ASRi20 OM S223 531 en 02 PDF

operator’s manual S223.531.
en
SANDVIK ASRi 2.0

This document is valid for:
Serial no. / Machine no. Sign.
SANDVIK ASRi 2.0
© Copyright 2009 Sandvik SRP AB.

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

Issue: 20091012
Version: 02
Sandvik
Stationsplan, SE-233 81 Svedala, Sweden
Tel: +46 (0)40 409000, Fax: +46 (0)40 409260
www.sandvik.com
OM Sandvik ASRi 2.0 Table of Contents
Table of Contents
1. Introduction
1.1 Equipment information.......................................................... 6
1.1.1 Document information.............................................. 7
1.2 Operating principles of a cone crusher ................................. 8
1.3 Function and benefits of the ASRi ...................................... 10
1.3.1 ASRi system description ........................................ 11
1.3.2 Hydroset pressure definitions ................................ 14
1.4 Information levels................................................................ 15
2. Safety precautions
2.1 Hazard information ............................................................. 18
2.1.1 Warning signs ........................................................ 18
2.1.2 Risk levels.............................................................. 18
2.1.3 Prohibition signs..................................................... 19
2.1.4 Mandatory signs..................................................... 19
2.2 Personnel............................................................................ 19
2.2.1 Personal protection ................................................ 20
2.3 General safety precautions................................................. 21
2.3.1 Machine safety guards........................................... 22
2.3.2 Machine access ..................................................... 22
2.3.3 Electrical safety...................................................... 22
2.3.4 Welding .................................................................. 23
2.3.5 Hydraulic system.................................................... 23
2.3.6 Lubrication system ................................................. 23
2.3.7 Lifting and moving loads ........................................ 24
2.3.8 Feed and jams ....................................................... 25
2.4 Emissions ........................................................................... 26
2.4.1 Dust........................................................................ 26
2.4.2 Noise...................................................................... 27
2.4.3 Radioactivity........................................................... 27
© 2009 Sandvik SRP AB S223.531.en-02 1

3. Set-up: Operation
3.1 Starting up........................................................................... 30
3.2 Display ................................................................................ 30
3.3 Service ................................................................................ 32
3.3.1 Connections ........................................................... 33
4. Main picture
4.1 General ............................................................................... 36
4.2 The Main picture layout....................................................... 36
4.2.1 Menu bar ................................................................ 37
4.2.2 Hydroset pressure indicator ................................... 38
4.2.3 Motor power indicator............................................. 38
4.2.4 CSS indicator ......................................................... 39
4.2.5 Status bar ............................................................... 39
4.2.6 Crusher symbol ...................................................... 40
4.2.7 A-dimension indicator............................................. 40
4.2.8 Start/Stop buttons................................................... 41
4.2.9 Operating mode selector........................................ 41
4.2.10 Mainshaft control buttons ....................................... 41
4.2.11 Program/Calibration selector buttons ..................... 41
4.3 Calibration........................................................................... 42
4.3.1 Calibration: metal-to-metal ..................................... 43
4.3.2 Calibration: with lead.............................................. 45
4.4 Program .............................................................................. 47
4.4.1 Adding new programs ............................................ 47
4.4.2 Edit Program .......................................................... 50
4.4.3 Selecting programs ................................................ 53
4.4.4 Auto-CSS regulation mode .................................... 54
4.4.5 Multi-CSS regulation mode .................................... 55
4.4.6 Auto-Load regulation mode.................................... 57
2 S223.531.en-02 © 2009 Sandvik SRP AB

5. Operating data
5.1 Operating data .................................................................... 60
5.1.1 Motor power ........................................................... 60
5.1.2 Pressure................................................................. 62
5.1.3 CSS........................................................................ 64
5.1.4 Lubrication oil temperature .................................... 65
5.1.5 A-dimension ........................................................... 66
5.1.6 Overview ................................................................ 68
5.1.7 Event list ................................................................ 69
6. Alarms
6.1 Alarms................................................................................. 72
6.1.1 Alarm severity levels .............................................. 72
6.1.2 Alarm status ........................................................... 73
6.1.3 Alarm list ................................................................ 74
6.1.4 Alarm log................................................................ 75
6.1.5 A-alarms................................................................. 78
6.1.6 B-alarms................................................................. 79
6.1.7 C-alarms ................................................................ 81
7. History
7.1 Historical data—general ..................................................... 84
7.1.1 Motor power ........................................................... 86
7.1.2 Pressure................................................................. 87
7.1.3 CSS........................................................................ 88
7.1.4 Temperature........................................................... 89
7.1.5 A-dimension ........................................................... 89
7.1.6 Overview ................................................................ 90
7.1.7 Liner wear .............................................................. 91

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1. Introduction
OM Sandvik ASRi 2.0 5

OM Sandvik ASRi 2.0 1. Introduction
1.1 Equipment information

Purpose
The purpose of this Sandvik equipment is to regulate and protect a cone
crusher from overloads. The system also helps improve production and
achieve better control and use of the cone crusher. Sandvik SRP AB will not
accept any liability for damage to equipment or injury to personnel caused by
unauthorised or improper use or modification of this equipment.
Manufacturer
This Sandvik equipment has been manufactured by:
Sandvik SRP AB
Stationsplan 1
SE-233 81 Svedala
Sweden
www.sandvik.com
For maintenance
Contact the nearest Sandvik company, agent, representative or the
manufacturer directly:
Sandvik SRP AB
Service Dept.
SE-233 81 Svedala
Sweden
Telephone +46-40-40 90 00
Telefax +46-40-40 92 60
Identification
The ASRi serial number decal is located on the side of the ASRi control unit.
The serial number is needed when contacting Sandvik concerning this
specific equipment and when ordering spare parts.
Please enter the ASRi serial number in the intended field on the first page of
this document (the copyright page).
1 Serial number decal

1.1.1 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: manuals.srp@sandvik.com.

1.2 Operating principles of a cone crusher

In a cone crusher the process material is crushed between two rigid surfaces.
In general, the motion of the moving surface is independent of the load on
the crusher. The crushing action is achieved by an eccentric gyratory
movement of the mainshaft (6). Individual pieces of process material (e. g.
rock or ore) are nipped, compressed and crushed between the mantle (4) and
the concave ring (3).
The quality and quantity of the produced process material is a result of the
interaction between the crusher and the process material. The crushing
chamber’s geometry, the crusher’s dynamics and the process material are the
most important factors.
The concave ring (3), mantle (4), eccentric assembly (5) and the location of
the pivot point determine the chamber geometry of the cone crusher. The
crusher’s drive motor rotates the eccentric assembly at a constant speed
through a gear transmission. The rotation of the eccentric assembly causes
the lower end of the mainshaft to gyrate. At the top of the mainshaft (6) is the
spider bearing (1) that acts as the pivot point for this gyrating motion. The
mantle is fixed to the mainshaft and the concave ring is fixed to the topshell.
The gyration of the mainshaft means that the distance between the mantle
and the concave ring continually varies. When this distance decreases the
incoming process material will be subjected to a compressive stress and will
be crushed. When the mantle moves away from the concave ring, the process
material is able to flow down through the chamber.The mantle and the
concave ring must be replaced regularly as they are continuously worn. The
rate at which this wear occurs depends on the characteristics of the process
material.
1
2
3
4
1 Spider bearing
5
2 Topshell 6
3 Concave ring
4 Mantle
5 Eccentric assembly
6 Mainshaft
(Continued)

Setting adjustment
Due to the need to compensate for wear and the need to produce different
product sizes the crusher has a control system, named the Hydroset system. It
basically consists of a robust hydraulic jack, which supports the mainshaft
and adjusts its position. By moving the mainshaft up and down, the discharge
setting can be changed and the size of the crushed material can thereby be
changed. Read more in your cone crusher’s Operator’s manual.
setting decrease = finer product setting increase = coarser product
= =

1.3 Function and benefits of the ASRi

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

– 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)
(Continued)

The figure below shows an example of how the system can be arranged.
-PS -OP
Power supply unit Control unit
=PM =OT/HT
-U1N -CBT -L3
Power measurement unit Tank measurement unit 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)

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.
1 Peak Hydroset
pressure
2 Average peak
Hydroset pressure
3 Average Hydroset
pressure 1 2 3
The ASRi uses a measurement principle that permits observation of cyclic
variations in Hydroset pressure caused by an uneven feed, segregation, and
packing, etc. The ASRi system uses this information to analyse the operating
conditions by mathematically processing the pressure signal, providing a
value called the average peak Hydroset pressure (2). The Hydroset pressure
setpoint is set in accordance with the average peak Hydroset pressure, thus
the crusher can generally be run with higher average Hydroset pressure (3)
than would otherwise be possible.
The ASRi displays the amplitude of the Hydroset pressure variations. This is
done with a sector in the Hydroset pressure indicator in the main picture, see
also section 4.2.2 Hydroset pressure indicator. The wider the sector shown in
the Hydroset pressure indicator, the larger the amplitude of the pressure
variations. Ideally, the sector should be reduced to a single line, which would
correspond to a constant Hydroset pressure throughout the revolution of the
eccentric. In practice, there are often variations in the crushing pressure
around the crushing chamber and this shows up as a sector in the Hydroset
pressure indicator. The Hydroset pressure can also be studied in the History:
Pressure picture, see section 7.1.2 Pressure. These pictures can be used to
analyse the crusher’s operating conditions and thus help to optimize the
performance of the machine.

1.4 Information levels

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


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

OM Sandvik ASRi 2.0 2. Safety precautions
2.1 Hazard information

2.1.1 Warning signs
General danger Dangerous voltage Risk of crushing
Hanging load Risk of crushing Flying fragments
2.1.2 Risk levels

Throughout the manual, levels of risk are indicated as “DANGER”,
“WARNING” or “CAUTION”. The “DANGER” and “WARNING” levels
are accompanied by a warning sign (see above).
Failure to observe information marked “DANGER!” can result in life-

threatening injuries!
DANGER!
Failure to observe information marked “WARNING!” can result in
personal injury and/or serious damage to, or destruction of,
equipment!
WARNING!
CAUTION! Failure to observe information marked “Caution!” can result in damage
to equipment!

2.1.3 Prohibition signs
Do not remove
guards
2.1.4 Mandatory signs
Disconnect current Read the manual

before any work
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

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

Falling stones
Clear the feed arrangement from process material before any
maintenance work is carried out inside or below the crusher, to
WARNING! prevent stones from falling down.
Always switch off power and lock out the equipment (so that it cannot
inadvertently be switched on) before any maintenance work is started. Also
ensure that it is not possible for anyone else to switch the power on while
maintenance work is being carried out.
Avoid staying on the crusher, unless necessary for maintenance work.
Risk of crushing
Never remain on the crusher while crushing. Moving parts constitute a
risk of crushing. Falling into the crusher implies danger of being
DANGER! crushed.
Risk of crushing
If the crusher is mounted on rubber dampers, there is a risk of
crushing between the oscillating parts of the crusher and the
WARNING! stationary frame.
Ejection
Never look into the crusher while crushing. Fragments and possibly
harmful matter fed to the crusher may be ejected.
WARNING!

2.3.1 Machine safety guards

Do not remove guards
Make sure that all guards are in place and functioning, to prevent
exposure to flying fragments and rotating parts. Never operate the
PROHIBITION! equipment unless guards are mounted.
Rotating parts
Exposure to rotating parts of the equipment shall be prevented by
guards. Always attach guards after maintenance work.
WARNING!
Flying fragments
Fragments ejected upwards may fall down in the vicinity of the
crusher. Provide adequate guards and warning signs at appropriate
WARNING! places around the danger zone.
Upwardly ejected fragments may fall down in the vicinity of the crusher.
Therefore Sandvik SRP AB recommends additional protection.
Make sure all defective guards and dust sealing components are checked,
repaired and replaced before starting the equipment.
2.3.2 Machine access

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

CAUTION! Only electrical personnel working according to European Standard
EN 50110 or similar are permitted to perform electrical operations on
the crusher.
Dangerous voltage
Personnel must regard all electrical equipment as live until it is proven
dead by proper testing procedures.
DANGER!
Make sure all broken or damaged electrical cables and connectors are
checked, repaired and replaced before starting the equipment.
Control cabinets must be lockable.

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.
Toxic gases
Inhalation of welding fumes can be dangerous to health. Always follow
instructions provided by the welding equipment supplier.
WARNING! Some parts of the crusher are made of manganese steel. Long-term
exposure to manganese oxide can affect the nervous system.
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).
Oil pressure
Pressurized oil is dangerous if released incorrectly. Relieve all
pressure before carrying out maintenance or repair work on the
WARNING! hydraulic system.
CAUTION! Never adjust pressure relief valves beyond the recommended values.
Oil temperature
Hydraulic oil can get very hot in operation. Allow the oil to cool before
working on the hydraulic system. Equipment and hoses/pipes
WARNING! containing hydraulic oil may be hot on surface.
CAUTION! Make sure all defective hoses, valves or fittings are checked, repaired
and replaced before starting the equipment.
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.

2.3.7 Lifting and moving loads

CAUTION! Only personnel with adequate lifting training are permitted to perform
lifting operations.
Hanging load
Never work or stand underneath a crane that is lifting material. Keep a
safe distance from a hanging load.
DANGER!
Make sure that the capacity of the lifting equipment is adequate and that the
equipment itself is in good working order.
If lifting tackle has to be made up by joining separate components, make sure
that the joints are secure and have the same lifting capacity as the rest of the
tackle.
NOTE! Always use lifting tackle certified in accordance with local conditions.
Always engage the safety clips on lifting hooks to prevent the tackle from
slipping off.
Use ropes or poles to steady and maneuver loads. Do not use hands or feet.
Make sure that the route and the destination are free from obstacles before
moving a suspended load. It must be possible to lower the load to the floor
quickly and safely in an emergency.
When depositing loads, keep the lifting equipment in place until the stability
of the load has been checked.

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.
Flying fragments
Never use wedges etc. to clear jams in the feed opening. Stones and
fragments can be thrown out at high speed from the crushing
WARNING! chamber.
Explosives
Never remove blocking boulders from the crusher by blasting.
Blasting may cause personal injury and seriously damage bearings or
WARNING! other parts. Sandvik SRP AB takes no responsibility for injury to
personnel or damage to the equipment when blasting is used.
Risk of crushing
Never stand inside the crusher when a blockage is removed. You might
be pulled forcefully and suddenly downwards together with the
DANGER! material in the crushing chamber and be crushed.
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.

2.4 Emissions
Since Sandvik’s crushers are used for handling and/or processing of minerals
or other materials which can give rise to health risks for human beings and
animals, it is the responsibility of the user to follow the relevant rules and
regulations intended to prevent health risks for example specific regulation
applying to dust emission, asbestos, quartzite, radon etc.
2.4.1 Dust
Health hazard
Breathing or inhaling dust particles will cause death or severe injury.
Always wear approved respirator.
DANGER!
Always work with a respirator approved by the respirator manufacturer
for the job you are doing. It is essential that the respirator that you use
protects you from the tiny dust particles which cause silicosis and
which may cause other serious lung diseases. You should not use the
equipment until you are sure your respirator is working properly. This
means the respirator must be checked to make sure that it is clean,
that its filter has been changed, and to otherwise make sure the
respirator will protect you in the way it is meant to.
Make sure the dust suppression system in your equipment is working

properly. If the dust suppression system is not working properly, stop
working immediately.
Always make sure dust has been cleaned off your boots and clothes
when you leave your shift.
The smallest particles of dust are the most harmful. They may be so
fine that you can not see them.
Remember, you must protect yourself from the danger of breathing or

inhaling dust.
Sandvik SRP AB strongly recommends using additional equipment for dust

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

2.4.2 Noise
Health hazards
Crushing and processing material will create noise. Such noise can be
more or less dangerous to the hearing. Use ear protection.
WARNING!
Refer to OM - Technical specifications for measured noise levels and
measurement conditions.
Rubber compression mountings and dust encapsulation result in lower noise
levels.
2.4.3 Radioactivity
Health hazards
Radon is a radioactive gas that occurs naturally in bedrock. Radon
may cause lung cancer. Mineral type, ventilation and water are all
DANGER! factors that influence the contents of radon gases.
Sandvik SRP AB declines all responsibility for any health hazards caused by
the release of radon or any other harmful substances when processing
minerals in the crusher.


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

OM Sandvik ASRi 2.0 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
Language
Deutsch
English
Español Select
Reset
Date and time at latest reset:
Reset
Date Time
Report
Save Export
Main Op. data Alarm History Set-up Help
(Continued)

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 Danish German Polish Romanian

Chinese English Hungarian Portuguese Slovene
Croatian Finnish Italian Portuguese (Br) Spanish
Czech French Norwegian Russian 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.

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 at
Pressure sector angle Degrees
Digital signals Input Output
Motor protection Contactor up Feeder Pump up
Contactor down Reserve Pump down Alarm
Internal communication
Reset Connection
Analog signals
The top section of the picture displays current information on motor power,
pressure, lubrication oil temperature, A-dimension, CSS, wear compensation
factor, shaft speed, and pressure sector angle as numerical values.
(Continued)

Digital signals
The middle section of the picture displays current information on inputs from
motor protection, contactor up/down, and reserve; and information on
outputs to feeder, pump up/down, and alarm. Active signals are indicated by
green lights.
The mainshaft can also be pumped up or down to check inputs and outputs:
b) Press the [] or [] button to pump the mainshaft up or down.
Internal communication
The bottom section of the picture displays the current status of the internal
communication from the Power measurement unit (U1N), the Tank
measurement unit (CB), and the Hydraulic drive unit (L3) to the ASRi
control unit (OP).
Reset
The communication error counters count the amount of bus messages that
have not been acknowledged by the distributed I/O units and can be reset.
a) Press the [Reset] button.
b) Press the [Reset] button to reset the communication error counters or
the [Cancel] button to cancel.
3.3.1 Connections
In the Connections picture you can check the connections between the
different units of the ASRi.
a) Check that transducers, I/O units and cables are correctly connected
before the system is put into operation. If they are not, set up the
connections.
b) From the Service picture, press the [Connections] button to open the
Connections picture.
(Continued)

The Connections picture shows a schematic view of the connections:

Set-up: Service: Connections
Alarm
& Feed
Oil tank unit
Close
The cable designations are unlit with a green ring when the cables are
correctly connected and communication is active.
The cable designations are red when there is a transmission error. These
errors can be due to disconnected cables, faults in the cables or in the units
that are linked by the cables.
c) Exchange any faulty parts and re-check the connections.

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

OM Sandvik ASRi 2.0 4. Main picture
4.1 General
The control unit (operator’s panel) pictures are divided into 3 sections. At the
top is the status bar, the middle section displays all the main information, and
at the bottom is the menu bar. The contents of the menu bar are consistent
throughout the menu system. When pressing a menu button, a pop-up menu
appears with further picture alternatives. Once one of these alternatives has
been selected, the corresponding picture will open. When a picture is active
its corresponding menu button is shadowed.
4.2 The Main picture layout

The Main picture is the default picture. In the following pages you will find
descriptions of the indicators and buttons on this picture.
1 Menu bar
2 Hydroset pressure
indicator
3 Motor power
indicator
4 CSS indicator
5 Status bar Auto
6 Crusher symbol
Man
7 A-dimension
indicator
8 Start/Stop buttons
9 Operating mode
selector
0 Mainshaft control
buttons Program
11 Program/
Calibration
Calibration
selector buttons

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.
(Continued)

Alarms:
When a type A or B alarm is currently active, the Alarm menu button and the
status bar (5) turn red and start flashing. The left section of the Status bar (5)
displays information about the type of alarm according to the alarm codes
listed in section 6.1 Alarms. When a C-alarm is active, only the alarm menu
button turns red.
Alarm: A01
4.2.6 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.
NOTE! If the feed system is not interlocked with the ASRi system, the feed indication
arrow has no connection with reality.
4.2.9 Operating mode selector

The Operating mode selector (9) is used to select either automatic or manual
Auto
control mode for the crusher’s mainshaft position.
Man
• 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
Program picture where you select, edit, or add programs, or you can open the
Calibration 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.

4.3 Calibration
The CSS calibration procedure is needed to obtain the null-position for the
CSS measurement. The term CSS, Closed Side Setting, refers to the
discharge setting at the closed side of the crushing chamber, that is the spot
in the crushing chamber where the gap between the crushing surfaces is the
smallest. As the liners wear, the real CSS increases in relation to the value
indicated by the ASRi. The required calibration frequency normally depends
on the rate at which the crushing liners wear. A more abrasive stone type will
require more frequent calibrations, whereas a non-abrasive material will
require only occasional calibrations. There are two different calibration
methods:
– metal-to-metal calibration
– calibration with lead
Metal-to-metal calibration is the easiest way to calibrate a crusher. This
method is the one generally used with H-type cone crushers.
We recommend regular inspection of the concave ring to make sure that it
has not been worn unevenly or has become oval. One consequence of oval
concave rings is that it is much more difficult to measure the CSS.
NOTE! If uneven wear is suspected, check the CSS with lead at 4 points around the
crushing chamber. See the cone crusher Operator’s manual for further
information.
You should also look for any localized wear or other damage in the crushing
chamber.
If the crushing liners are worn, you cannot raise the mantle (on the
mainshaft) so high that it comes into contact with the concave ring without
risking that the head nut comes into contact with the underside of the
crusher’s spider hub. The risk of this occurring appears relatively early in the
case of a coarse crushing chamber that operates with a large CSS. The ASRi
system prevents further upward movement of the mainshaft if the
A-dimension is reduced below the minimum value for the crusher1. The
system will then automatically switch to calibration with lead.
For more information about CSS and A-dimension, see section
4.3 Calibration and A-dimension range set-up in the Installation manual as
well as the cone crusher Operator’s manual.
1. The minimum A-dimension is 15 mm for cone crushers CH420–CH660, and 25 mm for cone crushers CH870–
CH880 and S-type crushers. This data i subsequent to model changes and may be changed without further notice.
Always refer to the crusher manual for machine specific data.

4.3.1 Calibration: metal-to-metal

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

calibration.The calibration procedure starts automatically.
(Continued)

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.
STOP: New program
Calibration
Auto
Man
Program
Lead Metal-to-metal Close Calibration
b) Press the [Lead] button to start calibration with lead.The calibration

procedure starts automatically.
(Continued)

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.
Program
New program
New program
New program
Parameters
Auto
Regulation type Not programmed
Man
1 Program menu Program
Edit Select Close Calibration
(Continued)

b) Press the [] or [] button on the right of the Program menu (1) to
scroll the menu and select a “New program” in the Program menu.
c) Press the [Edit] button to open the Edit program picture.
Edit program New program
Auto-CSS Multi-CSS Auto-Load
Program name New program
Auto
Man
Program
Save Cancel Calibration
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)

CSS setpoint Auto
Man
Initial CSS factor
Initial CSS setpoint
Program
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.
(Continued)

Initial CSS factor

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

If the crusher is to be operated in an automatic regulation mode, one or more
crushing program(s) must first be configured.
NOTE! The Edit program function may be password protected, if configured as such
during installation of the ASRi system. See the Installation manual for more
information. If the password prompt appears and you do not have a
password, turn to your supervisor for assistance.
(Continued)

To edit a crushing program, follow this sequence:

a) Press the [Program] button on the main picture to open the Program
picture.
Program
Multi-CSS
Auto-Load
Parameters
Auto
Regulation type Auto-Load
Power setpoint Man
Pressure setpoint
Minimum CSS
Initial CSS factor
Initial A-dim. setpoint
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)

Program name Auto-CSS
CSS setpoint Auto
Man
Initial CSS factor
Program
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.

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.
Program
New program
New program
New program
Parameters
Auto
Regulation type
Power setpoint Man
Pressure setpoint
Minimum CSS
Initial CSS factor
scroll the menu and select a crushing program. In the area below the
crushing program menu there is information about the currently
highlighted crushing program, such as regulation type and CSS setpoint.
The information displayed varies depending on whether it is an “Auto-
CSS”, a “Multi-CSS”, or an “Auto-Load” crushing program.
c) Press the [Select] button to display the desired crushing program. The
information in the left section of the Status bar will change to reflect the
program you have selected.
d) Press the [Close] button to exit the program picture.
e) Press the [Auto] button on the Main picture to select automatic
regulation.
f) Press the [ I ] button on the Main picture to start automatic regulation.

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.
CSS setpoint Auto
Man
Initial CSS factor
Program
(Continued)

To set up an Auto-CSS regulation program, follow this sequence:

a) Set the desired CSS value in the CSS setpoint field.
b) The system checks that the CSS setpoint you enter is not out of range. If
it is, the display indicates this in red and you must adjust the invalid CSS
setpoint value.
c) Set the initial CSS factor in the Initial CSS factor field. The product of
the initial CSS factor and the CSS setpoint will result in the Initial CSS
setpoint.
4.4.5 Multi-CSS regulation mode

During Multi-CSS regulation, two different product curves can be combined
to give a new desired product. This is accomplished by the ASRi system
cyclically switching between two different settings—CSS setpoint 1 and
CSS setpoint 2. You also define the time share between the two settings.
For example, a smaller CSS can be selected in the CSS Setpoint 1 field. The
resulting crusher product might contain sufficient fines material while there
is a shortfall in coarse material. Coarse material can be produced by entering
a CSS value in the Setpoint 2 field that is larger than CSS Setpoint 1. The
crusher could, for example, operate at CSS Setpoint 1 for 60% of the time
and at CSS Setpoint 2 for 40% of the time. This cycle is constantly repeated
and completely automatic. The result is two different product curves that are
delivered one after the other on the crusher's discharge conveyor. However,
after a few transition chutes the material, that reaches the stockpile or storage
bin, will have a single average grading and contain both the fines and the
coarse material.
In a program using Multi-CSS regulation, the following parameters must be
set:
• CSS setpoint 1: The first desired operating CSS.
• CSS setpoint 2: The second desired operating CSS.
The CCS range available depends on the crusher’s size and the wear of
the mantle. The maximum CSS cannot be larger than what it is when the
mainshaft is in its bottom position
• Time-share (%): The operating time share between the two CSS
setpoints.
• Initial CSS factor: The desired factor to be multiplied with the CSS
setpoint in order to provide the Initial CSS setpoint.
(Continued)


starts.
CSS setpoint 1 Auto
Man
CSS setpoint 2
Time share, CSS setpoint 1
Initial CSS factor

Program
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.

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.
starts.
(Continued)

Power setpoint Auto
Man
Pressure setpoint
Min. CSS
Initial CSS factor

Program
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.

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

OM Sandvik ASRi 2.0 5. Operating data
5.1 Operating data

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

The Motor power picture displays detailed information about the crusher's
motor power draw.
a) Press the [Op. data] button on the menu bar, and then the [Power]
button in the pop-up menu to open the Motor power picture.
Operating data: Motor power
Current Average
Latest 30 min Since reset
Average Max. Average Max.
(Continued)

Trend curves
The current and average motor power draw are displayed in the upper section
of the picture (1), both in numerical values and as trend curves. The curves
move towards the left and show the latest 30 seconds.
Latest 30 min
The lower left section of the picture (2) displays statistics that show the
crusher's motor power draw during the latest 30 minutes. The information
presented is based on the “total operating time”, i.e. the time during which
the crusher's drive motor is running.
Since reset
The lower right section of the picture (3) displays the motor power draw
since the data collection feature was reset.
Presentation of statistics
The statistics for the “latest 30 min” and “since reset” are displayed as bar
charts. In each chart, the total power range corresponds to 150% of the lower
of the two values entered for parameter 502 (Motor output power) and
parameter 601 (Crusher max. input power). There can be up to 30 bars, each
representing 5% of the total power range.
An example: If parameter 502 is 220 kW and parameter 601 is 200 kW, the
total power range will be 300 kW and each bar covers a 10 kW interval.The
height of each column indicates the time—expressed as a percentage of 30
minutes or since the feature was reset—during which the crusher's motor
power draw was within the range represented by the respective column.

5.1.2 Pressure
The Pressure picture displays detailed information about the crusher's
Hydroset pressure.
a) Press the [Op. data] button on the menu bar, and then the [Pressure]
button in the pop-up menu to open the Pressure picture.
Operating data: Pressure
Current Avg. pressure Avg. peak pressure
Avg. pressure Max. Avg. pressure Max.
Trend curves
The current, average, and average peak Hydroset pressures are displayed in
the upper section of the picture (1), both in numerical values and as trend
curves. The average peak Hydroset pressure value is a calculated average of
pressure peaks, see section 1.3.2 Hydroset pressure definitions. The curves
move towards the left and show the latest 30 seconds.
Latest 30 min
The lower left section of the picture displays information on the crusher's
Hydroset pressure over the latest 30 minutes (2). The information presented
is based on the “total operating time”, i.e. the time during which the crusher's
drive motor is running.
(Continued)

Since reset
The lower right section of the picture displays the Hydroset pressure since
the data collection feature was reset (3).
Presentation of statistics
The statistics for the “latest 30 min” and “since reset” are displayed as
column charts. In each chart, the total pressure range corresponds to 150% of
the value entered for parameter 602 (Crusher max. pressure). There can be
up to 30 columns, each representing 5% of the total pressure range.
An example: If parameter 602 is 5.0 MPa, the total pressure range will be
7.5 MPa and each column covers a 0.25 MPa interval.
The height of each column indicates the time—expressed as a percentage of
30 minutes or since the feature was reset—during which the crusher's
Hydroset pressure was within the range represented by the respective
column.
The upper portion of each column can have a contrasting colour. This gives a
rough indication of the width of the sector in the Hydroset pressure indicator
in the Main picture.

5.1.3 CSS
The CSS picture displays detailed information about the CSS.
a) Press the [Op. data] button on the menu bar, and then the [CSS] button
in the Operating pop-up menu to open the CSS picture.
Operating data: CSS
Current

Minimum Minimum
Average Average
Maximum Maximum
Trend curves
The current CSS is displayed in the upper section of the picture (1), both in
numerical values and as a trend curve. The curve moves towards the left and
shows the latest 30 seconds.
Latest 30 min
The lower left section (2) of the picture displays information on the crusher’s
CSS over the latest 30 minutes (minimum, average, maximum).
Since reset
The lower right section (3) of the picture displays information on the
crusher’s CSS since the data collection feature was reset (minimum, average,
maximum).

5.1.4 Lubrication oil temperature

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

Minimum Minimum
Average Average
Maximum Maximum
Trend curves
The current temperature of the lubrication oil returning from the crusher to
the tank is displayed in the upper section of the picture (1), both as a
numerical value and as a trend curve. The curve moves towards the left and
shows lubrication oil temperature over the latest 5 minutes. The information
presented is based on the “total operating time”, i.e. the time during which
the crusher's drive motor is running.
(Continued)

Latest 30 min
The lower left section (2) of the picture displays information on the
lubrication oil temperature over the latest 30 minutes (minimum, average,
maximum). The information presented is based on the “total operating time”,
i.e. the time during which the crusher's drive motor is running.
Since reset
The lower right section (3) of the picture displays information on the
lubrication oil temperature since the data collection feature was reset
(minimum, average, maximum).
5.1.5 A-dimension
The A-dimension picture displays detailed information about the position of
the crusher's mainshaft.
a) Press the [Op. data] button on the menu bar, and then the [A-dim.]
button in the Operating pop-up menu to open the A-dimension picture.
Operating data: A-dimension
Estimated contact position
Calibrated contact position
Mainshaft position
Initial A-dim setpoint
(Continued)

The contact A-dimension value (or contact mainshaft position) is gathered in

two different ways:
• By measuring the A-dimension at which the liners come in contact with
each other during metal-to-metal calibration
• By calculating the A-dimension at which the liners would theoretically
come into contact with each other—if it were possible—during
calibration with lead.
A-dimension indicator
At the left hand side there is an A-dimension indicator that shows the relative
positions of the mainshaft. The indicator also shows the minimum permitted
A-dimension at the top and the maximum permitted A-dimension at the
bottom. The maximum permitted A-dimension, corresponding to the lowest
position of the mainshaft, is set 2 mm from the absolute bottom position.
This is to avoid the risk of running the Hydroset pump dry.
• Estimated contact position (1): The estimated metal-to-metal position
of the mainshaft, taking into consideration the estimated wear since the
latest calibration took place.
• Calibrated contact position (2): The contact position at the latest
calibration.
• Mainshaft position (3): The current mainshaft position.
• Initial A-dimension setpoint: The average A-dimension over the last
30 minutes that the crusher has been loaded.
• Initial CSS setpoint: The average CSS over the last 30 minutes the that
crusher has been loaded.

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.
Operating data: Overview

Power Pressure CSS Lub. oil. temp. A-dim.
Operating time Total Loaded
Since original start-up
Since latest liner change
Since latest calibration
Since reset
Energy consumption
Since original start-up
Since reset
Indicators
In the upper section (1) of the picture, there are indicators for the motor
power, the Hydroset pressure, the CSS, the lubrication oil temperature, and
the A-dimension.
(Continued)

Operating time
The middle section (2) of the picture displays information about the
crusher’s operating time, i.e. the time that the crusher’s drive motor has been
running, and the time during which the crusher has been loaded. From top to
bottom:
• Since original start-up (of the system—can only be reset by installation
personnel).
• Since latest liner change (resets automatically during the first calibration
after new liners have been fitted).
• Since the latest calibration (resets automatically during calibration).
• Since reset (of operating data—can be reset in the Set-up picture, see
section 3.1 Starting up).
Energy consumption
The lower section of the picture displays information about the energy
consumption since the system was started up and since it was reset. The
values refer to the power consumption during the time the crusher has been
loaded.
5.1.7 Event list

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

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.
Operating data: Event list
Group Time Event

Mode Crushing program 2, Auto-Load, activated
Mode Activated stop mode
Mode Activated calibration mode
Mode Crushing program 1, Auto-CSS, activated
Mode Program 3 saved
Mode Crushing program 2, Multi-CSS, activated
Mode Crushing program 1, Auto-CSS, activated
System System start-up
b) Press the Group, the Time, or the Event title button in the title bar to
change the sorting of events.
The following mode changes can be reviewed in the Event list:
• New crusher data loaded
• Activated stop mode
• Activated A-Range set-up, M-M
• Activated A-Range set-up, Lead
• Activated calibration mode
• Crushing program X, regulation mode Z, activated
• Crushing program X saved
• System start-up
• New liners detected
• Uncrushable object detected
• Activated manual mode
• Updated from x.xx to x.xx

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

OM Sandvik ASRi 2.0 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.
6.1.1 Alarm severity levels

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

6.1.2 Alarm status

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

6.1.3 Alarm list

The Alarm list shows all alarms which are active and those which are
inactive but have not yet been acknowledged. By default, the Alarm list is
arranged in chronological order.
a) Press the [Alarm] button on the menu bar, and then the [List] button in
the Alarm pop-up menu to open the Alarm list picture.
Alarm: List
Time Alarm text
History sync
The first column is the Alarm status column where alarm symbols indicate
the alarm type and the current status of the alarm. See section 6.1.2 Alarm
status.
The second column displays the Time at which the alarm was initiated.
(Continued)

The third column is the Alarm text column, in which a short description of
the alarm is displayed.
• Press the Alarm status symbol, the Time, or the Alarm text column title
button in the title bar to change the sorting of alarms.
• Switch between descending and ascending order by pressing the same
column title button again.
• Press the [] button to scroll up, or the [] button to scroll down in the
list.
• To acknowledge an alarm, select it in the list and press the [] button. In
the dialogue box that comes up, press the Acknowledge button.
• Press the [History sync] button to set all the History pictures to the
time indicated in the Time column.
When an alarm occurs it is displayed in the Alarm list, together with the
degree of severity and the time when the alarm was initiated. This happens
irrespective of whether or not the alarm has previously featured in the Alarm
list. The alarm condition must disappear and the alarm must be
acknowledged before it disappears from the Alarm list. For more information
on alarm severity levels, see section 6.1.1 Alarm severity levels.
6.1.4 Alarm log

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

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.
Alarm: Log
Time Alarm text
C23 Mainshaft in bottom position!

C27 Liner change necessary!

C24 Mainshaft in top position!
C27 Liner change necessary! Information
C24 Mainshaft in top position!

History sync
C23 Mainshaft in bottom position
C23 Mainshaft in bottom position
A05 A-dimension signal too high!
The first column is the Alarm status column where alarm symbols indicate
the alarm type and the current status of the alarm. See section 6.1.2 Alarm
status
The second column displays the Time at which the alarm status was changed.
(Continued)

The third column is the Alarm text column, in which a short description of
the alarm is displayed.
• Press the Alarm status symbol, the Time, or the Alarm text column title
button in the title bar to change the sorting of alarms.
Switch between descending and ascending order by pressing the same
column title button again.
• Press the [] button to scroll up, or the [] button to scroll down in the
log.
• Press the [Information] button for more information about a selected
alarm in the log.
Text: C23 Mainshaft at bottom position
Group:
Status: Active -> Inactive
Time:
Severity:
Descr: C23 Mainshaft at bottom position
Close
• Press the [History sync] button to set all the History pictures to the
time indicated in the Time column.

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
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
A05: A-dimension signal too high!
The system displays an alarm when the mainshaft position signal, measured
as current, is higher than 19.5 mA for more than 3 seconds. The alarm stops
the feed to the crusher and stops regulation. Regulation and feed should be
manually resumed after the alarm has become inactive.
A12: Mainshaft at bottom when crusher is loaded!
The system displays an alarm when the mainshaft position is less than 4 mm
from the bottom position and the power signal exceeds the lowest of the
following values: crusher maximum input power (parameter 601), program
maximum power or motor nominal power (parameter 502) during more than
3 seconds or when the mainshaft position is less than 4 mm from the bottom
position and the pressure signal is higher than the lowest of the following
values: crusher maximum pressure (parameter 602) or program maximum
value for more than 3 seconds. The alarm stops the feed to the crusher. The
feed resumes when the alarm turns inactive.

6.1.6 B-alarms
B10: Oil temperature signal too high!
The system displays an alarm when the lubrication oil temperature sensor
signal, measured as current, is higher than 19.5 mA for more than 3 seconds
and the lubrication oil temperature limit (parameter 507) is set at a value
above 20 ºC. The alarm stops the feed to the crusher. The feed resumes when
the alarm turns inactive.
B11: No power signal!
The system displays an alarm when the power signal is lower than 3.6 mA
for more than 3 seconds. The alarms stops the feed to the crusher. The feed
resumes when the alarm turns inactive.
B14: Hydroset pump motor-protection (breaker) tripped!
The system displays an alarm when the motor-protection of the motor that
drives the Hydroset pump has tripped. The alarm stops the feed to the
crusher. The feed resumes when the alarm turns inactive.
B15: Oil temperature high!
The system displays an alarm when the lubrication oil temperature is higher
than the lubrication oil temperature limit (parameter 507) for more than 3
seconds and the limit is set at a value above 20 ºC. The alarm stops the feed
to the crusher. The feed resumes when the alarm turns inactive.
B16: External pumping up too long!
The system displays an alarm when feedback from the contactor that drives
the mainshaft up indicates that it has been closed for more than 10 minutes.
The alarm stops the feed to the crusher. The feed resumes when the alarm
turns inactive.
B17: External pumping down too long!
The system displays an alarm when the feedback from the contactor that
drives the mainshaft down indicates that it has been closed for more than
10 minutes. The alarm stops the feed to the crusher. The feed resumes when
(Continued)

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!
Control unit and the Tank measurement unit. The alarm stops the feed to the
B22: No communication with the Hydroset drive unit!
Control unit and the Hydroset drive unit. The alarm stops the feed to the
B23: Power level low in regard to pressure level!
The system displays an alarm when the pressure is more than 0.3 MPa over
the unloaded pressure, the pressure sector is greater than 3 degrees, and the
power is less than 20% of the crusher’s maximum input power
(parameter 601) for more than one minute. The alarm stops the feed to the
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

6.1.7 C-alarms
C21: No oil temperature signal!
The system displays a warning when the oil temperature sensor signal is
lower than 3.6 mA for more than 3 seconds and the lubrication oil
temperature limit (parameter 507) is set at a value above 20 ºC.
C23: Mainshaft in bottom position!
The system displays a warning when the mainshaft position is less than
4 mm from the maximum mainshaft position (A-dimension), corresponding
to the bottom position, for more than 3 seconds. The warning is never active
during the A-range calibration procedure.
C24: Mainshaft in top position!
The system displays a warning when the mainshaft position is higher than
the position corresponding to the minimum A-dimension for more than
3 seconds.
C27: Liner change necessary!
The system displays a warning when the current mainshaft position (A-
dimension) is less than the liner change mainshaft position (parameter 503)
and one of the two following conditions is also fulfilled for more than
one hour:
– When not in Auto-Load regulation mode, the power is at least 50% of
the lower of the two values entered for the motor output power
(parameter 502) and the crusher maximum input power
(parameter 601), and the pressure is at least 50% of the crusher’s
maximum pressure (parameter 602).
– When in Auto-Load regulation mode, the power and the pressure are
both at least 50% of their corresponding setpoints.
(Continued)

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
C31: Mainshaft moves up too slowly!
The system displays a warning when the system records that the upward
C32: Mainshaft moves down too slowly!
The system displays a warning when the system records that the downward

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

OM Sandvik ASRi 2.0 7. History
7.1 Historical data—general

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

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.

7.1.1 Motor power

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

Average power Pump down Off
Power Feed On
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)

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)

Pump up (D1)
Pump down (D2)
Feed (D3)
Indicates that the ASRi system permits feeding to the crusher
7.1.3 CSS
The CSS picture displays historical data on the crusher’s CSS, both in
numerical values and as trend curves.
a) Press the [History] button on the menu bar and then the [CSS] button
in the pop-up menu to open the CSS picture.
CSS setpoint
Indicates the desired CSS for the current regulation mode. If the crusher is
operating in Auto-load mode, the CSS-setpoint is the same as the minimum
permitted CSS. If the crusher is operating in Auto-CSS mode, the CSS-
setpoint is equal to the CSS-setpoint defined in the crushing program. If the
crusher is operating in Multi-CSS mode, the CSS-setpoint alternates between
the two CSS-setpoints defined in the crushing program.
CSS
Indicates the gap between the crusher's mantle and concave ring on the
closed side.
Pump up (D1)
Pump down (D2)
Feed (D3)

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)
Pump down (D2)
Feed (D3)
7.1.5 A-dimension
The A-dimension picture displays historical data on the position of the
crusher’s mainshaft, both in numerical values and as trend curves.
a) Press the [History] button on the menu bar and then the [A-dim] button
in the pop-up menu to open the A-dimension picture
Mainshaft position
Indicates the A-dimension for the position of the mainshaft.
New liner contact position
Indicates the A-dimension that corresponds to the actual or calculated
“metal-to-metal” position with new liners.
Calibrated contact position
Indicates the A-dimension that corresponds to the latest calibrated or
calculated “metal-to-metal” position.
Estimated contact position
Indicates the estimated A-dimension for the “metal-to-metal” position.
(Continued)

Pump up (D1)
Pump down (D2)
Feed (D3)
7.1.6 Overview
The Overview picture displays historical data on the crusher’s CSS, average
motor power, and average pressure, both in numerical values and as trend
curves.
a) Press the [History] button on the menu bar and then the [Overview]
button in the pop-up menu to open the Overview picture.
History: Overview
CSS Pump up Off

Average power Pump down Off
Average peak pressure Feed On
CSS
Indicates the gap between the crusher's mantle and concave ring on the
closed side.
(Continued)

Average power
Indicates the average value of the power draw.
Average peak pressure
Indicates the average peak value of the average peak pressure signal.
Pump up (D1)
Pump down (D2)
Feed (D3)
7.1.7 Liner wear

The Liner wear picture displays historical data on mainshaft contact position
in relation to time and energy consumption. It gives an indication of the liner
wear over time. Data can be stored for up to 10 liner sets.
a) Press the [History] button on the menu bar and then the [Wear] button
in the pop-up menu to enter the Liner wear picture.
History: Liner wear
Time Energy Table Previous Next Current
Estimated Calibrated Liner start date:
(Continued)

The liner wear information is presented in trend curves. Below the curve
presentation frame there are buttons for the selection of different views:
• Press the [Time] button to view the liner wear in relation to time.
• Press the [Energy] button to view the liner wear in relation to energy
consumption.
• Press the [Table] button for a tabular overview of the liner wear in
relation to both time and energy consumption:
History: Liner wear
Loaded operating time Calibrated contact position (mm)

Energy consumed since
since liner change (h) liner change (MWh) Estimated Calibrated
Time Energy Table Previous Next Current
Estimated Calibrated Liner start date:
• 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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operator’s manual S223.531.

SANDVIK ASRi 2.0

Serial no. / Machine no. Sign.

SANDVIK ASRi 2.0

© Copyright 2009 Sandvik SRP AB.

Document number: S223.531.en

© 2009 Sandvik SRP AB S223.531.en-02 1

2 S223.531.en-02 © 2009 Sandvik SRP AB

© 2009 Sandvik SRP AB S223.531.en-02 3

This page is intentionally left blank

4 S223.531.en-02 © 2009 Sandvik SRP AB

OM Sandvik ASRi 2.0 5

1.1 Equipment information

6 S223.531.en-02 © 2009 Sandvik SRP AB

1.1.1 Document information

© 2009 Sandvik SRP AB S223.531.en-02 7

1.2 Operating principles of a cone crusher

8 S223.531.en-02 © 2009 Sandvik SRP AB

setting decrease = finer product setting increase = coarser product

© 2009 Sandvik SRP AB S223.531.en-02 9

1.3 Function and benefits of the ASRi

10 S223.531.en-02 © 2009 Sandvik SRP AB

1.3.1 ASRi system description

© 2009 Sandvik SRP AB S223.531.en-02 11

Power supply unit Control unit

-U1N -CBT -L3

Power measurement unit Tank measurement unit Hydroset drive unit

The system incorporates a number of transducers that provide the

12 S223.531.en-02 © 2009 Sandvik SRP AB

© 2009 Sandvik SRP AB S223.531.en-02 13

1.3.2 Hydroset pressure definitions

14 S223.531.en-02 © 2009 Sandvik SRP AB

1.4 Information levels

© 2009 Sandvik SRP AB S223.531.en-02 15

This page is intentionally left blank

16 S223.531.en-02 © 2009 Sandvik SRP AB

OM Sandvik ASRi 2.0 17

2.1 Hazard information

General danger Dangerous voltage Risk of crushing

Hanging load Risk of crushing Flying fragments

2.1.2 Risk levels

Failure to observe information marked “DANGER!” can result in life-

18 S223.531.en-02 © 2009 Sandvik SRP AB

2.1.3 Prohibition signs

2.1.4 Mandatory signs

Disconnect current Read the manual

© 2009 Sandvik SRP AB S223.531.en-02 19

Sandvik SRP AB provides technical documentation appropriate to all three

2.2.1 Personal protection

Ear protection Safety helmet Eye protection

Protective gloves Safety boots Mask or breathing

20 S223.531.en-02 © 2009 Sandvik SRP AB

2.3 General safety precautions

© 2009 Sandvik SRP AB S223.531.en-02 21

2.3.1 Machine safety guards

2.3.2 Machine access

2.3.3 Electrical safety

22 S223.531.en-02 © 2009 Sandvik SRP AB

CAUTION! Only welders qualified according to European Standard EN 287 or

2.3.5 Hydraulic system

2.3.6 Lubrication system

© 2009 Sandvik SRP AB S223.531.en-02 23

2.3.7 Lifting and moving loads