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S223.531.en
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Sandvik Stationsplan, SE-233 81 Svedala, Sweden Tel: +46 (0)40 409000, Fax: +46 (0)40 409260 www.sandvik.com
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........................................................... 18 18 18 19 19 19 20 21 22 22 22 23 23 23 24 25 26 26 27 27
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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.................................... 36 36 37 38 38 39 39 40 40 41 41 41 41 42 43 45 47 47 50 53 54 55 57
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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 datageneral ..................................................... 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 .............................................................. 84 86 87 88 89 89 90 91
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Table of Contents
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1. Introduction
1. Introduction
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1. Introduction
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) Operators 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 Operators manual or problems connected to the ASRi 2.0 documentation, send an e-mail to: manuals.srp@sandvik.com.
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1. Introduction
1 2 3 4 5 6
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 crushers Operators manual.
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1. Introduction
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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 crushers 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 crushers 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.
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1. Introduction
The figure below shows an example of how the system can be arranged.
-PS
Power supply unit
-OP
Control unit
=PM
=OT/HT
-U1N
Power measurement unit
-CBT
Tank measurement unit
-L3
Hydroset drive unit
NOTE!
The power supply unit (PS) must be installed close to the control unit (OP). The other units can be installed in the most convenient positions as they are connected by a bus system. The 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 crushers 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 Peak Hydroset pressure 2 Average peak Hydroset pressure 3 Average Hydroset pressure
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 crushers operating conditions and thus help to optimize the performance of the machine.
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1. Introduction
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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
General danger
Dangerous voltage
Risk of crushing
Hanging load
Risk of crushing
Flying fragments
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2. Safety precautions
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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2. Safety precautions
Sandvik SRP AB provides technical documentation appropriate to all three work roles: Installation manual Operators 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.
Ear protection
Safety helmet
Eye protection
Protective gloves
Safety boots
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2. Safety precautions
WARNING!
Always switch off power and lock out the equipment (so that it cannot inadvertently be switched on) before any maintenance work is started. Also ensure that it is not possible for anyone else to switch the power on while maintenance work is being carried out. Avoid staying on the crusher, unless necessary for maintenance work.
Risk of crushing Never remain on the crusher while crushing. Moving parts constitute a risk of crushing. Falling into the crusher implies danger of being crushed. Risk of crushing If the crusher is mounted on rubber dampers, there is a risk of crushing between the oscillating parts of the crusher and the stationary frame. Ejection Never look into the crusher while crushing. Fragments and possibly harmful matter fed to the crusher may be ejected. WARNING!
DANGER!
WARNING!
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2. Safety precautions
WARNING!
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.
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. Safety precautions
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. Only welders qualified according to European Standard EN 287 or similar are permitted to perform welding operations on the crusher.
CAUTION!
If welding an item to the crusher, the grounding cable must be attached to the item itself. If a crusher component is to be welded, the grounding cable should be attached as near to the welding area as possible.
Toxic gases Inhalation of welding fumes can be dangerous to health. Always follow instructions provided by the welding equipment supplier. Some parts of the crusher are made of manganese steel. Long-term exposure to manganese oxide can affect the nervous system.
WARNING!
WARNING! CAUTION!
WARNING! CAUTION!
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2. Safety precautions
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. Safety precautions
WARNING!
WARNING!
DANGER!
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. Safety precautions
2.4 Emissions
Since Sandviks 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 crushers 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. Safety precautions
2.4.2 Noise
Health hazards Crushing and processing material will create noise. Such noise can be more or less dangerous to the hearing. Use ear protection. WARNING!
Refer to OM - Technical specifications for measured noise levels and measurement conditions. Rubber compression mountings and dust encapsulation result in lower noise levels.
2.4.3 Radioactivity
Health hazards Radon is a radioactive gas that occurs naturally in bedrock. Radon may cause lung cancer. Mineral type, ventilation and water are all factors that influence the contents of radon gases.
DANGER!
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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2. Safety precautions
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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 User Log off
Set-up: Operation
Date & time Adjust
Backlight luminance
Main
Op. data
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:
Bulgarian Chinese Croatian Czech Danish English Finnish French German Hungarian Italian Norwegian Polish Portuguese Portuguese (Br) Russian Romanian Slovene Spanish Swedish
NOTE!
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. Set-up: Operation
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 Mainshaft movement speed Pressure sector angle Digital signals Motor protection Contactor down Internal communication Input Contactor up Reserve Feeder Pump down Degrees at
Reset
Connection
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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3. Set-up: Operation
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 (operators panel) pictures are divided into 3 sections. At the top is the status bar, the middle section displays all the main information, and at the bottom is the menu bar. The contents of the menu bar are consistent throughout the menu system. When pressing a menu button, a pop-up menu appears with further picture alternatives. Once one of these alternatives has been selected, the corresponding picture will open. When a picture is active its corresponding menu button is shadowed.
1 Menu bar 2 Hydroset pressure indicator 3 Motor power indicator 4 CSS indicator 5 Status bar 6 Crusher symbol 7 A-dimension indicator 8 Start/Stop buttons 9 Operating mode selector 0 Mainshaft control buttons 11 Program/ Calibration selector buttons
Main Op. data Alarm History Set-up
Auto Man
Program Calibration
Help
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4. Main picture
Main The Main picture is the main operating picture and shows the crushers 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
...of the maximum permitted motor power. The crushers 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
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
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4. Main picture
NOTE!
If the feed system is not interlocked with the ASRi system, the feed indication arrow has no connection with reality.
The Operating mode selector (9) is used to select either automatic or manual control mode for the crushers 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.
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 Operators 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 crushers 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 Operators manual.
1. The minimum A-dimension is 15 mm for cone crushers CH420CH660, 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
Calibration
Auto Man
Main
Op. data
Alarm
History
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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OM Sandvik ASRi 2.0 Crusher calibrated! Press Finish The crusher has now been calibrated.
4. Main picture
d) Press the [Finish] button to confirm that the calibration procedure has been completed. e) Restart regulation and feeding by pressing the [ l ] button.
Calibration
Auto Man
Main
Op. data
Alarm
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
Program
New program New program New program
1 Program menu
Edit Select Close
Program Calibration
Main
Op. data
Alarm
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
Auto-CSS
New program
Multi-CSS
Auto-Load
Program name
New program
Auto Man
Main
Op. data
Alarm
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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4. Main picture
Edit program
Auto-CSS
New program
Multi-CSS
Auto-Load
Program name
New program
CSS setpoint
Auto Man
Main
Op. data
Alarm
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. Deselect the regulation mode by pressing the corresponding button, [Auto-CSS], [Multi-CSS], or [Auto-Load]. k) Press the [Save] button. j)
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
a) Press the [Program] button on the main picture to open the Program picture.
RUNNING: New program
Program
Multi-CSS Auto-Load
Parameters Regulation type Power setpoint Pressure setpoint Minimum CSS Initial CSS factor Initial A-dim. setpoint Auto-Load Auto Man
1 Program menu
Edit Select Close
Program Calibration
Main
Op. data
Alarm
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
Auto-CSS
New program
Multi-CSS
Auto-Load
Program name
Auto-CSS
CSS setpoint
Auto Man
Main
Op. data
Alarm
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
Program
New program New program New program
Parameters Regulation type Power setpoint Pressure setpoint Minimum CSS Initial CSS factor Initial A-dim. setpoint Auto Man
1 Program menu
Edit Select Close
Program Calibration
Main
Op. data
Alarm
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
The feed to the crusher must be interlocked with the ASRi system, or else the crusher is not protected by the system.
Edit program
Auto-CSS
New program
Multi-CSS
Auto-Load
Program name
New program
CSS setpoint
Auto Man
Main
Op. data
Alarm
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.
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4. Main picture
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
Auto-CSS
New program
Multi-CSS
Auto-Load
Program name
New program
CSS setpoint 1
Auto Man
CSS setpoint 2
Main
Op. data
Alarm
History
Set-up
Help
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 crushers 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. Main picture
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.
(Continued)
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4. Main picture
Edit program
Auto-CSS
New program
Multi-CSS
Auto-Load
Program name
New program
Power setpoint
Auto Man
Pressure setpoint
Min. CSS
Main
Op. data
Alarm
History
Set-up
Help
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. Operating data
Current
Average
Latest 30 min
Since reset
Average
Max.
Average
Max.
Main
Op. data
Alarm
History
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 timeexpressed as a percentage of 30 minutes or since the feature was resetduring which the crusher's motor power draw was within the range represented by the respective column.
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5. Operating data
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
Current
Avg. pressure
Latest 30 min
Since reset
Avg. pressure
Max.
Avg. pressure
Max.
Main
Op. data
Alarm
History
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 timeexpressed as a percentage of 30 minutes or since the feature was resetduring 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. Operating data
5.1.3 CSS
The CSS picture displays detailed information about the CSS. a) Press the [Op. data] button on the menu bar, and then the [CSS] button in the Operating pop-up menu to open the CSS picture.
RUNNING: New program
Current
Latest 30 min
Minimum Average Maximum
Since reset
Minimum Average 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 crushers CSS over the latest 30 minutes (minimum, average, maximum). Since reset The lower right section (3) of the picture displays information on the crushers CSS since the data collection feature was reset (minimum, average, maximum).
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5. Operating data
Current
Latest 30 min
Minimum Average Maximum
Since reset
Minimum Average 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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5. Operating data
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
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 otherif it were possibleduring 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. Operating data
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 time Since original start-up Since latest liner change Since latest calibration Since reset
Total
Loaded
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 crushers operating time, i.e. the time that the crushers 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 systemcan 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 datacan 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.
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5. Operating data
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
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: 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 Operators work role should carry out corrective actions. The Operators 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. Alarms
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.
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6. Alarms
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6. Alarms
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.
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6. Alarms
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! C27 Liner change necessary! C24 Mainshaft in top position! 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! History sync Information
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: Group: Status: Time: Severity: Descr: C23 Mainshaft at bottom position Active -> Inactive 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. Alarms
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. Alarms
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 C. 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 C. 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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6. Alarms
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 crushers 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. Alarms
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 C. 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 crushers 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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6. Alarms
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 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. History
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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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OM Sandvik ASRi 2.0 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. History
7.1.3 CSS
The CSS picture displays historical data on the crushers 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 crushers 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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OM Sandvik ASRi 2.0 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. History
7.1.6 Overview
The Overview picture displays historical data on the crushers 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
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CSS Indicates the gap between the crusher's mantle and concave ring on the closed side. (Continued)
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OM Sandvik ASRi 2.0 Average power Indicates the average value of the power draw.
7. History
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.
Time Estimated
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Table Calibrated
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(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:
Time Estimated
Energy
Table Calibrated
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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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