dangerous if released incorrectly. Relieve all
pressure before carrying out maintenance or repair work on the
WARNING! hydraulic system.
CAUTION! Never adjust pressure relief valves beyond the recommended values.
Oil temperature
Hydraulic oil can get very hot in operation. Allow the oil to cool before
working on the hydraulic system. Equipment and hoses/pipes
WARNING! containing hydraulic oil may be hot on surface.
CAUTION! Make sure all defective hoses, valves or fittings are checked, repaired
and replaced before starting the equipment.
Hanging load
Never work or stand underneath a crane that is lifting material. Keep a
safe distance from a hanging load.
DANGER!
Make sure that the capacity of the lifting equipment is adequate and that the
equipment itself is in good working order.
If lifting tackle has to be made up by joining separate components, make sure
that the joints are secure and have the same lifting capacity as the rest of the
tackle.
NOTE! Always use lifting tackle certified in accordance with local conditions.
Always engage the safety clips on lifting hooks to prevent the tackle from
slipping off.
Use ropes or poles to steady and maneuver loads. Do not use hands or feet.
Make sure that the route and the destination are free from obstacles before
moving a suspended load. It must be possible to lower the load to the floor
quickly and safely in an emergency.
When depositing loads, keep the lifting equipment in place until the stability
of the load has been checked.
Flying fragments
Never use wedges etc. to clear jams in the feed opening. Stones and
fragments can be thrown out at high speed from the crushing
WARNING! chamber.
Explosives
Never remove blocking boulders from the crusher by blasting.
Blasting may cause personal injury and seriously damage bearings or
WARNING! other parts. Sandvik SRP AB takes no responsibility for injury to
personnel or damage to the equipment when blasting is used.
Risk of crushing
Never stand inside the crusher when a blockage is removed. You might
be pulled forcefully and suddenly downwards together with the
DANGER! material in the crushing chamber and be crushed.
2.4 Emissions
Since Sandvik’s crushers are used for handling and/or processing of minerals
or other materials which can give rise to health risks for human beings and
animals, it is the responsibility of the user to follow the relevant rules and
regulations intended to prevent health risks for example specific regulation
applying to dust emission, asbestos, quartzite, radon etc.
2.4.1 Dust
Health hazard
Breathing or inhaling dust particles will cause death or severe injury.
Always wear approved respirator.
DANGER!
Always work with a respirator approved by the respirator manufacturer
for the job you are doing. It is essential that the respirator that you use
protects you from the tiny dust particles which cause silicosis and
which may cause other serious lung diseases. You should not use the
equipment until you are sure your respirator is working properly. This
means the respirator must be checked to make sure that it is clean,
that its filter has been changed, and to otherwise make sure the
respirator will protect you in the way it is meant to.
Always make sure dust has been cleaned off your boots and clothes
when you leave your shift.
The smallest particles of dust are the most harmful. They may be so
fine that you can not see them.
2.4.2 Noise
Health hazards
Crushing and processing material will create noise. Such noise can be
more or less dangerous to the hearing. Use ear protection.
WARNING!
Refer to OM - Technical specifications for measured noise levels and
measurement conditions.
Rubber compression mountings and dust encapsulation result in lower noise
levels.
2.4.3 Radioactivity
Health hazards
Radon is a radioactive gas that occurs naturally in bedrock. Radon
may cause lung cancer. Mineral type, ventilation and water are all
DANGER! factors that influence the contents of radon gases.
Sandvik SRP AB declines all responsibility for any health hazards caused by
the release of radon or any other harmful substances when processing
minerals in the crusher.
3.1 Starting up
a) Switch on the ASRi system by pressing the switch at the far right of the
underside of the control unit.
In cold weather the system may need to warm up before operation can
commence. The blue pilot light on the front of the cabinet will flash while
the system is warming up.
3.2 Display
Most ASRi settings are configured prior to delivery or during installation of
the system. However, some features can be configured by the operator.
NOTE! The Date and time function may be password protected, if configured as such
during installation of the ASRi system. See the Installation manual for more
information. If the password prompt appears and you do not have a
password, turn to your supervisor for assistance.
a) Press the [Set-up] button in the menu bar, and then the [Operation]
button in the pop-up menu to open the Operation set-up picture.
RUNNING: New program User Log off
Set-up: Operation
Adjust
Backlight luminance
Language
Deutsch
English
Español Select
Reset
Date and time at latest reset:
Reset
Date Time
Report
Save Export
(Continued)
f) Press the [] or [] button to scroll in the language menu and select a
language.
g) Press the [Select] button to apply.
Reset
Most of the statistical data shown on the Operating data pictures can be
cleared on the reset panel. Statistical data stored since the commissioning of
the machine will not be cleared.
h) Press the [Reset] button to access the reset panel.
i) Press the [Reset] button in the dialogue box to reset the operating data.
Report
You can save and export information from the ASRi system that can be
unpacked and used in ASRi-Reporter (unpack in folder
Transfers\TransferName).
j) Press the [Save] button to save ASRi information.
k) Insert a USB memory stick into the USB port on the side of the Control
unit OP.
l) Press the [Export] button to download the latest 5 ASRi information
files. These files can also be downloaded from the ASRi system web
page, see ASRi update in the Installation manual.
3.3 Service
In the service picture you can check all the analog and digital signals as well
as the serial communication between the different units. This information
can be useful when troubleshooting the system.
a) Press the [Set-up] button in the menu bar, and then the [Service]
button to open the Service picture.
RUNNING: New program
Set-up: Service
Analog signals
Motor power
Pressure
Internal communication
Reset Connection
Analog signals
The top section of the picture displays current information on motor power,
pressure, lubrication oil temperature, A-dimension, CSS, wear compensation
factor, shaft speed, and pressure sector angle as numerical values.
(Continued)
Digital signals
The middle section of the picture displays current information on inputs from
motor protection, contactor up/down, and reserve; and information on
outputs to feeder, pump up/down, and alarm. Active signals are indicated by
green lights.
The mainshaft can also be pumped up or down to check inputs and outputs:
b) Press the [] or [] button to pump the mainshaft up or down.
Internal communication
The bottom section of the picture displays the current status of the internal
communication from the Power measurement unit (U1N), the Tank
measurement unit (CB), and the Hydraulic drive unit (L3) to the ASRi
control unit (OP).
Reset
The communication error counters count the amount of bus messages that
have not been acknowledged by the distributed I/O units and can be reset.
a) Press the [Reset] button.
b) Press the [Reset] button to reset the communication error counters or
the [Cancel] button to cancel.
3.3.1 Connections
In the Connections picture you can check the connections between the
different units of the ASRi.
a) Check that transducers, I/O units and cables are correctly connected
before the system is put into operation. If they are not, set up the
connections.
b) From the Service picture, press the [Connections] button to open the
Connections picture.
(Continued)
Alarm
& Feed
Close
The cable designations are unlit with a green ring when the cables are
correctly connected and communication is active.
The cable designations are red when there is a transmission error. These
errors can be due to disconnected cables, faults in the cables or in the units
that are linked by the cables.
c) Exchange any faulty parts and re-check the connections.
4.1 General
The control unit (operator’s panel) pictures are divided into 3 sections. At the
top is the status bar, the middle section displays all the main information, and
at the bottom is the menu bar. The contents of the menu bar are consistent
throughout the menu system. When pressing a menu button, a pop-up menu
appears with further picture alternatives. Once one of these alternatives has
been selected, the corresponding picture will open. When a picture is active
its corresponding menu button is shadowed.
1 Menu bar
2 Hydroset pressure
indicator
3 Motor power
indicator
4 CSS indicator
5 Status bar Auto
6 Crusher symbol
Man
7 A-dimension
indicator
8 Start/Stop buttons
9 Operating mode
selector
0 Mainshaft control
buttons Program
11 Program/
Calibration
Calibration
selector buttons
Main Op. data Alarm History Set-up Help
Main
The Main picture is the main operating picture and shows the crusher’s
operating status. On the main picture you can access all of the operating
functions of the ASRi, such as start/stop and movement of the mainshaft.
Op. data
The Operation data menu consists of several sub pictures that show trends in
motor power draw, Hydroset pressure, mainshaft position, lubrication oil
temperature etc.
Alarm
The Alarm menu consists of sub pictures that show information on current
alarms and logged alarms.
History
The History menu consists of several sub pictures that show different
historical trends in power draw, Hydroset pressure, CSS, temperature, wear,
etc.
Set-up
The Set-up menu consists of several sub pictures where you can set time and
date, set up connections, set crusher and communication settings etc. Some
settings will only be viewable, but not editable, depending on level of access
to the system. As an operator, you can modify all the settings found in the
operation sub picture. The rest of the settings are only viewable.
Help
The Help picture consists of an integrated ASRi manual.
Right section
The right section of the Status bar (5) displays information about the crusher
model and the name of the crusher to which the ASRi system is fitted.
RUNNING: New program
(Continued)
Alarms:
When a type A or B alarm is currently active, the Alarm menu button and the
status bar (5) turn red and start flashing. The left section of the Status bar (5)
displays information about the type of alarm according to the alarm codes
listed in section 6.1 Alarms. When a C-alarm is active, only the alarm menu
button turns red.
Alarm: A01
4.3 Calibration
The CSS calibration procedure is needed to obtain the null-position for the
CSS measurement. The term CSS, Closed Side Setting, refers to the
discharge setting at the closed side of the crushing chamber, that is the spot
in the crushing chamber where the gap between the crushing surfaces is the
smallest. As the liners wear, the real CSS increases in relation to the value
indicated by the ASRi. The required calibration frequency normally depends
on the rate at which the crushing liners wear. A more abrasive stone type will
require more frequent calibrations, whereas a non-abrasive material will
require only occasional calibrations. There are two different calibration
methods:
– metal-to-metal calibration
– calibration with lead
Metal-to-metal calibration is the easiest way to calibrate a crusher. This
method is the one generally used with H-type cone crushers.
We recommend regular inspection of the concave ring to make sure that it
has not been worn unevenly or has become oval. One consequence of oval
concave rings is that it is much more difficult to measure the CSS.
NOTE! If uneven wear is suspected, check the CSS with lead at 4 points around the
crushing chamber. See the cone crusher Operator’s manual for further
information.
You should also look for any localized wear or other damage in the crushing
chamber.
If the crushing liners are worn, you cannot raise the mantle (on the
mainshaft) so high that it comes into contact with the concave ring without
risking that the head nut comes into contact with the underside of the
crusher’s spider hub. The risk of this occurring appears relatively early in the
case of a coarse crushing chamber that operates with a large CSS. The ASRi
system prevents further upward movement of the mainshaft if the
A-dimension is reduced below the minimum value for the crusher1. The
system will then automatically switch to calibration with lead.
For more information about CSS and A-dimension, see section
4.3 Calibration and A-dimension range set-up in the Installation manual as
well as the cone crusher Operator’s manual.
1. The minimum A-dimension is 15 mm for cone crushers CH420–CH660, and 25 mm for cone crushers CH870–
CH880 and S-type crushers. This data i subsequent to model changes and may be changed without further notice.
Always refer to the crusher manual for machine specific data.
Calibration
Auto
Man
Program
c) If you want to terminate the calibration procedure, you can do this at any
time by pressing the [Cancel] button.
You will be guided through the various stages of the calibration procedure on
the picture:
Stopping Feeder
The feed to the crusher stops.
CAUTION! If the feed arrangement is not interlocked with the ASRi, the operator
has to stop the feed to the crusher.
Start Crusher
If the crusher's drive motor has not been started, you must start the motor.
The ASRi will automatically detect this and continue with the calibration
procedure. If you desire to accomplish the calibration procedure while the
motor is not running, you can press the [Disregard] button and then the
[Continue] button to continue.
If the crusher is loaded again, the system will make 3 attempts to proceed
with the calibration procedure before it is automatically interrupted. This is
indicated by an error message: “Crusher load too high, terminating”. In
this case, press the [OK] button to cancel the procedure.
Waiting for metal-to-metal contact
The ASRi system raises the mainshaft to reach the metal-to-metal position. If
the mainshaft is raised so high that the A-dimension becomes smaller than
the minimum permitted A-dimension, the picture indicates that the system is
switching to calibration with lead. Accept this by pressing the [OK] button,
or terminate the calibration procedure by pressing the [Cancel] button.
If the system indicates that the switch from metal-to-metal calibration to
calibration with lead was unsuccessful, the calibration procedure is
terminated and the message “Error, terminating” appears on the picture.
Press the [OK] button to acknowledge. Try carrying out calibration with the
lead procedure by following the instructions in section 4.3.2 Calibration:
with lead.
Metal-to-metal position detected, restoring CSS
The ASRi system has detected that the mainshaft cannot be raised further. If
the pressure is too high, the calibration procedure is halted and the message
“Pressure too high, terminating” appears. Press the [OK] button to
acknowledge. The ASRi repositions the mainshaft to its previous position.
(Continued)
Calibration
Auto
Man
Program
c) If you want to terminate the calibration procedure, you can do this at any
time by pressing the [Cancel] button.
You will be guided through the various stages of the calibration procedure on
the picture:
Stopping Feeder
The feed to the crusher stops.
CAUTION! If the feed arrangement is not interlocked with the ASRi, the operator
has to stop the feed to the crusher.
Start Crusher
If the crusher's drive motor has not been started, you must start the motor.
The ASRi will automatically detect this and continue with the calibration
procedure. If you desire to accomplish the calibration procedure while the
motor is not running, you can press the [Disregard] button and then the
[Continue] button to continue.
If the crusher is loaded again, the system will make 3 attempts to proceed
with the calibration procedure before it is automatically interrupted. This is
indicated by an error message: “Crusher load too high, terminating”. In
this case, press the [OK] button to cancel the procedure.
Position the shaft and measure the CSS. Enter the value and
press [Continue]
d) Go to the crusher and measure the CSS manually. Use at least one lump
of lead, hanging in a steel wire, and lower it through the crushing
chamber at 4 different places. If the CSS is too large for the lead lump
available, use some other suitable tool.
e) Use a vernier indicator to measure the thickness of the lead lump after it
has passed through the crushing chamber.
f) The average thickness of the 4 measurements corresponds to the CSS.
Enter this value by using the key pad that appears on the picture.
Note! Do not move the shaft until you have pressed the [Continue] button.
Crusher calibrated! Press Finish
The crusher has now been calibrated.
g) Press the [Finish] button to confirm that the calibration procedure has
been completed.
h) Restart regulation and feeding by pressing the [ l ] button.
4.4 Program
The Program picture is the picture where you can add, edit or select crushing
programs. Programs need to be set up before running the ASRi system.
It is possible to configure up to 20 different crushing programs. For each
program, you must first choose the regulation mode to be used for the
program in question. These regulation modes are:
• Auto-CSS. See section 4.4.4 Auto-CSS regulation mode
• Multi-CSS. See section 4.4.5 Multi-CSS regulation mode
• Auto-Load. See section 4.4.6 Auto-Load regulation mode
Program
New program
New program
New program
Parameters
Auto
Regulation type Not programmed
Man
(Continued)
b) Press the [] or [] button on the right of the Program menu (1) to
scroll the menu and select a “New program” in the Program menu.
c) Press the [Edit] button to open the Edit program picture.
RUNNING: New program
Auto
Man
Program
Man
Initial CSS factor
Program
(Continued)
Program
Multi-CSS
Auto-Load
Parameters
Auto
Regulation type Auto-Load
Pressure setpoint
Minimum CSS
b) Press the [] or [] button on the right of the Program menu (1) to
scroll the menu and select the crushing program in the Program
menu that you want to edit.
c) Press the [Edit] button to open the Edit program picture.
(Continued)
Man
Initial CSS factor
Program
Program
New program
New program
New program
Parameters
Auto
Regulation type
Pressure setpoint
Minimum CSS
b) Press the [] or [] button on the right of the Program menu (1) to
scroll the menu and select a crushing program. In the area below the
crushing program menu there is information about the currently
highlighted crushing program, such as regulation type and CSS setpoint.
The information displayed varies depending on whether it is an “Auto-
CSS”, a “Multi-CSS”, or an “Auto-Load” crushing program.
c) Press the [Select] button to display the desired crushing program. The
information in the left section of the Status bar will change to reflect the
program you have selected.
d) Press the [Close] button to exit the program picture.
e) Press the [Auto] button on the Main picture to select automatic
regulation.
f) Press the [ I ] button on the Main picture to start automatic regulation.
Man
Initial CSS factor
Program
(Continued)
Man
CSS setpoint 2
Man
Pressure setpoint
Min. CSS
d) If any of the values entered are out of range, the display will indicate this
in red and you must adjust the value.
Current Average
(Continued)
Trend curves
The current and average motor power draw are displayed in the upper section
of the picture (1), both in numerical values and as trend curves. The curves
move towards the left and show the latest 30 seconds.
Latest 30 min
The lower left section of the picture (2) displays statistics that show the
crusher's motor power draw during the latest 30 minutes. The information
presented is based on the “total operating time”, i.e. the time during which
the crusher's drive motor is running.
Since reset
The lower right section of the picture (3) displays the motor power draw
since the data collection feature was reset.
Presentation of statistics
The statistics for the “latest 30 min” and “since reset” are displayed as bar
charts. In each chart, the total power range corresponds to 150% of the lower
of the two values entered for parameter 502 (Motor output power) and
parameter 601 (Crusher max. input power). There can be up to 30 bars, each
representing 5% of the total power range.
An example: If parameter 502 is 220 kW and parameter 601 is 200 kW, the
total power range will be 300 kW and each bar covers a 10 kW interval.The
height of each column indicates the time—expressed as a percentage of 30
minutes or since the feature was reset—during which the crusher's motor
power draw was within the range represented by the respective column.
5.1.2 Pressure
The Pressure picture displays detailed information about the crusher's
Hydroset pressure.
a) Press the [Op. data] button on the menu bar, and then the [Pressure]
button in the pop-up menu to open the Pressure picture.
RUNNING: New program
Trend curves
The current, average, and average peak Hydroset pressures are displayed in
the upper section of the picture (1), both in numerical values and as trend
curves. The average peak Hydroset pressure value is a calculated average of
pressure peaks, see section 1.3.2 Hydroset pressure definitions. The curves
move towards the left and show the latest 30 seconds.
Latest 30 min
The lower left section of the picture displays information on the crusher's
Hydroset pressure over the latest 30 minutes (2). The information presented
is based on the “total operating time”, i.e. the time during which the crusher's
drive motor is running.
(Continued)
Since reset
The lower right section of the picture displays the Hydroset pressure since
the data collection feature was reset (3).
Presentation of statistics
The statistics for the “latest 30 min” and “since reset” are displayed as
column charts. In each chart, the total pressure range corresponds to 150% of
the value entered for parameter 602 (Crusher max. pressure). There can be
up to 30 columns, each representing 5% of the total pressure range.
An example: If parameter 602 is 5.0 MPa, the total pressure range will be
7.5 MPa and each column covers a 0.25 MPa interval.
The height of each column indicates the time—expressed as a percentage of
30 minutes or since the feature was reset—during which the crusher's
Hydroset pressure was within the range represented by the respective
column.
The upper portion of each column can have a contrasting colour. This gives a
rough indication of the width of the sector in the Hydroset pressure indicator
in the Main picture.
5.1.3 CSS
The CSS picture displays detailed information about the CSS.
a) Press the [Op. data] button on the menu bar, and then the [CSS] button
in the Operating pop-up menu to open the CSS picture.
RUNNING: New program
Current
Average Average
Maximum Maximum
Trend curves
The current CSS is displayed in the upper section of the picture (1), both in
numerical values and as a trend curve. The curve moves towards the left and
shows the latest 30 seconds.
Latest 30 min
The lower left section (2) of the picture displays information on the crusher’s
CSS over the latest 30 minutes (minimum, average, maximum).
Since reset
The lower right section (3) of the picture displays information on the
crusher’s CSS since the data collection feature was reset (minimum, average,
maximum).
Current
Average Average
Maximum Maximum
Trend curves
The current temperature of the lubrication oil returning from the crusher to
the tank is displayed in the upper section of the picture (1), both as a
numerical value and as a trend curve. The curve moves towards the left and
shows lubrication oil temperature over the latest 5 minutes. The information
presented is based on the “total operating time”, i.e. the time during which
the crusher's drive motor is running.
(Continued)
Latest 30 min
The lower left section (2) of the picture displays information on the
lubrication oil temperature over the latest 30 minutes (minimum, average,
maximum). The information presented is based on the “total operating time”,
i.e. the time during which the crusher's drive motor is running.
Since reset
The lower right section (3) of the picture displays information on the
lubrication oil temperature since the data collection feature was reset
(minimum, average, maximum).
5.1.5 A-dimension
The A-dimension picture displays detailed information about the position of
the crusher's mainshaft.
a) Press the [Op. data] button on the menu bar, and then the [A-dim.]
button in the Operating pop-up menu to open the A-dimension picture.
RUNNING: New program
Mainshaft position
(Continued)
5.1.6 Overview
The Overview picture displays detailed information about the crusher's
operating time.
a) Press the [Op.data] button on the menu bar, and then the [Overview]
button in the pop-up menu to open the Overview picture.
RUNNING: New program
Since reset
Energy consumption
Since reset
Indicators
In the upper section (1) of the picture, there are indicators for the motor
power, the Hydroset pressure, the CSS, the lubrication oil temperature, and
the A-dimension.
(Continued)
Operating time
The middle section (2) of the picture displays information about the
crusher’s operating time, i.e. the time that the crusher’s drive motor has been
running, and the time during which the crusher has been loaded. From top to
bottom:
• Since original start-up (of the system—can only be reset by installation
personnel).
• Since latest liner change (resets automatically during the first calibration
after new liners have been fitted).
• Since the latest calibration (resets automatically during calibration).
• Since reset (of operating data—can be reset in the Set-up picture, see
section 3.1 Starting up).
Energy consumption
The lower section of the picture displays information about the energy
consumption since the system was started up and since it was reset. The
values refer to the power consumption during the time the crusher has been
loaded.
a) Press the [Op. data] button on the menu bar, and then the [Event list]
button in the pop-up menu to open the Event list picture.
RUNNING: New program
b) Press the Group, the Time, or the Event title button in the title bar to
change the sorting of events.
The following mode changes can be reviewed in the Event list:
• New crusher data loaded
• Activated stop mode
• Activated A-Range set-up, M-M
• Activated A-Range set-up, Lead
• Activated calibration mode
• Crushing program X, regulation mode Z, activated
• Crushing program X saved
• System start-up
• New liners detected
• Uncrushable object detected
• Activated manual mode
• Updated from x.xx to x.xx
6.1 Alarms
The ASRi system incorporates a general alarm system which monitors a
number of analog and digital signals. Some of the signals come from
transducers and some are values that are calculated internally by the
computer. In addition, the system monitors so-called internal system
variables, e.g. repeated loss of communication with I/O units.
The two different Alarm pictures can be opened by pressing the [Alarm]
button in the menu bar, and then the corresponding button for the desired
picture in the pop-up menu. The Alarm list and the Alarm log have the same
basic appearance.
Alarm: List
History sync
The first column is the Alarm status column where alarm symbols indicate
the alarm type and the current status of the alarm. See section 6.1.2 Alarm
status.
The second column displays the Time at which the alarm was initiated.
(Continued)
The third column is the Alarm text column, in which a short description of
the alarm is displayed.
• Press the Alarm status symbol, the Time, or the Alarm text column title
button in the title bar to change the sorting of alarms.
• Switch between descending and ascending order by pressing the same
column title button again.
• Press the [] button to scroll up, or the [] button to scroll down in the
list.
• To acknowledge an alarm, select it in the list and press the [] button. In
the dialogue box that comes up, press the Acknowledge button.
• Press the [History sync] button to set all the History pictures to the
time indicated in the Time column.
When an alarm occurs it is displayed in the Alarm list, together with the
degree of severity and the time when the alarm was initiated. This happens
irrespective of whether or not the alarm has previously featured in the Alarm
list. The alarm condition must disappear and the alarm must be
acknowledged before it disappears from the Alarm list. For more information
on alarm severity levels, see section 6.1.1 Alarm severity levels.
a) Press the [Alarm] button on the menu bar, and then the [Log] button in
the Alarm pop-up menu to open the Alarm log picture.
RUNNING: New program
Alarm: Log
The first column is the Alarm status column where alarm symbols indicate
the alarm type and the current status of the alarm. See section 6.1.2 Alarm
status
The second column displays the Time at which the alarm status was changed.
(Continued)
The third column is the Alarm text column, in which a short description of
the alarm is displayed.
• Press the Alarm status symbol, the Time, or the Alarm text column title
button in the title bar to change the sorting of alarms.
Switch between descending and ascending order by pressing the same
column title button again.
• Press the [] button to scroll up, or the [] button to scroll down in the
log.
• Press the [Information] button for more information about a selected
alarm in the log.
Text: C23 Mainshaft at bottom position
Group:
Time:
Severity:
Close
• Press the [History sync] button to set all the History pictures to the
time indicated in the Time column.
6.1.5 A-alarms
A01: No pressure signal!
The system displays an alarm when the Hydroset pressure sensor signal,
measured as current, is lower than 3.6 mA for more than 3 seconds. This
alarm stops the feed to the crusher and stops regulation. Regulation and feed
should be manually resumed after the alarm has become inactive.
A02: No mainshaft position signal!
The system displays an alarm when the mainshaft position sensor signal,
measured as current, is lower than 3.6 mA for more than 3 seconds. The
alarm stops the feed to the crusher and stops regulation. Regulation and feed
should be manually resumed after the alarm has become inactive.
A03: Power signal too high!
The system displays an alarm when the motor power transducer signal is
higher than the signal corresponding to 97% of the power transducer span
(parameter 501) for more than 10 seconds. The alarm stops the feed to the
crusher and stops regulation. Regulation and feed should be manually
resumed when the alarm has become inactive.
A04: Pressure signal too high!
The system displays an alarm when the Hydroset pressure sensor signal,
measured as current, is higher than 19.5 mA for more than 3 seconds. The
alarm stops the feed to the crusher and stops regulation. Regulation and feed
should be manually resumed after the alarm has become inactive.
A05: A-dimension signal too high!
The system displays an alarm when the mainshaft position signal, measured
as current, is higher than 19.5 mA for more than 3 seconds. The alarm stops
the feed to the crusher and stops regulation. Regulation and feed should be
manually resumed after the alarm has become inactive.
A12: Mainshaft at bottom when crusher is loaded!
The system displays an alarm when the mainshaft position is less than 4 mm
from the bottom position and the power signal exceeds the lowest of the
following values: crusher maximum input power (parameter 601), program
maximum power or motor nominal power (parameter 502) during more than
3 seconds or when the mainshaft position is less than 4 mm from the bottom
position and the pressure signal is higher than the lowest of the following
values: crusher maximum pressure (parameter 602) or program maximum
value for more than 3 seconds. The alarm stops the feed to the crusher. The
feed resumes when the alarm turns inactive.
6.1.6 B-alarms
B10: Oil temperature signal too high!
The system displays an alarm when the lubrication oil temperature sensor
signal, measured as current, is higher than 19.5 mA for more than 3 seconds
and the lubrication oil temperature limit (parameter 507) is set at a value
above 20 ºC. The alarm stops the feed to the crusher. The feed resumes when
the alarm turns inactive.
B11: No power signal!
The system displays an alarm when the power signal is lower than 3.6 mA
for more than 3 seconds. The alarms stops the feed to the crusher. The feed
resumes when the alarm turns inactive.
B14: Hydroset pump motor-protection (breaker) tripped!
The system displays an alarm when the motor-protection of the motor that
drives the Hydroset pump has tripped. The alarm stops the feed to the
crusher. The feed resumes when the alarm turns inactive.
B15: Oil temperature high!
The system displays an alarm when the lubrication oil temperature is higher
than the lubrication oil temperature limit (parameter 507) for more than 3
seconds and the limit is set at a value above 20 ºC. The alarm stops the feed
to the crusher. The feed resumes when the alarm turns inactive.
B16: External pumping up too long!
The system displays an alarm when feedback from the contactor that drives
the mainshaft up indicates that it has been closed for more than 10 minutes.
The alarm stops the feed to the crusher. The feed resumes when the alarm
turns inactive.
B17: External pumping down too long!
The system displays an alarm when the feedback from the contactor that
drives the mainshaft down indicates that it has been closed for more than
10 minutes. The alarm stops the feed to the crusher. The feed resumes when
the alarm turns inactive.
(Continued)
6.1.7 C-alarms
C21: No oil temperature signal!
The system displays a warning when the oil temperature sensor signal is
lower than 3.6 mA for more than 3 seconds and the lubrication oil
temperature limit (parameter 507) is set at a value above 20 ºC.
C23: Mainshaft in bottom position!
The system displays a warning when the mainshaft position is less than
4 mm from the maximum mainshaft position (A-dimension), corresponding
to the bottom position, for more than 3 seconds. The warning is never active
during the A-range calibration procedure.
C24: Mainshaft in top position!
The system displays a warning when the mainshaft position is higher than
the position corresponding to the minimum A-dimension for more than
3 seconds.
C27: Liner change necessary!
The system displays a warning when the current mainshaft position (A-
dimension) is less than the liner change mainshaft position (parameter 503)
and one of the two following conditions is also fulfilled for more than
one hour:
– When not in Auto-Load regulation mode, the power is at least 50% of
the lower of the two values entered for the motor output power
(parameter 502) and the crusher maximum input power
(parameter 601), and the pressure is at least 50% of the crusher’s
maximum pressure (parameter 602).
– When in Auto-Load regulation mode, the power and the pressure are
both at least 50% of their corresponding setpoints.
(Continued)
There are several ways to scroll forwards and backwards between time
frames:
• Press the [I] button, to the right of the time axis, to select the latest
time frame.
• Press the [] button, to the right of the time axis, to move forward in
time.
• Press the [] button, to the left of the time axis, to move backward in
time.
The lower section of the picture displays the legends and values of the
curves. The colours of the various curves are shown as well as the values at
the points where the cursor intersects the curves.
• The cursor has a time stamp handle at the bottom. Drag this to move the
cursor along the time axis and check what the variable values were at a
particular time.
Power
Indicates the instantaneous value of the motor power draw signal. This value
is only displayed when the 10 s interval is selected.
Pump up (D1)
Indicates that the mainshaft is pumped upwards.
Pump down (D2)
Indicates that the mainshaft is pumped downwards.
Feed (D3)
Indicates that the ASRi system permits feeding to the crusher.
7.1.2 Pressure
The Pressure picture displays historical data on the Hydroset pressure in the
crusher, both in numerical values and as trend curves.
a) Press the [History] button on the menu bar and then the [Pressure]
button in the pop-up menu to open the Pressure picture.
Pump up (D1)
Indicates that the mainshaft is pumped upwards.
Pump down (D2)
Indicates that the mainshaft is pumped downwards.
Feed (D3)
Indicates that the ASRi system permits feeding to the crusher
7.1.3 CSS
The CSS picture displays historical data on the crusher’s CSS, both in
numerical values and as trend curves.
a) Press the [History] button on the menu bar and then the [CSS] button
in the pop-up menu to open the CSS picture.
CSS setpoint
Indicates the desired CSS for the current regulation mode. If the crusher is
operating in Auto-load mode, the CSS-setpoint is the same as the minimum
permitted CSS. If the crusher is operating in Auto-CSS mode, the CSS-
setpoint is equal to the CSS-setpoint defined in the crushing program. If the
crusher is operating in Multi-CSS mode, the CSS-setpoint alternates between
the two CSS-setpoints defined in the crushing program.
CSS
Indicates the gap between the crusher's mantle and concave ring on the
closed side.
Pump up (D1)
Indicates that the mainshaft is pumped upwards.
Pump down (D2)
Indicates that the mainshaft is pumped downwards.
Feed (D3)
Indicates that the ASRi system permits feeding to the crusher.
7.1.4 Temperature
The Temperature picture displays historical data on the temperature of the
lubrication oil returning from the crusher, both in numerical values and as a
trend curve.
a) Press the [History] button on the menu bar and then the
[Temperature] button in the pop-up menu to open the Temperature
picture.
Temperature
Indicates the temperature of the lubrication oil returning to the tank.
Pump up (D1)
Indicates that the mainshaft is pumped upwards.
Pump down (D2)
Indicates that the mainshaft is pumped downwards.
Feed (D3)
Indicates that the ASRi system permits feeding to the crusher.
7.1.5 A-dimension
The A-dimension picture displays historical data on the position of the
crusher’s mainshaft, both in numerical values and as trend curves.
a) Press the [History] button on the menu bar and then the [A-dim] button
in the pop-up menu to open the A-dimension picture
Mainshaft position
Indicates the A-dimension for the position of the mainshaft.
New liner contact position
Indicates the A-dimension that corresponds to the actual or calculated
“metal-to-metal” position with new liners.
Calibrated contact position
Indicates the A-dimension that corresponds to the latest calibrated or
calculated “metal-to-metal” position.
Estimated contact position
Indicates the estimated A-dimension for the “metal-to-metal” position.
(Continued)
Pump up (D1)
Indicates that the mainshaft is pumped upwards.
Pump down (D2)
Indicates that the mainshaft is pumped downwards.
Feed (D3)
Indicates that the ASRi system permits feeding to the crusher.
7.1.6 Overview
The Overview picture displays historical data on the crusher’s CSS, average
motor power, and average pressure, both in numerical values and as trend
curves.
a) Press the [History] button on the menu bar and then the [Overview]
button in the pop-up menu to open the Overview picture.
RUNNING: New program
History: Overview
CSS
Indicates the gap between the crusher's mantle and concave ring on the
closed side.
(Continued)
Average power
Indicates the average value of the power draw.
Average peak pressure
Indicates the average peak value of the average peak pressure signal.
Pump up (D1)
Indicates that the mainshaft is pumped upwards.
Pump down (D2)
Indicates that the mainshaft is pumped downwards.
Feed (D3)
Indicates that the ASRi system permits feeding to the crusher.
(Continued)
The liner wear information is presented in trend curves. Below the curve
presentation frame there are buttons for the selection of different views:
• Press the [Time] button to view the liner wear in relation to time.
• Press the [Energy] button to view the liner wear in relation to energy
consumption.
• Press the [Table] button for a tabular overview of the liner wear in
relation to both time and energy consumption:
RUNNING: New program
• Press the [Previous] button to view data from a previous liner set.
• Press the [Next] button to view data from a subsequent liner set.
• Press the [Current] button to view data from the current liner set.
Below the trend curve frame there are also legends for the curves:
Estimated
This curve shows an estimation of the liner wear.
Calibrated
This curve shows the mainshaft contact position at the different calibration
times.