ASRi20_OM_S223.531.en-02

operator’s manual

S223.531.en

SANDVIK ASRi 2.0

This document is valid for:

Serial no. / Machine no.

Sign.

SANDVIK ASRi 2.0 © Copyright 2009 Sandvik SRP AB. All rights reserved. No parts of this document may be reproduced or copied in any form or by any means without written permission from Sandvik SRP AB. All data and information in this manual may be changed without further notice. Reservations for misprints. Document number: S223.531.en Issue: 20091012 Version: 02

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 ............................................................. 2.1.1 Warning signs ........................................................ 2.1.2 Risk levels.............................................................. 2.1.3 Prohibition signs..................................................... 2.1.4 Mandatory signs..................................................... 2.2 Personnel............................................................................ 2.2.1 Personal protection ................................................ 2.3 General safety precautions................................................. 2.3.1 Machine safety guards........................................... 2.3.2 Machine access ..................................................... 2.3.3 Electrical safety...................................................... 2.3.4 Welding .................................................................. 2.3.5 Hydraulic system.................................................... 2.3.6 Lubrication system ................................................. 2.3.7 Lifting and moving loads ........................................ 2.3.8 Feed and jams ....................................................... 2.4 Emissions ........................................................................... 2.4.1 Dust........................................................................ 2.4.2 Noise...................................................................... 2.4.3 Radioactivity...........................................................

© 2009 Sandvik SRP AB

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Table of Contents

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 ............................................................................... 4.2 The Main picture layout....................................................... 4.2.1 Menu bar ................................................................ 4.2.2 Hydroset pressure indicator ................................... 4.2.3 Motor power indicator............................................. 4.2.4 CSS indicator ......................................................... 4.2.5 Status bar ............................................................... 4.2.6 Crusher symbol ...................................................... 4.2.7 A-dimension indicator............................................. 4.2.8 Start/Stop buttons................................................... 4.2.9 Operating mode selector........................................ 4.2.10 Mainshaft control buttons ....................................... 4.2.11 Program/Calibration selector buttons ..................... 4.3 Calibration........................................................................... 4.3.1 Calibration: metal-to-metal ..................................... 4.3.2 Calibration: with lead.............................................. 4.4 Program .............................................................................. 4.4.1 Adding new programs ............................................ 4.4.2 Edit Program .......................................................... 4.4.3 Selecting programs ................................................ 4.4.4 Auto-CSS regulation mode .................................... 4.4.5 Multi-CSS regulation mode .................................... 4.4.6 Auto-Load regulation mode....................................

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Table of Contents

5. Operating data 5.1 Operating data .................................................................... 5.1.1 Motor power ........................................................... 5.1.2 Pressure................................................................. 5.1.3 CSS........................................................................ 5.1.4 Lubrication oil temperature .................................... 5.1.5 A-dimension ........................................................... 5.1.6 Overview ................................................................ 5.1.7 Event list ................................................................

60 60 62 64 65 66 68 69

6. Alarms 6.1 Alarms................................................................................. 6.1.1 Alarm severity levels .............................................. 6.1.2 Alarm status ........................................................... 6.1.3 Alarm list ................................................................ 6.1.4 Alarm log................................................................ 6.1.5 A-alarms................................................................. 6.1.6 B-alarms................................................................. 6.1.7 C-alarms ................................................................

72 72 73 74 75 78 79 81

7. History 7.1 Historical data—general ..................................................... 7.1.1 Motor power ........................................................... 7.1.2 Pressure................................................................. 7.1.3 CSS........................................................................ 7.1.4 Temperature........................................................... 7.1.5 A-dimension ........................................................... 7.1.6 Overview ................................................................ 7.1.7 Liner wear ..............................................................


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1. Introduction

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1. Introduction

1.1 Equipment information Purpose The purpose of this Sandvik equipment is to regulate and protect a cone crusher from overloads. The system also helps improve production and achieve better control and use of the cone crusher. Sandvik SRP AB will not accept any liability for damage to equipment or injury to personnel caused by unauthorised or improper use or modification of this equipment. Manufacturer This Sandvik equipment has been manufactured by: Sandvik SRP AB Stationsplan 1 SE-233 81 Svedala Sweden www.sandvik.com For maintenance Contact the nearest Sandvik company, agent, representative or the manufacturer directly: Sandvik SRP AB Service Dept. SE-233 81 Svedala Sweden Telephone +46-40-40 90 00 Telefax +46-40-40 92 60 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

1

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1. Introduction

1.1.1 Document information Purpose of this document The purpose of this Operator’s manual is to provide information on how to safely use this Sandvik equipment. It is important to: • read through the whole of this manual before performing any work • •

keep the manual for the lifetime of the equipment pass the manual on to any subsequent holder or user of the equipment

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: [email protected].


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1. Introduction

1.2 Operating principles of a cone crusher In a cone crusher the process material is crushed between two rigid surfaces. In general, the motion of the moving surface is independent of the load on the crusher. The crushing action is achieved by an eccentric gyratory movement of the mainshaft (6). Individual pieces of process material (e. g. rock or ore) are nipped, compressed and crushed between the mantle (4) and the concave ring (3). The quality and quantity of the produced process material is a result of the interaction between the crusher and the process material. The crushing chamber’s geometry, the crusher’s dynamics and the process material are the most important factors. The concave ring (3), mantle (4), eccentric assembly (5) and the location of the pivot point determine the chamber geometry of the cone crusher. The crusher’s drive motor rotates the eccentric assembly at a constant speed through a gear transmission. The rotation of the eccentric assembly causes the lower end of the mainshaft to gyrate. At the top of the mainshaft (6) is the spider bearing (1) that acts as the pivot point for this gyrating motion. The mantle is fixed to the mainshaft and the concave ring is fixed to the topshell. The gyration of the mainshaft means that the distance between the mantle and the concave ring continually varies. When this distance decreases the incoming process material will be subjected to a compressive stress and will be crushed. When the mantle moves away from the concave ring, the process material is able to flow down through the chamber.The mantle and the concave ring must be replaced regularly as they are continuously worn. The rate at which this wear occurs depends on the characteristics of the process material.

1 2 3 4 5 6

Spider bearing Topshell Concave ring Mantle Eccentric assembly Mainshaft

1 2 3 4 5 6

(Continued)

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1. Introduction 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.

setting decrease = finer product

=


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setting increase = coarser product

=

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1. Introduction

1.3 Function and benefits of the ASRi The ASRi (Automatic Setting Regulation–Intelligent) is the cone crusher’s setting and regulation system. It can also display statistical and historical data, store different crushing programs, etc. The duties of the ASRi system are to automatically regulate the crusher and to protect the crusher from overloads. In addition, the ASRi system incorporates several functions which simplify operation. When the discharge setting is adjusted manually by the operator, the setting must be kept large enough to avoid possible overload conditions. Consequently, the crusher is not utilized to its full potential. When the crusher is controlled by the ASRi, the system keeps the setting as close as permitted by the machine without risk of damaging it. Thus, the ASRi helps the user achieve higher production, a higher degree of reduction, and improved product distribution. In addition, a better product shape can be obtained. A further benefit is that the crusher's wearing liners can be utilized better. The ASRi monitors the cone crusher’s performance and ensures that the measured values lie within the permitted limits that have been set in the system. If these limits are exceeded, the ASRi will adjust the setting until the desired values are attained. The ASRi operator’s panel, hereafter called the control unit, can be mounted almost anywhere it is desired, but most likely in the control room. It can also communicate with other systems in the local plant. The control unit incorporates an integrated colour touch screen which is the operator’s interface. The ASRi control unit is continuously fed, through the distributed I/O units, with information about – The power (kW or hp) drawn by the cone crusher’s drive motor. – The pressure (MPa or psi) in the Hydroset system. This value is an indication of the crushing force inside the cone crusher. (Continued)

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1. Introduction – 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 Adimension 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 Adimension 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.

1.3.1 ASRi system description The computer in the control unit monitors and regulates the crusher. The computer stores the statistics, historical data, and crushing programs etc. The control unit provides a variety of possibilities for communication with other systems in the plant. The ASRi system consists of the following subsystems: • • • • •

Power supply unit (PS) Control unit with a colour touch screen (OP) Power measurement unit (U1N) Tank measurement unit (CBT) Hydroset drive unit (L3) (Continued)


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1. Introduction

The figure below shows an example of how the system can be arranged. -PS

-OP Power supply unit

=PM

Control unit

=OT/HT

-U1N

-CBT

Power measurement unit

NOTE!

Tank measurement unit

-L3 Hydroset drive unit

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 system incorporates a number of transducers that provide the measurement values and signals that the control unit needs in order to monitor and regulate the crusher: – A pressure transducer measures the pressure in the crusher's Hydroset system. – A position transducer measures the position of the crusher's mainshaft. – A temperature transducer measures the temperature of the lubricating oil returning to the tank from the crusher. (Continued)

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1. Introduction 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.


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1. Introduction

1.3.2 Hydroset pressure definitions All Sandvik cone crushers with a Hydroset system have the mainshaft assembly supported by a Hydroset piston. The oil beneath the piston is under pressure. This Hydroset pressure is a direct indicator of the crushing force inside the crushing chamber. The crushing force in a cone crusher with a Hydroset system can thus be measured at any crusher load level.

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.

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1. Introduction

1.4 Information levels The ASRi system has four different information levels: • Operation • Installation • Service • Regulation Operation The operation level allows the user to control the main functions of the ASRi such as start and stop of regulation, set-up of regulation modes, positioning of the mainshaft, selection of crushing programs, editing of crushing programs, CSS range calibration, and set-up of the display. Operators can view, but not necessarily edit, all information on the different pictures of the ASRi. It is possible to set up password protection of the edit crushing program function during installation of the ASRi. In such a case, operators can only edit the crushing programs if they are authorized. Service The service level is used for maintenance of the ASRi system, such as checking connections and signals. Installation The installation level is mostly used during installation and set-up of the ASRi. It allows the access holder to configure the ASRi system with regard to units, A-dimension range set-up, crusher model, and crusher settings. Regulation The regulation level is restricted to Sandvik and personnel with detailed knowledge of the plant, the crusher, and the ASRi system since these parameters will considerably change regulation and the performance of the system. The parameters on this level can be viewed by all users, but can only be changed by Sandvik personnel that have regulation (administrator) rights to the ASRi.


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1. Introduction


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2. Safety precautions To ensure maximum safety, always read this section carefully before carrying out any work on the equipment or making any adjustments.

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2. Safety precautions

2.1 Hazard information 2.1.1 Warning signs

General danger

Dangerous voltage

Risk of crushing

Hanging load

Risk of crushing

Flying fragments

2.1.2 Risk levels Throughout the manual, levels of risk are indicated as “DANGER”, “WARNING” or “CAUTION”. The “DANGER” and “WARNING” levels are accompanied by a warning sign (see above). Failure to observe information marked “DANGER!” can result in lifethreatening injuries! DANGER! Failure to observe information marked “WARNING!” can result in personal injury and/or serious damage to, or destruction of, equipment! WARNING! CAUTION!

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Failure to observe information marked “Caution!” can result in damage to equipment!

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2.1.3 Prohibition signs

Do not remove guards

2.1.4 Mandatory signs

Disconnect current before any work

Read the manual

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

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Sandvik SRP AB provides technical documentation appropriate to all three work roles: • Installation manual • Operator’s manual and Wear parts catalog • Maintenance manual and Spare parts catalog Sandvik SRP AB can provide adequate training for all three work roles and can carry out authorization of trained personnel. The technical documentation from Sandvik SRP AB covers only work on the production equipment itself – it does not cover work tasks associated with other equipment or routines at the site. It is the responsibility of the plant management to assign responsibility for: • The production equipment and the work area around the equipment • All personnel in the vicinity of the equipment • Compliance with national and local safety regulations • Checking that all safety devices are fully operational Sandvik SRP AB declines all responsibility for injury or damage resulting from non-compliance with the instructions in this manual.

2.2.1 Personal protection Sandvik SRP AB strongly recommends that personal protective equipment is always worn when working in the vicinity of the equipment. Sandvik SRP AB strongly recommends to use a safety harness when working above, inside and under the equipment. The Sandvik SRP AB recommendation for personal protective equipment includes:

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Ear protection

Safety helmet

Eye protection

Protective gloves

Safety boots

Mask or breathing apparatus

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2.3 General safety precautions

WARNING!

Falling stones Clear the feed arrangement from process material before any maintenance work is carried out inside or below the crusher, to prevent stones from falling down.

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.

DANGER!

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 crushed.

WARNING!

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 stationary frame. Ejection Never look into the crusher while crushing. Fragments and possibly harmful matter fed to the crusher may be ejected.

WARNING!


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2.3.1 Machine safety guards Do not remove guards Make sure that all guards are in place and functioning, to prevent exposure to flying fragments and rotating parts. Never operate the PROHIBITION! equipment unless guards are mounted. Rotating parts Exposure to rotating parts of the equipment shall be prevented by guards. Always attach guards after maintenance work. WARNING!

WARNING!

Flying fragments Fragments ejected upwards may fall down in the vicinity of the crusher. Provide adequate guards and warning signs at appropriate 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.

2.3.2 Machine access Every machine requires access for personnel who carry out inspections and/ or maintenance work. Suitable access platforms and guard rails shall be installed. Walkways, stairs and ladders must be designed in accordance with applicable regulations. (These parts are not included in the crusher’s standard specification. For advice, contact Sandvik SRP AB.) Areas where access is required are indicated on installations drawings, see the Installation manual.

2.3.3 Electrical safety CAUTION!

Only electrical personnel working according to European Standard EN 50110 or similar are permitted to perform electrical operations on the crusher. 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.

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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.

CAUTION!

Only welders qualified according to European Standard EN 287 or similar are permitted to perform welding operations on the crusher.

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.

WARNING!

Toxic gases Inhalation of welding fumes can be dangerous to health. Always follow instructions provided by the welding equipment supplier. Some parts of the crusher are made of manganese steel. Long-term exposure to manganese oxide can affect the nervous system.

2.3.5 Hydraulic system CAUTION!

Only personnel certified in hydraulics are permitted to perform maintenance on the hydraulic system (except bleeding air from the Hydroset system).

WARNING!

Oil pressure Pressurized oil is dangerous if released incorrectly. Relieve all pressure before carrying out maintenance or repair work on the hydraulic system.

CAUTION!

Never adjust pressure relief valves beyond the recommended values.

WARNING!

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 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.

2.3.6 Lubrication system CAUTION! CAUTION! CAUTION!


Equipment and hoses/pipes containing lubrication oil may be hot on surface. Make sure all defective hoses, valves or fittings are checked, repaired and replaced before starting the equipment. Always remove oil stains to avoid skidding risk.

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2.3.7 Lifting and moving loads CAUTION!

Only personnel with adequate lifting training are permitted to perform lifting operations. 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.

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2.3.8 Feed and jams CAUTION!

When the crushing chamber is empty, avoid feeding solitary round rocks.

CAUTION!

Never feed combustible process material into the crusher.

WARNING!

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 chamber.

WARNING!

DANGER!

Explosives Never remove blocking boulders from the crusher by blasting. Blasting may cause personal injury and seriously damage bearings or 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 material in the crushing chamber and be crushed.

In some cases it is possible to increase the CSS (closed side setting) temporarily to clear a jam. Always follow local regulations when attempting to clear a jam.


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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. Make sure the dust suppression system in your equipment is working properly. If the dust suppression system is not working properly, stop working immediately. 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. Remember, you must protect yourself from the danger of breathing or inhaling dust.

Sandvik SRP AB strongly recommends using additional equipment for dust control. Examples are dust extraction (vacuum) and dust suppression by water spray or foam. Such equipment is not included in the crusher’s standard specification. Sandvik SRP AB declines all responsibility for any health hazards caused by dust, generated when processing minerals in the crusher.

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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

DANGER!

Health hazards Radon is a radioactive gas that occurs naturally in bedrock. Radon may cause lung cancer. Mineral type, ventilation and water are all 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.


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3. Set-up: Operation This section describes how to set up the display of the control unit.

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3. Set-up: Operation

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

Log off

User

Set-up: Operation Date & time Adjust

Backlight luminance

Language Deutsch English Select

Español

Reset Date and time at latest reset:

Reset

Time

Date

Report Save

Main

Op. data

Export

Alarm

History

Set-up

Help

(Continued)

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3. Set-up: Operation Date and time b) Press the [Adjust] button to access the date and time adjustment panel. c) Touch the field to be changed and adjust them by pressing the [] or [] button. d) Press the [OK] button. Backlight luminance e) Press the [] or [] button to set the brightness of the picture. Language The languages available in ASRi 2.0 are:

NOTE!

Bulgarian

Danish

German

Polish

Romanian

Chinese

English

Hungarian

Portuguese

Slovene

Croatian

Finnish

Italian

Portuguese (Br)

Spanish

Czech

French

Norwegian

Russian

Swedish

Other languages may be added in future program versions. 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.


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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 Lub. oil temperature A-dimension CSS Wear compensation factor at

Mainshaft movement speed Degrees

Pressure sector angle Digital signals

Output

Input Motor protection

Contactor up

Contactor down

Reserve

Pump up

Feeder

Alarm

Pump down

Internal communication

Connection

Reset

Main

Op. data

Alarm

History

Set-up

Help

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)

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3. Set-up: Operation 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)


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The Connections picture shows a schematic view of the connections: RUNNING: New program

Set-up: Service: Connections

Alarm & Feed Oil tank unit

Close

Main

Op. data

Alarm

History

Set-up

Help

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.

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4. Main picture This section describes how to navigate the main picture of the ASRi that contains all the functions needed to operate the crusher.

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4. Main picture

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.

4.2 The Main picture layout The Main picture is the default picture. In the following pages you will find descriptions of the indicators and buttons on this picture. RUNNING: New program

1 Menu bar 2 Hydroset pressure indicator 3 Motor power indicator 4 CSS indicator 5 Status bar 6 Crusher symbol 7 A-dimension indicator 8 Start/Stop buttons 9 Operating mode selector 0 Mainshaft control buttons 11 Program/ Calibration selector buttons

Auto Man

Program Calibration

Main

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4. Main picture

4.2.1 Menu bar Navigate the menus by pressing the buttons on the menu bar (1). Most of the buttons in the menu bar (1) have a pop-up menu. Below is a short description of the menus and the different picture features. 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.


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4. Main picture

4.2.2 Hydroset pressure indicator The Hydroset pressure indicator (2) displays the pressure in the crusher’s Hydroset system. • The green area on the indicator has a scale of 0-100% • The yellow area has a scale of 100-120% • The red area has a scale of 120-150% ...of the maximum permitted Hydroset pressure. The pressure is indicated by a sector where the lower edge represents the average Hydroset pressure, and the upper edge represents the average peak Hydroset pressure. The information can be used to determine how evenly the crusher is loaded and thus how well it runs. The narrower the sector, the better the crusher runs and the higher it can be loaded. The average peak Hydroset pressure is displayed numerically below the indicator. If an Auto-Load crushing program is active, the relevant setpoint is indicated by an arrow pointing to the scale. The relevant setpoint value is also displayed in the upper left corner and the numerical field is blue.

4.2.3 Motor power indicator The motor power indicator (3) displays the actual power drawn by the crusher: • • •

The green area on the indicator has a scale of 0-100% The yellow area has a scale of 100-140% The red area has a scale of 140-150%

...of the maximum permitted motor power. The crusher’s current power draw is displayed numerically below the indicator. If an Auto-Load crushing program is active, the relevant setpoint is indicated by an arrow pointing to the scale. The relevant setpoint value is also displayed in the upper left corner and the numerical field is blue.

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4. Main picture

4.2.4 CSS indicator The CSS indicator (4) displays the crusher's CSS. The crusher's current setting is displayed numerically below the indicator. If an Auto-CSS or a Multi-CSS crushing program is active, the centre of the scale corresponds to the desired CSS, which is shown at the top of the instrument, and the numerical field is blue.

4.2.5 Status bar The Status bar (5) displays general information about the status of the machine. It is divided into 3 sections: Left section The left section of the Status bar (5) contains information about the running status of the ASRi and crushing programs: •

Stop/Running/Calibration: A regulation program is currently not running, running, or the crusher is under calibration mode. • “Program XXX”: Indicates which program is currently selected. Middle section The middle section of the Status bar (5) displays the current date and time in the following order: •

Year-month-day hours:minutes

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)


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4. Main picture

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

4.2.6 Crusher symbol In the centre of the operating picture there is a crusher symbol (6). Arrows will appear in the mainshaft section of the crusher symbol when the Hydroset pump is running. Green arrows indicate that pumping is required. Blue arrows indicate feedback from Hydroset drive unit L3 that pumping is done according to the digital inputs in L3. Dark yellow arrows indicate that pumping is initiated by the push button box L1. The green arrow above the crushing chamber indicates that the system permits feeding to the crusher. When the pressure has increased so much that the crusher is considered to be loaded, the crushing chamber in the symbol fills up with material.

4.2.7 A-dimension indicator The A-dimension indicator (7) displays the A-dimension and the position of the mainshaft. The green section of the column indicates the currently available mainshaft travel. The top of the green section indicates the crusher's “metal-to-metal” position. The bottom of the green column indicates the lowest mainshaft position. As the crusher’s liners wear, the top of the green column moves upward each time a calibration is carried out. When the wear compensation is active a yellow section appears between the green and the red section, giving an estimation of the wear since the last calibration. The horizontal bar across the column indicates the current position of the mainshaft.

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4. Main picture

4.2.8 Start/Stop buttons The Start/Stop buttons (8) are used to start and stop the regulation of the crusher. • •

NOTE!

Press the [ l ] button to start the regulation. Press the [o] button to stop the regulation. If the crusher's feed system is interlocked with the ASRi system, the feed is also stopped – as indicated by the disappearance of the green arrow.

If the feed system is not interlocked with the ASRi system, the feed indication arrow has no connection with reality.

4.2.9 Operating mode selector Auto Man

The Operating mode selector (9) is used to select either automatic or manual control mode for the crusher’s mainshaft position. •

Press the [Auto] button to start regulation in accordance with the crushing program that is indicated in the left-hand end of the Status bar (5).

•

Press the [Man] button to assume manual control of the mainshaft's position.

4.2.10 Mainshaft control buttons With the mainshaft control buttons (10) you can at any time manually pump the mainshaft up or down. • •

Press the [] button to pump the mainshaft up. Press the [] button to pump down.

4.2.11 Program/Calibration selector buttons Program Calibration

With the Program/Calibration selector buttons (11) you can open the Program picture where you select, edit, or add programs, or you can open the Calibration picture where you carry out a null calibration of the CSS. • •


Press the [Program] button to open the Program picture. Press the [Calibration] button to open the Calibration picture.

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4. Main picture

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.

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4. Main picture

4.3.1 Calibration: metal-to-metal During the metal-to-metal calibration procedure the ASRi system raises the mainshaft until metal-to-metal contact is achieved, at which time the system saves this position as the new CSS zero, and then lowers the mainshaft to restore the CSS to the previous value. The crusher calibration procedure has then been completed. To carry out metal-to-metal calibration, follow the instructions below. a) Press the [Calibration] button in order to open the Calibration picture. STOP: New program

Calibration

Auto Man

Program Lead

Main

Op. data

Metal-to-metal

Alarm

History

Calibration

Close

Set-up

Help

b) Press the [Metal to metal] button to start metal-to-metal calibration.The calibration procedure starts automatically. (Continued)


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4. Main picture

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)

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4. Main picture Crusher calibrated! Press Finish The crusher has now been calibrated. d) Press the [Finish] button to confirm that the calibration procedure has been completed. e) Restart regulation and feeding by pressing the [ l ] button.

4.3.2 Calibration: with lead During the lead calibration method, the operator lowers a lump of lead down through the crushing chamber. The lead is nipped between the mantle and the concave ring. When the thickness of the lead has been measured and this value has been entered into the ASRi system, the calibration procedure has been completed. To carry out calibration with lead, follow the instructions below. a) Press the [Calibration] button in order to access the Calibration picture. STOP: New program

Calibration

Auto Man

Program Lead

Main

Op. data

Metal-to-metal

Alarm

Calibration

Close

History

Set-up

Help

b) Press the [Lead] button to start calibration with lead.The calibration procedure starts automatically. (Continued)


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4. Main picture

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.

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4. Main picture

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

4.4.1 Adding new programs To add a crushing program, follow this sequence: a) Press the [Program] button on the Main picture to open the Program picture. RUNNING: New program

Program New program New program New program

Parameters Not programmed

Regulation type

Auto Man

1 Program menu

Program Edit

Main

Op. data

Select

Alarm

Calibration

Close

History

Set-up

Help

(Continued)


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4. Main picture

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

Edit program

New program

Auto-CSS

Multi-CSS

Auto-Load

New program

Program name

Auto Man

Program Save

Main

Op. data

Alarm

Calibration

Cancel

History

Set-up

Help

d) Select the required regulation mode by pressing either the [Auto-CSS] button, the [Multi-CSS] button, or the [Auto-Load] button. All the parameter fields for the corresponding regulation mode appear. e) Clear the required regulation mode by pressing either the [Auto-CSS] button, the [Multi-CSS] button, or the [Auto-Load] button to remove the program. (Continued)

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RUNNING: New program

Edit program

New program

Auto-CSS

Multi-CSS

Auto-Load

New program

Program name

CSS setpoint

Auto Man

Initial CSS factor

Initial CSS setpoint

Program

Main

Op. data

Alarm

Calibration

Cancel

Save

History

Set-up

Help

f) Write the desired program name in the Program name field. g) Enter the required parameter values, as described in section 4.4.4 AutoCSS regulation mode, section 4.4.5 Multi-CSS regulation mode, or section 4.4.6 Auto-Load regulation mode. h) Press the [Save] button to save the program, or the [Cancel] button to cancel. i) Select the next program to be configured, or press the [Close] button on the Program picture (see previous image) to finish the Add new program procedure. (Continued)


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4. Main picture

Initial CSS factor With a coarse crushing chamber, there is sometimes a risk of overloading the crusher when feeding starts. In such a case it can be a good idea to choose an Initial CSS factor greater than 1. The CSS will be greater than the desired operating CSS when the feed to the crusher starts and will then slowly decrease towards the desired operating CSS setpoint. In other cases – with a fine crushing chamber, for example – it may be difficult to fill the crushing chamber when the feed is started. In such a case it can be a good idea to choose an Initial CSS factor smaller than 1. The CSS will be smaller than the desired operating CSS when the feed to the crusher starts and will then slowly increase towards the desired operating CSS setpoint. The starting CSS is normally calculated automatically by the ASRi system, but can also be set manually during the installation set-up, see Crusher settings in the Installation manual. The initial CSS setpoint is calculated as the product of the initial CSS factor, which can lie between 0.5 and 2.5, multiplied with the CSS setpoint. Removing programs Existing programs can be removed. j)

Deselect the regulation mode by pressing the corresponding button, [Auto-CSS], [Multi-CSS], or [Auto-Load]. k) Press the [Save] button.

4.4.2 Edit Program If the crusher is to be operated in an automatic regulation mode, one or more crushing program(s) must first be configured. NOTE!

The Edit program 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. (Continued)

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4. Main picture To edit a crushing program, follow this sequence: a) Press the [Program] button on the main picture to open the Program picture.


Program Multi-CSS Auto-Load

Parameters Auto-Load

Regulation type

Auto Man

Power setpoint Pressure setpoint Minimum CSS Initial CSS factor Initial A-dim. setpoint

1 Program menu

Program Edit

Main

Op. data

Select

Alarm

Calibration

Close

History

Set-up

Help

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)


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4. Main picture


Edit program

New program

Auto-CSS

Multi-CSS

Auto-Load

Auto-CSS

Program name

CSS setpoint

Auto Man

Initial CSS factor


Program Save

Main

Op. data

Alarm

Calibration

Cancel

History

Set-up

Help

d) Select the required regulation mode by pressing either the [Auto-CSS], [Multi-CSS], or [Auto-Load] button. e) Enter the required parameter values, as described in section 4.4.4 AutoCSS regulation mode, section 4.4.5 Multi-CSS regulation mode, or section 4.4.6 Auto-Load regulation mode. f) Press the [Save] button to save the changes. g) Select the next program to be edited, or press the [Close] button on the Program picture to finish the edit program procedure.

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4. Main picture

4.4.3 Selecting programs To select a pre-configured crushing program, follow the instructions below. a) Press the [Program] button to open the Program picture. RUNNING: New program

Program New program New program New program

Parameters Auto

Regulation type

Man

Power setpoint Pressure setpoint Minimum CSS Initial CSS factor Initial A-dim. setpoint

1 Program menu

Program Select

Edit

Main

Op. data

Alarm

Calibration

Close

History

Set-up

Help

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 “AutoCSS”, 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.


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4. Main picture

4.4.4 Auto-CSS regulation mode During Auto-CSS regulation, the ASRi system aims to maintain the desired CSS. The crusher's setting will never go below this CSS setpoint during normal crushing operation, but can exceed the CSS setpoint if the power draw or the Hydroset pressure is excessive. When Auto-CSS regulation is started, the mainshaft is moved to its initial CSS setpoint before feeding is permitted. Once the initial CSS setpoint has been reached, and as soon as the ASRi detects that the crusher is loaded, the automatic regulation will try to reach the CSS setpoint. In a program using Auto-CSS regulation, the following parameters must be set: •

•

CSS Setpoint: The desired operating CSS. The CCS range available depends on the crusher’s size and the wear of the mantle. The maximum CSS cannot be larger than what it is when the mainshaft is in its bottom position. Initial CSS factor: The factor to be multiplied by the CSS setpoint in order to obtain the Initial CSS setpoint.

The following parameter is automatically calculated by the system: • CAUTION!

Initial CSS setpoint: The CSS setpoint to be reached before the feed starts.

The feed to the crusher must be interlocked with the ASRi system, or else the crusher is not protected by the system.


Edit program

New program

Auto-CSS

Multi-CSS

Auto-Load

New program

Program name

CSS setpoint

Auto Man

Initial CSS factor


Program

Main

Op. data

Alarm

Calibration

Cancel

Save

History

Set-up

Help

(Continued)

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4. Main picture To set up an Auto-CSS regulation program, follow this sequence: a) Set the desired CSS value in the CSS setpoint field. b) The system checks that the CSS setpoint you enter is not out of range. If it is, the display indicates this in red and you must adjust the invalid CSS setpoint value. c) Set the initial CSS factor in the Initial CSS factor field. The product of the initial CSS factor and the CSS setpoint will result in the Initial CSS setpoint.

4.4.5 Multi-CSS regulation mode During Multi-CSS regulation, two different product curves can be combined to give a new desired product. This is accomplished by the ASRi system cyclically switching between two different settings—CSS setpoint 1 and CSS setpoint 2. You also define the time share between the two settings. For example, a smaller CSS can be selected in the CSS Setpoint 1 field. The resulting crusher product might contain sufficient fines material while there is a shortfall in coarse material. Coarse material can be produced by entering a CSS value in the Setpoint 2 field that is larger than CSS Setpoint 1. The crusher could, for example, operate at CSS Setpoint 1 for 60% of the time and at CSS Setpoint 2 for 40% of the time. This cycle is constantly repeated and completely automatic. The result is two different product curves that are delivered one after the other on the crusher's discharge conveyor. However, after a few transition chutes the material, that reaches the stockpile or storage bin, will have a single average grading and contain both the fines and the coarse material. In a program using Multi-CSS regulation, the following parameters must be set: • •

• •


CSS setpoint 1: The first desired operating CSS. CSS setpoint 2: The second desired operating CSS. The CCS range available depends on the crusher’s size and the wear of the mantle. The maximum CSS cannot be larger than what it is when the mainshaft is in its bottom position Time-share (%): The operating time share between the two CSS setpoints. Initial CSS factor: The desired factor to be multiplied with the CSS setpoint in order to provide the Initial CSS setpoint. (Continued)

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4. Main picture

The following parameter is automatically calculated by the system: • CAUTION!




Edit program

New program

Auto-CSS

Multi-CSS

Auto-Load

New program

Program name

CSS setpoint 1

Auto Man

CSS setpoint 2

Time share, CSS setpoint 1

Initial CSS factor

Initial CSS setpoint Program Save

Main

Op. data

Alarm

Calibration

Cancel

History

Help

Set-up

To set up a Multi-CSS regulation program, follow this sequence: a) Set the desired value in the CSS setpoint 1 field for the first operating CSS. b) Set the desired value in the CSS setpoint 2 field for the second operating CSS c) Set the desired figure in the Time-share field for the operating time distribution. d) The system checks that the CSS setpoints you enter are not out of range. If they are, the display indicates this in red and you must adjust the invalid CSS setpoint value. The CCS range depends on the crusher’s size and the wear of the mantle. The maximum CSS cannot be larger than what it is when the mainshaft is in its bottom position e) Set the initial CSS factor in the Initial CSS factor field. The product of the initial CSS factor and the CSS setpoint will result in the Initial CSS setpoint.

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4.4.6 Auto-Load regulation mode During Auto-load regulation, the ASRi system regulates the setting so that the crusher operates at a desired load level. The system will decrease the CSS until either the power setpoint or the pressure setpoint is reached. The system will keep the crusher loaded to that setpoint from there on. If the desired highest permitted load level is selected, the CSS will always be the smallest possible and this will result in maximum reduction. With Auto-Load regulation there is automatic compensation for liner wear, which means that the intervals between calibrations can be fairly long. In a program using Auto-Load regulation, the following parameters must be set: •

Power setpoint: The nominal drive motor power draw set in the crushing program in question. • Pressure setpoint: The highest average peak Hydroset pressure set in the crushing program in question. • Min CSS: The smallest permitted CSS in the crushing program in question. • Initial CSS factor: The desired factor to be multiplied with the CSS setpoint in order to provide the Initial CSS setpoint. The following parameter is automatically calculated by the system: • CAUTION!



(Continued)


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Edit program

New program

Auto-CSS

Multi-CSS

Auto-Load

New program

Program name

Power setpoint

Auto Man

Pressure setpoint

Min. CSS

Initial CSS factor

Initial A-dim. setpoint Program Save

Main

Op. data

Alarm

Calibration

Cancel

History

Help

Set-up

To set up an Auto-load regulation program, follow this sequence: a) Set the value of the desired highest permitted drive motor power draw in the Power setpoint field (1). b) Set the value of the desired highest permitted average peak Hydroset pressure in the Pressure setpoint field (2). c) Set the value for the desired smallest permitted CSS in the Min CSS field. NOTE!

It is important that the power setpoint value does not exceed the crusher maximum input power (parameter 601) by more than 10 % or the power transducer span (parameter 501), see in the Setup: Installation: Settings picture and Crusher settings in the Installation manual, by more than 10%. d) If any of the values entered are out of range, the display will indicate this in red and you must adjust the value.

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5. Operating data This section describes how to navigate the operating data of the ASRi.

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5.1 Operating data The ASRi contains a feature that presents detailed information on the different measured and calculated signals, events etc. Some statistics are also presented that are continuously updated on the picture. Whatever the operating mode, the operator can select the display of operating data. All the different Operating data pictures can be opened by pressing the [Op. data] button in the menu bar, and then the corresponding button for the desired picture in the pop-up menu

5.1.1 Motor power The Motor power picture displays detailed information about the crusher's motor power draw. a) Press the [Op. data] button on the menu bar, and then the [Power] button in the pop-up menu to open the Motor power picture. RUNNING: New program

Operating data: Motor power

Average

Current

Latest 30 min

Since reset

Average

Main

Average

Max.

Op. data

Alarm

History

Max.

Set-up

Help

(Continued)

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5. Operating data 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.


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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

Operating data: Pressure

Latest 30 min

Since reset

Avg. pressure

Main

Avg. peak pressure

Avg. pressure

Current

Avg. pressure

Max.

Op. data

Alarm

History

Max.

Set-up

Help

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)

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5. Operating data 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.


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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

Operating data: CSS

Current

Latest 30 min

Since reset

Minimum

Minimum

Average

Average

Maximum

Maximum

Main

Op. data

Alarm

History

Set-up

Help

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).

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5.1.4 Lubrication oil temperature The Lubrication oil temperature picture displays detailed information about the crusher's load. a) Press the [Op. data] button on the menu bar, and then the [Temperature] button in the pop-up menu to open the Lubrication oil temperature picture. RUNNING: New program

Operating data: Lubrication oil temperature

Current

Latest 30 min

Since reset

Minimum

Minimum

Average

Average

Maximum

Maximum

Main

Op. data

Alarm

History

Set-up

Help

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)


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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

Operating data: A-dimension Estimated contact position Calibrated contact position Mainshaft position

Initial A-dim setpoint Initial CSS setpoint

Main

Op. data

Alarm

History

Set-up

Help

(Continued)

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5. Operating data The contact A-dimension value (or contact mainshaft position) is gathered in two different ways: •

By measuring the A-dimension at which the liners come in contact with each other during metal-to-metal calibration • By calculating the A-dimension at which the liners would theoretically come into contact with each other—if it were possible—during calibration with lead. A-dimension indicator At the left hand side there is an A-dimension indicator that shows the relative positions of the mainshaft. The indicator also shows the minimum permitted A-dimension at the top and the maximum permitted A-dimension at the bottom. The maximum permitted A-dimension, corresponding to the lowest position of the mainshaft, is set 2 mm from the absolute bottom position. This is to avoid the risk of running the Hydroset pump dry. •

• • • •


Estimated contact position (1): The estimated metal-to-metal position of the mainshaft, taking into consideration the estimated wear since the latest calibration took place. Calibrated contact position (2): The contact position at the latest calibration. Mainshaft position (3): The current mainshaft position. Initial A-dimension setpoint: The average A-dimension over the last 30 minutes that the crusher has been loaded. Initial CSS setpoint: The average CSS over the last 30 minutes the that crusher has been loaded.

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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

Operating data: Overview Power

Pressure

CSS

Operating time

Lub. oil. temp.

Total

A-dim.

Loaded

Since original start-up Since latest liner change Since latest calibration Since reset

Energy consumption Since original start-up Since reset

Main

Op. data

Alarm

History

Set-up

Help

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)

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5. Operating data 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.

5.1.7 Event list The Event list picture displays information about changes which have occurred in regulation mode. The list is presented in chronological order but can also be temporarily sorted in Group order, Time order, or Event text order by pressing the corresponding title bar at the top of the columns. The event list can contain up to 200 events depending on type. When the list is full, the oldest event is deleted to make room for a new one. (Continued)


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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

Operating data: Event list Group

Time

Event

Mode

Crushing program 2, Auto-Load, activated

Mode

Activated stop mode

Mode


Mode

Activated stop mode

Mode

Activated calibration mode

Mode

Activated stop mode

Mode


Mode

Crushing program 1, Auto-CSS, activated

Mode

Program 3 saved

Mode

Program 2 saved

Mode

Crushing program 2, Multi-CSS, activated

Mode

Program 3 saved

Mode

Program 1 saved

Mode

Program 2 saved

Mode

Program 1 saved

Mode

Crushing program 1, Auto-CSS, activated

System

System start-up

Mode

Activated stop mode

System

System start-up

Mode

Activated stop mode

System

System start-up

Main

Op. data

Alarm

History

Set-up

Help

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: • • • • • • • • • • • •

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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

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6. Alarms This section describes the alarm functions of the ASRi and it is intended to assist maintenance personnel in troubleshooting the system. It is not intended that personnel with an Operator’s work role should carry out corrective actions. The Operator’s responsibility is to identify the fault or error and report to a supervisor. The supervisor decides on the appropriate action.

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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.

6.1.1 Alarm severity levels When an alarm is active, the Status bar and the Alarm button in the menu bar flash in red. There are three degrees of severity for ASRi alarms: A, B, and C alarms. •

An A-alarm is the most serious type of alarm. An A-alarm will immediately stop regulation and will also stop the feed to the crusher if the feed interlock output from the ASRi system is used. If the feed interlock is not connected, the feed must be stopped in some other way. Regulation cannot be restarted until the fault has been corrected. • A B-alarm results in a feed shut-down, if the feed interlock output from the ASRi system is used, but regulation continues while the fault persists. When the fault has been corrected, the feed is restarted and regulation continues as before. • A C-alarm is a warning that indicates that an undesirable condition has been reached. These conditions are not harmful to the machine and neither regulation nor feed are interrupted. Alarms that are no longer active but have not yet been acknowledged are indicted with grey alarm icons in the Alarm log. See section 6.1.5 A-alarms, section 6.1.6 B-alarms, and section 6.1.7 C-alarms for more information on each alarm.

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6.1.2 Alarm status Each alarm exists in one of the following statuses: Active and unacknowledged: The signal in question has assumed an abnormal value. The operator has not yet acknowledged the fault, which is indicated in the Alarm list and the Alarm log by a framed yellow A, B, or C symbol. Active and acknowledged: The fault condition persists but the operator has acknowledged the alarm. The symbol is similar to the one for an active and unacknowledged alarm, but has a green check mark. Inactive and unacknowledged: There is currently no fault, but a fault has occurred previously, without the operator acknowledging it. This is indicated by a grey A or B symbol. Inactive and acknowledged: The fault has been acknowledged and is no longer active. This is indicated by a grey A, B, or C symbol with a green check mark. This symbol only occurs in the Alarm log.


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6.1.3 Alarm list The Alarm list shows all alarms which are active and those which are inactive but have not yet been acknowledged. By default, the Alarm list is arranged in chronological order. a) Press the [Alarm] button on the menu bar, and then the [List] button in the Alarm pop-up menu to open the Alarm list picture. RUNNING: New program

Alarm: List Time

Alarm text

History sync

Main

Op. data

Alarm

History

Set-up

Help

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)

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6. Alarms 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.

6.1.4 Alarm log The Alarm log shows all status changes for all alarms. Each line in the display denotes a change from one status to another for a certain alarm signal. The icons used in the Alarm log are the same as the ones used in the Alarm list. The time displayed indicates the time when the status changed. The Alarm log can contain up to approximately 200 alarm status changes. When the log is full, the oldest status change is deleted to make room for a new one. By default, the Alarm log displays the status changes in descending order of time, i.e. with the latest status change at the top. (Continued)


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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 Time

Alarm text C23 Mainshaft in bottom position! C23 Mainshaft in bottom position! C23 Mainshaft in bottom position! C27 Liner change necessary! C24 Mainshaft in top position! Information

C27 Liner change necessary! C24 Mainshaft in top position!

History sync

C23 Mainshaft in bottom position C23 Mainshaft in bottom position C27 Liner change necessary! C27 Liner change necessary! A05 A-dimension signal too high! C23 Mainshaft in bottom position! C23 Mainshaft in bottom position!

Main

Op. data

Alarm

History

Set-up

Help

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)

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6. Alarms 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: Status:

Active -> Inactive

Time: Severity: Descr:

C23 Mainshaft at bottom position

Close

•


Press the [History sync] button to set all the History pictures to the time indicated in the Time column.

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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.

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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)


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B18: Internal pumping up too long! The system displays an alarm when the internal command that drives the mainshaft up has been active for more than 10 minutes. This alarm stops the feed to the crusher. The feed resumes when the alarm turns inactive. B19: Internal pumping down too long! The system displays an alarm when the internal command that drives the mainshaft down has been active for more than 10 minutes. This alarm stops the feed to the crusher. The feed resumes when the alarm turns inactive. B20: No communication with the Power measurement unit! The system displays an alarm when there is no communication between the Control unit and the Power measurement unit. The alarm stops the feed to the crusher. The feed resumes when the alarm turns inactive. B21: No communication with the Tank measurement unit! The system displays an alarm when there is no communication between the Control unit and the Tank measurement unit. The alarm stops the feed to the crusher. The feed resumes when the alarm turns inactive. B22: No communication with the Hydroset drive unit! The system displays an alarm when there is no communication between the Control unit and the Hydroset drive unit. The alarm stops the feed to the crusher. The feed resumes when the alarm turns inactive. B23: Power level low in regard to pressure level! The system displays an alarm when the pressure is more than 0.3 MPa over the unloaded pressure, the pressure sector is greater than 3 degrees, and the power is less than 20% of the crusher’s maximum input power (parameter 601) for more than one minute. The alarm stops the feed to the crusher. The feed resumes when the alarm turns inactive. B24: Pressure level low in regard to power level! The system displays an alarm when the pressure sector is less than 1 degree and the crusher is loaded, based on the power measurement, for more than one minute. The alarm stops the feed to the crusher. The feed resumes when the alarm turns inactive.

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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 (Adimension) 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)


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C28: Calibration needed! The system displays a warning that CSS calibration is needed if the following conditions occur: – When the system is not under Auto-Load regulation, the current CSS is smaller than the minimum CSS of the crusher (parameter 605). When the system is under Auto-Load regulation mode, the current CSS is smaller than the minimum CSS of the regulation program (this can never be smaller than parameter 605). – Both power and pressure lie above 50% of the setpoints. – Where 100% of both power and pressure correspond with the maximum limits of the regulation program (if in Auto-Load regulation mode) or the maximum limits of the crusher (if in any other regulation mode). The power is multiplied with factor 1.1 (110%) to take into account the loss of power in the motor. C29: Mainshaft does not move up! The system displays a warning when the system records that the upward movement contactor is closed and the vertical shaft speed is lower than 10% of the nominal vertical shaft speed (shaft speed when pumping, parameter 604) for more than 3 seconds. C30: Mainshaft does not move down! The system displays a warning when the system records that the downward movement contactor is closed and the vertical shaft speed is lower than 10% of the nominal vertical shaft speed (shaft speed when pumping, parameter 604) for more than 3 seconds. C31: Mainshaft moves up too slowly! The system displays a warning when the system records that the upward movement contactor is closed and the vertical shaft speed is lower than 60% of the nominal vertical shaft speed (shaft speed when pumping, parameter 604) for more than 3 seconds. C32: Mainshaft moves down too slowly! The system displays a warning when the system records that the downward movement contactor is closed and the vertical shaft speed is lower than 60% of the nominal vertical shaft speed (shaft speed when pumping, parameter 604) for more than 3 seconds.

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7. History This section describes the history functions of the ASRi.

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7. History

7.1 Historical data—general The ASRi system continuously monitors the various signals and values. These are logged in historical data log files. All the different History pictures can be opened by pressing the [History] button in the menu bar, and then the corresponding button for the desired picture in the pop-up menu. The different History pictures look similar to each other and present information in trend curves. In the Motor power picture, the Pressure picture, the CSS picture, the Lubrication oil temperature picture, the A-dimension picture, and the Overview picture, the upper section of the trend curve frame displays the analog curves, and the lower section of the trend curve frame displays the digital signals (D1-D3). The system displays data in 10 s, 1 min, 10 min, 1 h, and 12 h windows. A smaller time window also means a shorter signal storage time. The selection of time window is made through buttons below the curve presentation frame: Press the [10 s] button to view the information in 10 second windows. The signal storage time for this view is approximately 1 hour. • Press the [1 min] button to view the information in 1 minute windows. The signal storage time for this view is approximately 1 hour. • Press the [10 min] button to view the information in 10 minute windows. The signal storage time for this view is approximately 24 hours. • Press the [1 h] button to view the information in 1 hour windows. The signal storage time for this view is approximately 1 week. • Press the [12 h] button to view the information in 12 hour windows. The signal storage time for this view is approximately 4 weeks. The storage times referred to above apply if the ASRi OP control cabinet is switched on around the clock. If the supply is switched off when the ASRi system is not in use, information can be stored for a longer period. •

(Continued)

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7. History 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.

Studying data with higher or lower resolution If you discover something interesting in the CSS picture or the Overview picture, you can switch to a higher or lower resolution in the following way: a) Use the [] and [] buttons to position the event close to the right-hand edge of the picture. b) Press the [+] (zoom in) button for the next higher resolution, or the [-] (zoom out) button for the next lower resolution. c) If necessary, repeat steps a and b. NOTE!


If the event lies too far back in time, there may be no data at the highest resolutions. See above.

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7.1.1 Motor power The Motor power picture displays historical data on the crusher’s motor power draw, both in numerical values and as trend curves. a) Press the [History] button on the menu bar and then the [Power] button in the pop-up menu to open the Motor power picture. RUNNING: New program

History: Motor power

Average power setpoint

Pump up

Off

Average power

Pump down

Off

Power

Feed

On

Main

Op. data

Alarm

History

Set-up

Help

Average power setpoint Indicates the maximum power permitted for the current regulation mode. If the crusher is operating in “Auto-load” mode, this is the same as the desired power level (“Power setpoint” in the selected crushing program). In other cases it is the same as the maximum power rating for the motor or the crusher, whichever is the lowest. Average power Indicates the average value of the power draw signal. (Continued)

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7. History 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. Average peak pressure setpoint Indicates the maximum average peak pressure under the current regulation mode. If the crusher is operating in Auto-load mode, this is the same as the desired pressure level. In other modes it the same as the maximum permitted pressure. Average peak pressure Indicates the calculated average value of the peaks in the pressure signal. Average pressure Indicates the average value of the pressure signal. Pressure Indicates the instantaneous value of the pressure signal. This value is only displayed when the 10 s interval is selected. (Continued)


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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 CSSsetpoint 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.

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7. History

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)


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7. History

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

Pump up

Off

Average power

Pump down

Off

Average peak pressure

Feed

On

Main

Op. data

Alarm

History

Set-up

Help

CSS Indicates the gap between the crusher's mantle and concave ring on the closed side. (Continued)

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7. History 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.

7.1.7 Liner wear The Liner wear picture displays historical data on mainshaft contact position in relation to time and energy consumption. It gives an indication of the liner wear over time. Data can be stored for up to 10 liner sets. a) Press the [History] button on the menu bar and then the [Wear] button in the pop-up menu to enter the Liner wear picture. RUNNING: New program

History: Liner wear

Time

Energy

Previous

Calibrated

Estimated

Main

Table

Op. data

Next

Current

Liner start date:

Alarm

History

Set-up

Help

(Continued)


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7. History

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:


History: Liner wear Loaded operating time since liner change (h)

Time

Energy

Estimated

Main

Op. data

Energy consumed since liner change (MWh)

Calibrated contact position (mm) Estimated

Calibrated

Table

Previous

Calibrated

Liner start date:

Alarm

History

Next

Set-up

Current

Help

• 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.

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