2. Safety precautions
3.3 Service
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)
The Connections picture shows a schematic view of the connections:
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.
RUNNING: New program
Set-up: Service: Connections
Oil tank unit Alarm
& Feed
Close
Main Op. data Alarm History Set-up Help
This section describes how to navigate the main picture of the ASRi that contains all the functions needed to operate the crusher.
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.
1 Menu bar
2 Hydroset pressure indicator 9 Operating mode
selector
0 Mainshaft control buttons
11 Program/
Calibration selector buttons
Main Op. data Alarm History Set-up Help
Auto
Man
Calibration Program RUNNING: New program
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
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.
Main Op. data Alarm History Set-up Help
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.
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.
(Continued)
RUNNING: New program
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.
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.
Alarm: A01
4.2.8 Start/Stop buttons
The Start/Stop buttons (8) are used to start and stop the regulation of the crusher.
• 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.
4.2.9 Operating mode selector
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
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.
NOTE! If the feed system is not interlocked with the ASRi system, the feed indication arrow has no connection with reality.
Auto
Man
Calibration Program
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.
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.
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.
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.
b) Press the [Metal to metal] button to start metal-to-metal calibration.The calibration procedure starts automatically.
(Continued)
Main Op. data Alarm History Set-up Help
Auto
Man
Calibration Program STOP: New program
Lead Metal-to-metal Close
Calibration
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)
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.
b) Press the [Lead] button to start calibration with lead.The calibration procedure starts automatically.
(Continued)
Main Op. data Alarm History Set-up Help
Auto
Man
Calibration Program STOP: New program
Lead Metal-to-metal Close
Calibration
c) If you want to terminate the calibration procedure, you can do this at any time by pressing the [Cancel] button.
You will be guided through the various stages of the calibration procedure on the picture:
Stopping Feeder
The feed to the crusher stops.
CAUTION! If the feed arrangement is not interlocked with the ASRi, the operator has to stop the feed to the crusher.
Start Crusher
If the crusher's drive motor has not been started, you must start the motor.
The ASRi will automatically detect this and continue with the calibration procedure. If you desire to accomplish the calibration procedure while the motor is not running, you can press the [Disregard] button and then the [Continue] button to continue.
If the crusher is loaded again, the system will make 3 attempts to proceed with the calibration procedure before it is automatically interrupted. This is indicated by an error message: “Crusher load too high, terminating”. In this case, press the [OK] button to cancel the procedure.
Position the shaft and measure the CSS. Enter the value and press [Continue]
d) Go to the crusher and measure the CSS manually. Use at least one lump of lead, hanging in a steel wire, and lower it through the crushing chamber at 4 different places. If the CSS is too large for the lead lump available, use some other suitable tool.
e) Use a vernier indicator to measure the thickness of the lead lump after it has passed through the crushing chamber.
f) The average thickness of the 4 measurements corresponds to the CSS.
Enter this value by using the key pad that appears on the picture.
Note! Do not move the shaft until you have pressed the [Continue] button.
Crusher calibrated! Press Finish The crusher has now been calibrated.
g) Press the [Finish] button to confirm that the calibration procedure has been completed.
h) Restart regulation and feeding by pressing the [ l ] button.
4.4 Program
The Program picture is the picture where you can add, edit or select crushing programs. Programs need to be set up before running the ASRi system.
It is possible to configure up to 20 different crushing programs. For each program, you must first choose the regulation mode to be used for the program in question. These regulation modes are:
• Auto-CSS. See section 4.4.4 Auto-CSS regulation mode
• Multi-CSS. See section 4.4.5 Multi-CSS regulation mode
• Auto-Load. See section 4.4.6 Auto-Load regulation mode
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.
(Continued)
Main Op. data Alarm History Set-up Help
Auto
Man
Calibration Program RUNNING: New program
New program Program
New program New program
Parameters
Regulation type Not programmed
Edit Select Close
1 Program menu
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.
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)
Main Op. data Alarm History Set-up Help
Auto
Man
Calibration Program RUNNING: New program
New program Edit program
Program name Auto-CSS
Save Cancel
New program
Multi-CSS Auto-Load
f) Write the desired program name in the Program name field.
g) Enter the required parameter values, as described in section 4.4.4 Auto-CSS regulation mode, section 4.4.5 Multi-Auto-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)
Main Op. data Alarm History Set-up Help
Auto
Man
Calibration Program RUNNING: New program
New program Edit program
Program name
CSS setpoint
Initial CSS factor
Initial CSS setpoint Auto-CSS
Save Cancel
New program
Multi-CSS Auto-Load
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
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