operator’s manual
S223.531.enSerial no. / Machine no. Sign.
SANDVIK ASRi 2.0
© Copyright 2009 Sandvik SRP AB.
All rights reserved. No parts of this document may be reproduced or copied in any form or by any means without written permission from Sandvik SRP AB. All data and information in this manual may be changed without further notice. Reservations for misprints.
Document number: S223.531.en
Issue: 20091012 Version: 02
Table of Contents
1. Introduction
1.1 Equipment information... 6
1.1.1 Document information... 7
1.2 Operating principles of a cone crusher ... 8
1.3 Function and benefits of the ASRi ... 10
1.3.1 ASRi system description ... 11
1.3.2 Hydroset pressure definitions ... 14
1.4 Information levels... 15
2. Safety precautions
2.1 Hazard information ... 18 2.1.1 Warning signs ... 18 2.1.2 Risk levels... 18 2.1.3 Prohibition signs... 19 2.1.4 Mandatory signs... 19 2.2 Personnel... 19 2.2.1 Personal protection ... 202.3 General safety precautions... 21
2.3.1 Machine safety guards... 22
2.3.2 Machine access ... 22
2.3.3 Electrical safety... 22
2.3.4 Welding ... 23
2.3.5 Hydraulic system... 23
2.3.6 Lubrication system ... 23
2.3.7 Lifting and moving loads ... 24
2.3.8 Feed and jams ... 25
2.4 Emissions ... 26
2.4.1 Dust... 26
2.4.2 Noise... 27
3. Set-up: Operation
3.1 Starting up... 30 3.2 Display ... 30 3.3 Service ... 32 3.3.1 Connections ... 334. Main picture
4.1 General ... 364.2 The Main picture layout... 36
4.2.1 Menu bar ... 37
4.2.2 Hydroset pressure indicator ... 38
4.2.3 Motor power indicator... 38
4.2.4 CSS indicator ... 39
4.2.5 Status bar ... 39
4.2.6 Crusher symbol ... 40
4.2.7 A-dimension indicator... 40
4.2.8 Start/Stop buttons... 41
4.2.9 Operating mode selector... 41
4.2.10 Mainshaft control buttons ... 41
4.2.11 Program/Calibration selector buttons... 41
4.3 Calibration... 42
4.3.1 Calibration: metal-to-metal ... 43
4.3.2 Calibration: with lead... 45
4.4 Program ... 47
4.4.1 Adding new programs ... 47
4.4.2 Edit Program ... 50
4.4.3 Selecting programs ... 53
4.4.4 Auto-CSS regulation mode ... 54
4.4.5 Multi-CSS regulation mode ... 55
5. Operating data
5.1 Operating data ... 60
5.1.1 Motor power ... 60
5.1.2 Pressure... 62
5.1.3 CSS... 64
5.1.4 Lubrication oil temperature ... 65
5.1.5 A-dimension ... 66
5.1.6 Overview ... 68
5.1.7 Event list ... 69
6. Alarms
6.1 Alarms... 726.1.1 Alarm severity levels ... 72
6.1.2 Alarm status ... 73 6.1.3 Alarm list ... 74 6.1.4 Alarm log... 75 6.1.5 A-alarms... 78 6.1.6 B-alarms... 79 6.1.7 C-alarms ... 81
7. History
7.1 Historical data—general ... 84 7.1.1 Motor power ... 86 7.1.2 Pressure... 87 7.1.3 CSS... 88 7.1.4 Temperature... 89 7.1.5 A-dimension ... 89 7.1.6 Overview ... 90 7.1.7 Liner wear ... 911.1 Equipment information
Purpose
The purpose of this Sandvik equipment is to regulate and protect a cone crusher from overloads. The system also helps improve production and achieve better control and use of the cone crusher. Sandvik SRP AB will not accept any liability for damage to equipment or injury to personnel caused by unauthorised or improper use or modification of this equipment.
Manufacturer
This Sandvik equipment has been manufactured by: Sandvik SRP AB Stationsplan 1 SE-233 81 Svedala Sweden www.sandvik.com For maintenance
Contact the nearest Sandvik company, agent, representative or the manufacturer directly: Sandvik SRP AB Service Dept. SE-233 81 Svedala Sweden Telephone +46-40-40 90 00 Telefax +46-40-40 92 60 Identification
The ASRi serial number decal is located on the side of the ASRi control unit. The serial number is needed when contacting Sandvik concerning this specific equipment and when ordering spare parts.
Please enter the ASRi serial number in the intended field on the first page of this document (the copyright page).
1
1.1.1 Document information
Purpose of this document
The purpose of this Operator’s manual is to provide information on how to safely use this Sandvik equipment.
It is important to:
• read through the whole of this manual before performing any work • keep the manual for the lifetime of the equipment
• pass the manual on to any subsequent holder or user of the equipment
Design modifications
The instructions in this document are in accordance with the design and construction of the equipment at the time it was delivered from the Sandvik manufacturing plant.
Technical publications
The technical publications available for this equipment are: • Installation manual (IM)
• Operator’s manual (OM)
• Spare parts catalog (SPC)
When ordering technical publications, always specify the language and state the ASRi serial number.
Number of pages
This document contains a total of 92 numbered pages.
Feedback
If you have comments on this Operator’s manual or problems connected to the ASRi 2.0 documentation, send an e-mail to: [email protected].
1.2 Operating principles of a cone crusher
In a cone crusher the process material is crushed between two rigid surfaces. In general, the motion of the moving surface is independent of the load on the crusher. The crushing action is achieved by an eccentric gyratory movement of the mainshaft (6). Individual pieces of process material (e. g. rock or ore) are nipped, compressed and crushed between the mantle (4) and the concave ring (3).
The quality and quantity of the produced process material is a result of the interaction between the crusher and the process material. The crushing chamber’s geometry, the crusher’s dynamics and the process material are the most important factors.
The concave ring (3), mantle (4), eccentric assembly (5) and the location of the pivot point determine the chamber geometry of the cone crusher. The crusher’s drive motor rotates the eccentric assembly at a constant speed through a gear transmission. The rotation of the eccentric assembly causes the lower end of the mainshaft to gyrate. At the top of the mainshaft (6) is the spider bearing (1) that acts as the pivot point for this gyrating motion. The mantle is fixed to the mainshaft and the concave ring is fixed to the topshell. The gyration of the mainshaft means that the distance between the mantle and the concave ring continually varies. When this distance decreases the incoming process material will be subjected to a compressive stress and will be crushed. When the mantle moves away from the concave ring, the process material is able to flow down through the chamber.The mantle and the concave ring must be replaced regularly as they are continuously worn. The rate at which this wear occurs depends on the characteristics of the process material. (Continued)
1
3
2
4
6
5
1 Spider bearing 2 Topshell 3 Concave ring 4 Mantle 5 Eccentric assembly 6 MainshaftSetting adjustment
Due to the need to compensate for wear and the need to produce different product sizes the crusher has a control system, named the Hydroset system. It basically consists of a robust hydraulic jack, which supports the mainshaft and adjusts its position. By moving the mainshaft up and down, the discharge setting can be changed and the size of the crushed material can thereby be changed. Read more in your cone crusher’s Operator’s manual.
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1.3 Function and benefits of the ASRi
The ASRi (Automatic Setting Regulation–Intelligent) is the cone crusher’s setting and regulation system. It can also display statistical and historical data, store different crushing programs, etc. The duties of the ASRi system are to automatically regulate the crusher and to protect the crusher from overloads. In addition, the ASRi system incorporates several functions which simplify operation.
When the discharge setting is adjusted manually by the operator, the setting must be kept large enough to avoid possible overload conditions.
Consequently, the crusher is not utilized to its full potential. When the crusher is controlled by the ASRi, the system keeps the setting as close as permitted by the machine without risk of damaging it. Thus, the ASRi helps the user achieve higher production, a higher degree of reduction, and
improved product distribution. In addition, a better product shape can be obtained. A further benefit is that the crusher's wearing liners can be utilized better.
The ASRi monitors the cone crusher’s performance and ensures that the measured values lie within the permitted limits that have been set in the system. If these limits are exceeded, the ASRi will adjust the setting until the desired values are attained.
The ASRi operator’s panel, hereafter called the control unit, can be mounted almost anywhere it is desired, but most likely in the control room. It can also communicate with other systems in the local plant. The control unit
incorporates an integrated colour touch screen which is the operator’s interface.
The ASRi control unit is continuously fed, through the distributed I/O units, with information about
– The power (kW or hp) drawn by the cone crusher’s drive motor. – The pressure (MPa or psi) in the Hydroset system. This value is an
indication of the crushing force inside the cone crusher.
– The distance A (mm or in.) between the underside of the spider hub and the top of the headnut. This is also referred to as the A-dimension, and is used to describe the position of the mainshaft. The
A-dimension is also used to calculate the cone crusher’s setting, also referred to as the CSS, and the wear on the manganese. If the mantle is raised in order to reduce the setting or compensate for wear, the A-dimension will decrease.
Regulation of the crusher’s performance can be carried out in accordance with two basic principles:
– maintaining a constant, predetermined setting – maintaining a constant, predetermined crusher load.
The system checks the input information and compares it with the permitted levels. The system detects and registers repetitive pressure peaks and reacts by running the Hydroset pump in order to increase or decrease the setting. The system will also give warnings and alarms of different kinds, such as an indication that the manganese is nearing the end of its life or that a sensor is faulty.
1.3.1 ASRi system description
The computer in the control unit monitors and regulates the crusher. The computer stores the statistics, historical data, and crushing programs etc. The control unit provides a variety of possibilities for communication with other systems in the plant.
The ASRi system consists of the following subsystems:
• Power supply unit (PS)
• Control unit with a colour touch screen (OP)
• Power measurement unit (U1N)
• Tank measurement unit (CBT)
• Hydroset drive unit (L3)
The figure below shows an example of how the system can be arranged.
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)
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.
-CBT -U1N -OP -L3 -PS =PM =OT/HT Control unit
Power measurement unit Tank measurement unit Hydroset drive unit Power supply unit
The signals from these transducers are fed to a distributed I/O unit
designated as HT-CBT. This distributed I/O unit forwards the measurements to the control unit via a serial bus, also referred to as the ASRi bus.
There is a second I/O unit:
– A power transducer with an associated current transformer and if necessary, a voltage transformer, that measures the power drawn by the crusher’s drive motor.
The signal from the power transducer is forwarded to the control unit via the ASRi bus. If the motor is of the high-voltage type, the voltage measurements needed by the power transducer are made via appropriate high voltage transformers.
In addition to the analog transducer signals, the system incorporates the following digital inputs:
– Hydroset pump contactor status signals that tell the system that the pump motor is pumping the mainshaft up or down.
– An overload protector signal that trips out if the Hydroset pump motor is overloaded.
and the following digital outputs:
– A signal to other equipment that the crusher is able to receive feed material.
– Hydroset pump contactor control signals. The contactors open and close to provide power to the pump motor that moves the mainshaft (and the mantle) up and down.
– An alarm signal that indicates that the system has detected an alarm condition.
All of the digital signals are routed through a third distributed I/O unit in the L3 cabinet and forwarded to or sent from the control unit via the ASRi bus.
1.3.2 Hydroset pressure definitions
All Sandvik cone crushers with a Hydroset system have the mainshaft assembly supported by a Hydroset piston. The oil beneath the piston is under pressure. This Hydroset pressure is a direct indicator of the crushing force inside the crushing chamber. The crushing force in a cone crusher with a Hydroset system can thus be measured at any crusher load level.
The ASRi uses a measurement principle that permits observation of cyclic variations in Hydroset pressure caused by an uneven feed, segregation, and packing, etc. The ASRi system uses this information to analyse the operating conditions by mathematically processing the pressure signal, providing a value called the average peak Hydroset pressure (2). The Hydroset pressure setpoint is set in accordance with the average peak Hydroset pressure, thus the crusher can generally be run with higher average Hydroset pressure (3) than would otherwise be possible.
The ASRi displays the amplitude of the Hydroset pressure variations. This is done with a sector in the Hydroset pressure indicator in the main picture, see also section 4.2.2 Hydroset pressure indicator. The wider the sector shown in the Hydroset pressure indicator, the larger the amplitude of the pressure variations. Ideally, the sector should be reduced to a single line, which would correspond to a constant Hydroset pressure throughout the revolution of the eccentric. In practice, there are often variations in the crushing pressure around the crushing chamber and this shows up as a sector in the Hydroset pressure indicator. The Hydroset pressure can also be studied in the History: Pressure picture, see section 7.1.2 Pressure. These pictures can be used to analyse the crusher’s operating conditions and thus help to optimize the performance of the machine.
3
2
1
1 Peak Hydroset pressure 2 Average peak Hydroset pressure 3 Average Hydroset pressure1.4 Information levels
The ASRi system has four different information levels:
• Operation
• Installation
• Service
• Regulation
Operation
The operation level allows the user to control the main functions of the ASRi such as start and stop of regulation, set-up of regulation modes, positioning of the mainshaft, selection of crushing programs, editing of crushing programs, CSS range calibration, and set-up of the display. Operators can view, but not necessarily edit, all information on the different pictures of the ASRi. It is possible to set up password protection of the edit crushing program function during installation of the ASRi. In such a case, operators can only edit the crushing programs if they are authorized.
Service
The service level is used for maintenance of the ASRi system, such as checking connections and signals.
Installation
The installation level is mostly used during installation and set-up of the ASRi. It allows the access holder to configure the ASRi system with regard to units, A-dimension range set-up, crusher model, and crusher settings.
Regulation
The regulation level is restricted to Sandvik and personnel with detailed knowledge of the plant, the crusher, and the ASRi system since these parameters will considerably change regulation and the performance of the system. The parameters on this level can be viewed by all users, but can only be changed by Sandvik personnel that have regulation (administrator) rights to the ASRi.
To ensure maximum safety, always read this section carefully before carry-ing out any work on the equipment or makcarry-ing any adjustments.
2.1 Hazard information
2.1.1 Warning signs
2.1.2 Risk levels
Throughout the manual, levels of risk are indicated as “DANGER”, “WARNING” or “CAUTION”. The “DANGER” and “WARNING” levels are accompanied by a warning sign (see above).
CAUTION! Failure to observe information marked “Caution!” can result in damage to equipment!
General danger Dangerous voltage Risk of crushing
Hanging load Risk of crushing Flying fragments
DANGER!
Failure to observe information marked “DANGER!” can result in life-threatening injuries!
WARNING!
Failure to observe information marked “WARNING!” can result in personal injury and/or serious damage to, or destruction of, equipment!
2.1.3 Prohibition signs
2.1.4 Mandatory signs
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 Do not remove guards Disconnect current before any work
Sandvik SRP AB provides technical documentation appropriate to all three work roles:
• Installation manual
• Operator’s manual and Wear parts catalog
• Maintenance manual and Spare parts catalog
Sandvik SRP AB can provide adequate training for all three work roles and can carry out authorization of trained personnel.
The technical documentation from Sandvik SRP AB covers only work on the production equipment itself – it does not cover work tasks associated with other equipment or routines at the site.
It is the responsibility of the plant management to assign responsibility for:
• The production equipment and the work area around the equipment
• All personnel in the vicinity of the equipment
• Compliance with national and local safety regulations • Checking that all safety devices are fully operational
Sandvik SRP AB declines all responsibility for injury or damage resulting from non-compliance with the instructions in this manual.
2.2.1 Personal protection
Sandvik SRP AB strongly recommends that personal protective equipment is always worn when working in the vicinity of the equipment.
Sandvik SRP AB strongly recommends to use a safety harness when working above, inside and under the equipment.
The Sandvik SRP AB recommendation for personal protective equipment includes:
Ear protection Safety helmet Eye protection
Protective gloves Safety boots Mask or breathing apparatus
2.3 General safety precautions
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.
WARNING!
Falling stones
Clear the feed arrangement from process material before any maintenance work is carried out inside or below the crusher, to prevent stones from falling down.
DANGER!
Risk of crushing
Never remain on the crusher while crushing. Moving parts constitute a risk of crushing. Falling into the crusher implies danger of being crushed.
WARNING!
Risk of crushing
If the crusher is mounted on rubber dampers, there is a risk of crushing between the oscillating parts of the crusher and the stationary frame.
WARNING!
Ejection
Never look into the crusher while crushing. Fragments and possibly harmful matter fed to the crusher may be ejected.
2.3.1 Machine safety guards
Upwardly ejected fragments may fall down in the vicinity of the crusher. Therefore Sandvik SRP AB recommends additional protection.
Make sure all defective guards and dust sealing components are checked, repaired and replaced before starting the equipment.
2.3.2 Machine access
Every machine requires access for personnel who carry out inspections and/ or maintenance work. Suitable access platforms and guard rails shall be installed. Walkways, stairs and ladders must be designed in accordance with applicable regulations. (These parts are not included in the crusher’s standard specification. For advice, contact Sandvik SRP AB.)
Areas where access is required are indicated on installations drawings, see the Installation manual.
2.3.3 Electrical safety
CAUTION! Only electrical personnel working according to European Standard EN 50110 or similar are permitted to perform electrical operations on the crusher.
Make sure all broken or damaged electrical cables and connectors are checked, repaired and replaced before starting the equipment.
Control cabinets must be lockable.
PROHIBITION!
Do not remove guards
Make sure that all guards are in place and functioning, to prevent exposure to flying fragments and rotating parts. Never operate the equipment unless guards are mounted.
WARNING!
Rotating parts
Exposure to rotating parts of the equipment shall be prevented by guards. Always attach guards after maintenance work.
WARNING!
Flying fragments
Fragments ejected upwards may fall down in the vicinity of the crusher. Provide adequate guards and warning signs at appropriate places around the danger zone.
DANGER!
Dangerous voltage
Personnel must regard all electrical equipment as live until it is proven dead by proper testing procedures.
2.3.4 Welding
CAUTION! Welding on the crusher is only permitted when and as described in the manual. For all other welding operations on the crusher local service personnel must be consulted.
CAUTION! Only welders qualified according to European Standard EN 287 or similar are permitted to perform welding operations on the crusher.
If welding an item to the crusher, the grounding cable must be attached to the item itself. If a crusher component is to be welded, the grounding cable should be attached as near to the welding area as possible.
2.3.5 Hydraulic system
CAUTION! Only personnel certified in hydraulics are permitted to perform maintenance on the hydraulic system (except bleeding air from the Hydroset system).
CAUTION! Never adjust pressure relief valves beyond the recommended values.
CAUTION! Make sure all defective hoses, valves or fittings are checked, repaired and replaced before starting the equipment.
2.3.6 Lubrication system
CAUTION! Equipment and hoses/pipes containing lubrication oil may be hot on surface.
CAUTION! Make sure all defective hoses, valves or fittings are checked, repaired and replaced before starting the equipment.
CAUTION! Always remove oil stains to avoid skidding risk. WARNING!
Toxic gases
Inhalation of welding fumes can be dangerous to health. Always follow instructions provided by the welding equipment supplier.
Some parts of the crusher are made of manganese steel. Long-term exposure to manganese oxide can affect the nervous system.
WARNING!
Oil pressure
Pressurized oil is dangerous if released incorrectly. Relieve all pressure before carrying out maintenance or repair work on the hydraulic system.
WARNING!
Oil temperature
Hydraulic oil can get very hot in operation. Allow the oil to cool before working on the hydraulic system. Equipment and hoses/pipes
2.3.7 Lifting and moving loads
CAUTION! Only personnel with adequate lifting training are permitted to perform lifting operations.
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.
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.
DANGER!
Hanging load
Never work or stand underneath a crane that is lifting material. Keep a safe distance from a hanging load.
2.3.8 Feed and jams
CAUTION! When the crushing chamber is empty, avoid feeding solitary round rocks.
CAUTION! Never feed combustible process material into the crusher.
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.
WARNING!
Flying fragments
Never use wedges etc. to clear jams in the feed opening. Stones and fragments can be thrown out at high speed from the crushing
chamber.
WARNING!
Explosives
Never remove blocking boulders from the crusher by blasting.
Blasting may cause personal injury and seriously damage bearings or other parts. Sandvik SRP AB takes no responsibility for injury to personnel or damage to the equipment when blasting is used.
DANGER!
Risk of crushing
Never stand inside the crusher when a blockage is removed. You might be pulled forcefully and suddenly downwards together with the
2.4 Emissions
Since Sandvik’s crushers are used for handling and/or processing of minerals or other materials which can give rise to health risks for human beings and animals, it is the responsibility of the user to follow the relevant rules and regulations intended to prevent health risks for example specific regulation applying to dust emission, asbestos, quartzite, radon etc.
2.4.1 Dust
Sandvik SRP AB strongly recommends using additional equipment for dust control. Examples are dust extraction (vacuum) and dust suppression by water spray or foam. Such equipment is not included in the crusher’s standard specification.
Sandvik SRP AB declines all responsibility for any health hazards caused by dust, generated when processing minerals in the crusher.
DANGER!
Health hazard
Breathing or inhaling dust particles will cause death or severe injury. Always wear approved respirator.
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.
2.4.2 Noise
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
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.
WARNING!
Health hazards
Crushing and processing material will create noise. Such noise can be more or less dangerous to the hearing. Use ear protection.
DANGER!
Health hazards
Radon is a radioactive gas that occurs naturally in bedrock. Radon may cause lung cancer. Mineral type, ventilation and water are all factors that influence the contents of radon gases.
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.
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.
(Continued)
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.
Adjust
Set-up: Operation
Reset Date and time at latest reset:
Date Time
Date & time
Backlight luminance
Language
Reset
Select
Main Op. data Alarm History Set-up Help
RUNNING: New program User Log off
English
Deutsch
Español
Save Export
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:
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.
Bulgarian Danish German Polish Romanian
Chinese English Hungarian Portuguese Slovene
Croatian Finnish Italian Portuguese (Br) Spanish
Czech French Norwegian Russian Swedish
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.
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)
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 Contactor up Reserve Feeder Pump down Pump up Alarm Internal communication Reset
Main Op. data Alarm History Set-up Help
Connection
Input Output
Degrees
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.
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
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 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
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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.
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.
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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.
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.
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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.
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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.
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.
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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.
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.
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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.
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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-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.
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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 Initial CSS factor greater than 1. The CSS will be greater than the desired operating CSS when the feed to the crusher starts and will then slowly decrease towards the desired operating CSS setpoint.
In other cases – with a fine crushing chamber, for example – it may be difficult to fill the crushing chamber when the feed is started. In such a case it can be a good idea to choose an Initial CSS factor smaller than 1. The CSS will be smaller than the desired operating CSS when the feed to the crusher starts and will then slowly increase towards the desired operating CSS setpoint.
The starting CSS is normally calculated automatically by the ASRi system, but can also be set manually during the installation set-up, see Crusher settings in the Installation manual. The initial CSS setpoint is calculated as the product of the initial CSS factor, which can lie between 0.5 and 2.5, multiplied with the CSS setpoint.
Removing programs
Existing programs can be removed.
j) Deselect the regulation mode by pressing the corresponding button,
[Auto-CSS], [Multi-CSS], or [Auto-Load].
k) Press the [Save] button.
4.4.2 Edit Program
If the crusher is to be operated in an automatic regulation mode, one or more crushing program(s) must first be configured.
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NOTE! The Edit program function may be password protected, if configured as such
during installation of the ASRi system. See the Installation manual for more
information. If the password prompt appears and you do not have a password, turn to your supervisor for assistance.
To edit a crushing program, follow this sequence:
a) Press the [Program] button on the main picture to open the Program picture.
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.
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Power setpoint Pressure setpoint Minimum CSS Initial CSS factor Initial A-dim. setpoint
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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 Auto-CSS 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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RUNNING: New program
New program Edit program Program name CSS setpoint Initial CSS factor Initial CSS setpoint Auto-CSS Save Cancel Auto-CSS Multi-CSS Auto-Load
4.4.3 Selecting programs
To select a pre-configured crushing program, follow the instructions below. a) Press the [Program] button to open the Program picture.
b) Press the [] or [] button on the right of the Program menu (1) to
scroll the menu and select a crushing program. In the area below the crushing program menu there is information about the currently
highlighted crushing program, such as regulation type and CSS setpoint. The information displayed varies depending on whether it is an “Auto-CSS”, a “Multi-“Auto-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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New program Program New program New program Parameters Regulation type Power setpoint Pressure setpoint Minimum CSS Initial CSS factor Initial A-dim. setpoint
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4.4.4 Auto-CSS regulation mode
During Auto-CSS regulation, the ASRi system aims to maintain the desired CSS. The crusher's setting will never go below this CSS setpoint during normal crushing operation, but can exceed the CSS setpoint if the power draw or the Hydroset pressure is excessive.
When Auto-CSS regulation is started, the mainshaft is moved to its initial CSS setpoint before feeding is permitted. Once the initial CSS setpoint has been reached, and as soon as the ASRi detects that the crusher is loaded, the automatic regulation will try to reach the CSS setpoint.
In a program using Auto-CSS regulation, the following parameters must be set:
• CSS Setpoint: The desired operating CSS.
The CCS range available depends on the crusher’s size and the wear of the mantle. The maximum CSS cannot be larger than what it is when the mainshaft is in its bottom position.
• Initial CSS factor: The factor to be multiplied by the CSS setpoint in
order to obtain the Initial CSS setpoint.
The following parameter is automatically calculated by the system: • Initial CSS setpoint: The CSS setpoint to be reached before the feed
starts.
CAUTION! The feed to the crusher must be interlocked with the ASRi system, or else the crusher is not protected by the system.
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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
To set up an Auto-CSS regulation program, follow this sequence: a) Set the desired CSS value in the CSS setpoint field.
b) The system checks that the CSS setpoint you enter is not out of range. If it is, the display indicates this in red and you must adjust the invalid CSS setpoint value.
c) Set the initial CSS factor in the Initial CSS factor field. The product of the initial CSS factor and the CSS setpoint will result in the Initial CSS setpoint.
4.4.5 Multi-CSS regulation mode
During Multi-CSS regulation, two different product curves can be combined to give a new desired product. This is accomplished by the ASRi system cyclically switching between two different settings—CSS setpoint 1 and CSS setpoint 2. You also define the time share between the two settings. For example, a smaller CSS can be selected in the CSS Setpoint 1 field. The resulting crusher product might contain sufficient fines material while there is a shortfall in coarse material. Coarse material can be produced by entering a CSS value in the Setpoint 2 field that is larger than CSS Setpoint 1. The crusher could, for example, operate at CSS Setpoint 1 for 60% of the time and at CSS Setpoint 2 for 40% of the time. This cycle is constantly repeated and completely automatic. The result is two different product curves that are delivered one after the other on the crusher's discharge conveyor. However, after a few transition chutes the material, that reaches the stockpile or storage bin, will have a single average grading and contain both the fines and the coarse material.
In a program using Multi-CSS regulation, the following parameters must be set:
• CSS setpoint 1: The first desired operating CSS.
• CSS setpoint 2: The second desired operating CSS.
The CCS range available depends on the crusher’s size and the wear of the mantle. The maximum CSS cannot be larger than what it is when the mainshaft is in its bottom position
• Time-share (%): The operating time share between the two CSS
setpoints.
• Initial CSS factor: The desired factor to be multiplied with the CSS
setpoint in order to provide the Initial CSS setpoint.
The following parameter is automatically calculated by the system: • Initial CSS setpoint: The CSS setpoint to be reached before the feed
starts.
CAUTION! The feed to the crusher must be interlocked with the ASRi system, or else the crusher is not protected by the system.
To set up a Multi-CSS regulation program, follow this sequence:
a) Set the desired value in the CSS setpoint 1 field for the first operating CSS.
b) Set the desired value in the CSS setpoint 2 field for the second operating CSS
c) Set the desired figure in the Time-share field for the operating time distribution.
d) The system checks that the CSS setpoints you enter are not out of range. If they are, the display indicates this in red and you must adjust the invalid CSS setpoint value. The CCS range depends on the crusher’s size and the wear of the mantle. The maximum CSS cannot be larger than what it is when the mainshaft is in its bottom position
e) Set the initial CSS factor in the Initial CSS factor field. The product of the initial CSS factor and the CSS setpoint will result in the Initial CSS setpoint.
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RUNNING: New program
New program Edit program Program name CSS setpoint 1 Initial CSS factor Initial CSS setpoint Auto-CSS Save Cancel New program Multi-CSS Auto-Load CSS setpoint 2 Time share, CSS setpoint 1
4.4.6 Auto-Load regulation mode
During Auto-load regulation, the ASRi system regulates the setting so that the crusher operates at a desired load level. The system will decrease the CSS until either the power setpoint or the pressure setpoint is reached. The system will keep the crusher loaded to that setpoint from there on. If the desired highest permitted load level is selected, the CSS will always be the smallest possible and this will result in maximum reduction. With Auto-Load
regulation there is automatic compensation for liner wear, which means that the intervals between calibrations can be fairly long.
In a program using Auto-Load regulation, the following parameters must be set:
• Power setpoint: The nominal drive motor power draw set in the
crushing program in question.
• Pressure setpoint: The highest average peak Hydroset pressure set in
the crushing program in question.
• Min CSS: The smallest permitted CSS in the crushing program in
question.
• Initial CSS factor: The desired factor to be multiplied with the CSS
setpoint in order to provide the Initial CSS setpoint.
The following parameter is automatically calculated by the system: • Initial CSS setpoint: The CSS setpoint to be reached before the feed
starts.
CAUTION! The feed to the crusher must be interlocked with the ASRi system, or else the crusher is not protected by the system.