ASRi Manual S223.468.En

S 223.468.
00 en
Instruction Manual
and
Technical Documentation
ASRi Version 1.20
1 Introduction S 223.468-1
2 Connecting up a new system S 223.468-2
Manual
ASRi Version 1.20 3 Commissioning a new system S 223.468-3
S 223.468.00 en
2006-03-13 4 Normal operation S 223.468-4
5 Configuring crushing programs S 223.468-5
6 Calibration S 223.468-6
7 Operating data S 223.468-7
8 Alarms S 223.468-8
9 Historical data S 223.468-9
10 POT (the Product Optimization Tool) S 223.468-10
The service picture and Power

11 measurement
S 223.468-11
13 Safety regulations S 050.014 en
Appendix A 14 Components R 223.1252
Technical
Documentation
15 Circuit diagrams R 223.1251
16 Mainshaft position sensor R 223.1319

ASRi manual S 223.468.00 en 1 (10)
1. Introduction 2004-06-15 1
1. Introduction
1.1 Safety...........................................................................................................2
1.2 A presentation of the ASRi system...........................................................3
1.3 How the ASRi system is built up...............................................................4
1.4 The ASRi system in comparison with previous systems .......................5
1.4.1 In comparison with previous versions of ASRi .............................................5
1.4.2 In comparison with the ASR Plus system......................................................5
1.5 A general description of the ASRi control cabinet ..................................8
1.6 Information levels.......................................................................................9
1.7 A guide to using this manual ..................................................................10
1.7.1 Typographical conventions ...........................................................................10

ASRi manual S 223.468.00 en 2 (10)
1.1 Safety
During the development of the ASRi system, Sandvik Rock Processing has put a lot of
effort into the avoidance of health and safety risks.
When the system is to be installed it is important that only competent, qualified and trained
personnel work on the electrical installation and handle the electrical components. National
and local electrical regulations must be followed and the work must be carried out
accordingly in a professional manner.
Voltages above 100V can be present in the following units:

Warning !!! ASRi-PS, ASRi-L3, ASRi-U1N and ASRi-U1N/L3.
ASRi manual S 223.468.00 en 3 (10)
1.2 A presentation of the ASRi system
The duties of the ASRi system are to automatically regulate the crusher and to protect the
crusher from overloads.
The system helps the user to achieve higher production, a higher degree of reduction,
improved product distribution and better product shape. A further benefit is that the
crusher’s wearing liners can be utilized better.
The ASRi system also incorporates help functions which assist the user in achieving a
higher output of the desired fraction(s) or in optimizing the product curve. To save the
user’s time, the ASRi system incorporates several functions which simplify operation.
ASRi manual S 223.468.00 en 4 (10)
1.3 How the ASRi system is built up
The control cabinet contains a computer which monitors and regulates the crusher. It is
also possible to display statistics and historical data, store different crushing programs, etc.
The control cabinet provides a variety of possibilities for communication with other
systems in the plant. The operator’s interface is a colour touch screen and it is also possible
to connect an external monitor, a keyboard and a mouse.
To provide access to the values and signals which the system needs in order to regulate the
crusher, the control cabinet communicates continuously via an RS 485 link with three I/O
units (I/O = input/output unit). The system incorporates a number of transducers which
provide the necessary measurement values. A pressure transducer measures the pressure in
the crusher’s Hydroset system, a position transducer measures the position of the crusher’s
mainshaft and a temperature transducer measures the temperature of the lubricating oil
returning to the tank from the crusher. The signals from these transducers are fed to an I/O
unit placed in the CB-T box. There is another I/O unit connected to the power transducer
(CB-U). It is the power transducer and its associated current transformer that measures the
power drawn by the crusher’s drive motor. If the motor is of the high-voltage type, there
are also two voltage transformers.
In addition to the analog transducer signals, the system also has digital inputs and outputs.
There are two digital inputs for status signals from the contactors of the Hydroset pump.
These contactors open and close to provide power for the motor on the pump which moves
the mainshaft (and the mantle) up and down inside the crusher. Another digital input is
energized if the overload protector for the Hydroset pump motor trips out. The I/O unit has
a digital output which is used to give a signal to other equipment that the crusher is able to
receive feed material. Inside the L3 cabinet are two digital outputs that are connected
internally to the contactors. These are used when the ASRi system is to raise or lower the
mantle. Another digital output is used to indicate that the system has initiated an active
alarm. All of the digital signals are routed through the I/O unit in the L3 cabinet.
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1.4 The ASRi system in comparison with previous systems
1.4.1 In comparison with previous versions of ASRi
The major differences between ASRi 1.20 and previous ASRi versions are described
below.
• The number of languages installed before delivery has been increased to 13. The
languages which have been added are Portuguese (Brazilian), Russian, Polish and
Chinese. Chinese is not included as standard in up-dating packages for older
systems but must instead be installed separately when required.
• Increased communications possibilities with WINi, ASRi OPC server and Web-
based XML communication.
• The analog instrument for drive motor power now displays the power draw as a
percentage of the lower of the two values entered for the crusher’s max. motor
power and the drive motor’s max. power.
• Indication in the Normal picture that liner wear has become so great that it is soon
time to calibrate the crusher.
• A Service picture has been added. This presents miscellaneous information about
communication with the I/O units.
• The monitoring of signals from the transmitter has been increased to reduce the risk
of cable or sensor faults resulting in the overloading of the crusher.
• A greater number of more easily understood events in the Event list. The Event list
now also contains information on which crushing program and which regulation
mode are started and on when crushing programs were changed.
1.4.2 In comparison with the ASR Plus system
The major differences between the ASRi system and the ASR Plus system are described
below.
• The ASRi system uses a new method to regulate the crusher. We measure and
calculate the pressure at which the crusher operates in a new way and can thus
determine the crusher’s operating conditions. The system continuously monitors the
crusher’s operating conditions and can therefore optimize the crushing force. This
feature also protects the crusher from overloads.
• There are several changes in the way the crusher is calibrated. The ASRi system
incorporates a considerably simpler calibration function than previous systems.
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When the system is first put into operation, the user is presented with a step-by-step
guide to the setting-up procedure. Normal calibration of the crusher has been
developed further and a “metal-to-metal” calibration now requires just a single
press of a button.
• Thanks to an improved automatic wear compensation feature, the user does not
need to calibrate the crusher as often as before.
• The ASRi system automatically calculates the starting CSS which protects the
crusher against overloading when feeding starts.
• The ASRi system incorporates a program function with which the production of the
desired fraction(s) can be maximized. With data on product analyses as a starting
point, the system helps the user to find the CSS which gives optimum results.
Another program function uses the product analysis data to help the user establish
which CSS gives the optimum product curve.
• The ASRi system incorporates an improved Auto-cycle function, now called

Multi-CSS.
• The ASRi system permits the storage of 20 different crushing programs.
• The ASRi system is considerably easier to use since it features a graphic interface
in the form of a colour touch screen on which the user can read all of the
information needed. With the aid of the touch feature, the operator has easy access
to the desired functions.
• The Alarm list is easier to view and also incorporates various filtering possibilities.
• The ASRi system also incorporates an Alarm log, which stores all alarms – even
after the alarm has been acknowledged and has disappeared from the Alarm List.
The Alarm Log has various filtering possibilities.
• The ASRi system incorporates an Event log, which is continuously up-dated with
all changes initiated by the ASRi system or occurring in the crusher’s operation.
• The Normal picture incorporates an indication of the CSS discrepancy (i.e. the
difference between the actual CSS and the CSS setpoint).
• The crusher‘s Hydroset pressure is displayed as a sector, to illustrate the crusher’s

operating conditions.
• The ASRi system can present six different historical data curves to permit the
analysis of the crusher’s previous operating conditions.
• The ASRi system incorporates a graphic presentation of cables and transducers for
the checking of connections.
ASRi manual S 223.468.00 en 7 (10)
• The ASRi system can be connected via 10 Mbit and 10/100 Mbit Ethernet for
communication with a higher-level system.
• The ASRi system has a serial port for communication with existing Winplus
programs or with other programs, which are run on a PC and utilize the ASR Plus
system’s Comli protocol.
• The ASRi system incorporates a built-in instruction manual.

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1.5 A general description of the ASRi control cabinet
The control cabinet of the ASRi system incorporates an industrial computer with a screen
and various ports for connection with other systems. The control cabinet is fed with 24V
DC from the power supply unit supplied. The computer has a 12” SVGA touch screen. The
enclosure is of acid-proof stainless steel and has protection class IP65.
On the bottom of the cabinet are seven M12 connectors. There are additional connectors
beneath a panel on the left-hand side but these are not normally used. If these connections
are used, the cabinet no longer has protection class IP65. Read Chapter 2 for information
on how the control cabinet is connected up. Connectors shown below in brackets are not
used but are intended for future program versions.
10+11
12
13
14
15
1 2 3 4 5 6 7 8
1. RS232 9. Monitor
2. RS485 / ASRi – bus 10. (USB 1)
3. RS485 / ASRi – bus 11. (USB 2)
4. Ethernet 2, 10Mbit 12. Mouse
5. Ethernet 1, 100Mbit 13. Keyboard
6. (CAN - Bus) 14. (Printer)
7. Power supply 24VDC 15. Pilot light
8. On / Off
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1.6 Information levels
The ASRi system offers three different Information levels – Basic, Extended and
Configuration.
1. Basic information level displays all of the information which is necessary for normal
operation of the system.
2. The Extended information level can be selected in the Display settings picture. See
Section 3.2.
Amongst other things, this Extended information level contains the POT function and
other information which can be used to help optimize the crusher’s production. If the
Extended information has been selected and power to the system is cut off, it will still
be active when the power is switched on again.
3. The third information level – Configuration level – requires a user name and a
password. The user name and password can be found in a pocket inside the front
cover of the manual supplied together with the system. You log in to Configuration
level from the Extended information level, via the Log in button in the Advanced
picture. See Section 3.6.2.
In the Configuration level you can make changes which affect regulation
considerably. Access to the Configuration level should therefore be restricted to
personnel with more detailed knowledge of the plant, the crusher and the ASRi
system.
To exit from the Configuration level you must actively log out or restart the system.
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1.7 A guide to using this manual
To make it easier to read this manual, we explain below the typographical conventions
which are used in the manual.
1.7.1 Typographical conventions
The names of buttons and tabs are written in bold text, inside brackets, e.g. [Calibration].
Messages and other screen texts are written in bold text, inside quotation marks, e.g.
”Crusher load too high, aborting”.
Picture titles are written in bold text, e.g. Fraction Distribution Diagram.
Column headings in screen pictures are written in bold italics, e.g. Time.
Note ! This manual describes a standard ASRi system. Various

components and/or connections may differ from the standard
system described in this manual if a special system has been
ordered. In such a case, contact SRP for any applicable special
technical documentation.
ASRi manual S 223.468.00 en 1 (12)
2. Connecting up a new system 2004-06-15 2
2. Connecting up a new system
2.1 General ........................................................................................................2
2.2 ASRi bus cables (k5) ..................................................................................4
2.3 Components which are supplied ..............................................................6
2.4 Components which are not supplied........................................................9
2.5 Cables which are supplied ......................................................................10
2.6 Cables which are not supplied................................................................11
2.7 Connection of external monitor, mouse and keyboard.........................12

ASRi manual S 223.468.00 en 2 (12)
2.1 General
Sandvik Rock Processing sets up the ASRi system for the crusher with which it is to
operate, before the system is delivered. This is done by programming the ASRi computer
(ASRi-OP) with certain parameters. The system can however easily be reprogrammed if it
is to be used with another crusher model. See Section 3.6.1.
If you have any questions about connecting up, etc., please always give the serial number
of the ASRi system (the serial number is given on the control cabinet).
The ASRi system consists of various components, which are delivered together with some
of the necessary cables. These cables (K1, K2, K3 and K5) have connectors at both ends.
One end of cable K4 is permanently connected to power supply unit ASRi-PS. The other
end has a plug for connection to the control cabinet ASRi-OP.
The other necessary cables are designated X1, X2, X3, X4, X5, X6, X7 and X8. These
cables must be provided by the customer. All of the components supplied by Sandvik Rock
Processing – including cables K1-K5 – are connected up and tested in our workshop before
delivery.
The general arrangement of the ASRi system and its associated cables shown in the System
overview (drg. 194.0397, sheet 1) on the next page.
A lot of effort has been put into reducing to a minimum the

Note ! electrical connection work necessary at the site. However, a few
connections must be made by a qualified electrician.
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System overview for the ASRi system (194.0397, sheet 1)
Sandvik Rock Processing

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2.2 ASRi bus cables (K5)
The physical arrangement of the ASRi system’s major components and the distances
between them vary from plant to plant. These major components are:
• “ASRi” – The ASRi control cabinet (ASRi-OP)

• “L3” – The contactor/component box for the Hydroset pump motor
(ASRi-L3).
• “Tank” – The connection box mounted on, in or near the crusher’s oil tank unit
(ASRi-CB-T).
• “U1N” – The power measurement system (ASRi-CB-U1N).
The ASRi system has been designed so that these four major components can be installed
in the most convenient locations in the plant.
Since the four major components are linked by an ASRi bus, their relative positions are not
critical. Each major component has two bus connectors, one male and one female. A single
type of communication cable is used to link all four major components. These cables are
designated K5 and are stocked by Sandvik Rock Processing in various standard lengths:
5m, 10m, 20m, 30m, 40m, 80m, 100m, 150m, 200m and 250m.
Sandvik Rock Processing tests the entire ASRi system – including the cables which
Sandvik Rock Processing supplies – before the system is delivered to the customer. To
make this possible, it is necessary for the customer to provide information about the major
component layout and the required communication cable lengths when the system is
ordered. It is also necessary to state the length of the cable between L3 and the L1 push
button box.
To make this possible, we use an ASRi Order checklist, a copy of which can be found in
Section 17.
An example of a system configuration is shown below:
K5
L3 L=20 m
TANK L3 U1N ASRi L1
K5 K5 K5
L=40 m L=30 m L=20 m
-T -T
The cable used to connect the L1 push button box (used – if required – for direct control of
the Hydroset pump motor) to the L3 cabinet is of the same type as the ASRi bus
communication cables. The ASRi bus requires three cables, and one is needed for the L1
push button box. This means that four K5 are required.
ASRi manual S 223.468.00 en 5 (12)
If, for some reason, Sandvik Rock Processing does not receive information about the
required K5 cable lengths, a set of five cables will be delivered: one 10m long, two 20m
long, one 30m long and one 40m long.
All of the K5 cables have the same connectors so they can be switched around or can be
coupled together to make longer cables. This is why we supply five cables if we do not
receive full details – the extra (fifth) cable can be used as an extension if required.
Each cable has a male connector at one end and a female

Note ! connector at the other end. Make sure that you install the cables
the right way round.
Another point to remember is that the ASRi bus layout requires a termination plug at each
of the two extremities. Two termination plugs are supplied, one male and one female.
Install the K5 ASRI bus cables well away from items that can
Note ! generate interference – frequency converters and power cables,
for example.
If you have any doubts about the cable installation, contact Sandvik Rock Processing for
advice.
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2.3 Components which are supplied
The components described below – and shown by continuous lines in the System overview
(drg. 194.0397, sheet 1) – are supplied as standard with the ASRi system.
ASRi-OP control cabinet

Delivered separately for installation in a suitable place in the plant. The control cabinet
must be installed in a well-protected place and must not be subjected to vibration.
Outside dimensions: 350 mm wide, 291 mm high and 81 mm deep

Temperature range, operation: -10 - +40 °C
Temperature range, storage: -25 - +60 °C
Protection class: IP65
Component cabinet ASRi-L3

Delivered separately when a new crusher is delivered or when the system is to be used with
an existing crusher. ASRi-L3 contains motor protectors and contactors for the
forwards/backwards connection of the Hydroset pump, an I/O-unit with an ASRi bus
communication interface, a single-phase power supply unit (100-240V AC input/24V DC
2.5A output) plus an alarm relay and a relay for the interlocking of the crusher’s feeding
arrangement (feeder and/or conveyor).
Position sensor ASRi-B1N

This sensor provides information on the position of the crusher’s mainshaft and is mounted
in the crusher’s Hydroset cylinder cover. If the ASRi system is supplied together with a
new crusher, the position sensor is installed in the crusher before delivery. If the ASRi
system is intended for an existing crusher, B1N is supplied separately, together with the
mechanical components necessary for installation in the crusher at the site.
Pressure transducer ASRi-B2N

B2N measures the Hydroset pressure and is installed in the Hydroset tank unit (OT/HT) if
the system is supplied together with a new crusher. In the case of an existing crusher, B2N
is supplied separately, together with the mechanical components necessary for installation
at the site.
Temperature transducer ASRi-B3N

B3N measures the temperature of the lubricating oil returning to the oil tank unit. It is
installed in the oil tank unit (OT/HT) if the system is supplied together with a new crusher.
In the case of an existing crusher, B3N is supplied separately, together with the mechanical
components necessary for installation at the site.
Connection box ASRi-CB-T

Mounted on the tank unit (OT/HT) if a new crusher is supplied, or separately for
installation on/in an existing tank unit.
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Push button box ASRi-L1

L1 can be used for manual control of the crusher’s mainshaft (up and down) if there is a
fault with the ASRi system. Normally, it is not active. This push button box is directly
connected to the Hydroset pump motor’s contactors and is used for raising and lowering
the mainshaft, independently of the ASRi system.
If L1 is to be active, terminal blocks 205 and 206 in terminal

Note ! block assembly ASRi-X1 in the L3 cabinet must be linked with
the plug supplied.
When L1 is not going to be used, disconnect the cable from the

L3 and remove the linking plug. Sandvik Rock Processing
recommends that the L1 box is stored well away from the L3
cabinet.
When ASRi-L1 is used, there is no protective function to

Caution !! prevent the mainshaft being raised so far that there is metal-to-
metal contact between the crushing liners.
Current transformation ASRi-T11 and transducer ASRi-CB-U1N

Normally supplied separately for installation in an existing switch gear cabinet or switch
gear room. T11 and U1N can in some cases be delivered already installed if the order also
covers other electrical equipment from Sandvik Rock Processing. The power transducer is
supplied together with an I/O unit and a connection box with two ASRi bus connections.
The power transducer and the I/O unit require a separate 110/230V AC supply. The power
transducer, I/O unit and connection box are supplied mounted on a DIN rail and have the
collective designation ASRi-CB-U1N.
T11 must be installed as shown in the diagram 194.0397. The

Note ! voltage phase in which T11 is mounted must be connected to
terminal screw 10 on U1N. If the crusher’s drive motor has a
soft starter or a frequency converter, T11 and voltage measure-
ment inputs to U1N must be connected on the same side of the
starting equipment.
If you intend to use your own components for power measurement we recommend that you
contact Sandvik Rock Processing and discuss the question of the compatibility of the
proposed components.
ASRi manual S 223.468.00 en 8 (12)
Fuse F11
Power transducer U1N is protected by the 3-pole 1A automatic fuse (F11) supplied.
Equipment for high-voltage motor

If the ASRi system is ordered for a crusher driven by a high-voltage motor, suitable
transformers must be used.
ASRi manual S 223.468.00 en 9 (12)
2.4 Components which are not supplied
The components described below – and shown by chain-dotted lines in the general
connection diagram 194.0397, sheet 1 – are not supplied as standard with the ASRi system.
They are either already installed or can be ordered as optional extra equipment.
Hydroset pump motor M6

Mounted in the Hydroset tank unit when a new crusher or tank is supplied. If the ASRi
system is to be used with an existing crusher, the existing Hydroset pump is used, as long
as it is of the reversible type.
Feeder FC
We strongly recommend that the feed to the crusher is interlocked with the ASRi system
through relay –K21A in component cabinet L3, as shown in general connection diagram
194.0397, sheet 1. The ASRi system continuously registers the load on the crusher. If an
abnormal situation occurs and threatens to cause damage to the crusher, the ASRi system
will initiate an alarm beginning with the code A or B and will simultaneously stop the feed
to the crusher.
Alarm lamp H1
In component cabinet L3 there is a relay (–K24A) which is energized when an alarm
beginning with the code A eller B is initiated. The output contacts of relay –K24A can be
utilized to connect an external indicating lamp to draw the attention of plant personnel or
to give an alarm to a higher-level plant control system.
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2.5 Cables which are supplied
Cables K1, K2, K3, K4 and K5 – shown by continuous lines in the System overview (drg.
194.0397, sheet 1) – are special cables that are normally supplied by Sandvik Rock
Processing.
Cables marked K5 are supplied in the lengths required by the customer. See Section 2.2.
Cable K1
Standard lengths for the cable between ASRi-B1N (the mainshaft position sensor) and
connection box ASRi-CB-T are 6.5m, 10m and 15m. Sandvik Rock Processing selects the
appropriate cable for the crusher with which the system is to be used.
Cable K2
The cable between ASRi-B2N (the pressure transducer) and connection box ASRi-CB-T is
always 3m long.
Cable K3
The cable between ASRi-B3N (the temperature transducer) and connection box
ASRi-CB-T is always 3m long.
Cable K4
The cable between ASRi-PS (the power supply unit) and the control cabinet (ASRi-OP) is
always 5m long. This cable has a permanent connection in the power supply unit itself and
is fitted with a suitable plug at the other end, for connection to ASRi-OP.
Cables K5
See Section 2.2.
Special lengths for K5 cables

Other lengths can be delivered at extra cost if the standard lengths are not suitable,
although there may be a delivery time extension.
Termination plugs ASRi-T

Two termination plugs are supplied, for installation at the extremities of the ASRi bus.
See Section 2.2.
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2.6 Cables which are not supplied
Cables shown with chain-dotted lines and marked with the prefix X are not normally
included in Sandvik Rock Processing’s delivery, unless specially ordered. These cables are
of standard type and can most easily be obtained locally.
Cable X1
The power cable to the feeder FC must be dimensioned in accordance with local
conditions, to suit the voltage and the power rating of the feeder or conveyor.
Cable X2
The interlocking cable for the feeder/conveyor and the alarm lamp (if fitted). The contacts
of the relays (–K21A och –K24A) in ASRi-L3 are rated at 6A, 250V AC.
Cable X3
The power cable for the Hydroset pump motor (M6) must be dimensioned in accordance
with local conditions, to suit the voltage and the power rating of M6. The Hydroset pump
motor can vary between 0.75 kW and 7.5 kW, depending on the crusher model. Check the
Hydroset pump motor power for the crusher in question. This information can be found in
the crusher’s spare parts list/electrical documentation.
Cable X4
The control voltage supply cable for ASRi-L3. The power consumption of ASRi-L3 is
50W. The control voltage for L3 can lie between 100 and 240V AC.
Cable X5
See cable X3.
Cable X6
The power cable for the crusher’s drive motor must be dimensioned in accordance with
local conditions, to suit the voltage and the power rating of the drive motor.
Cable X7
The control voltage supply cable for ASRi-PS. The power consumption of ASRi-PS is
50W. The control voltage for ASRi-PS can lie between 100 and 240V AC.
Cable X8
The control voltage cable for the power transducer ASRi-U1N. The power consumption of
ASRi-U1N is approx. 3VA.
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2.7 Connection of external monitor, mouse and keyboard
It is possible to connect an external monitor, a keyboard and/or a mouse to the left-hand

side of the ASRi-OP control cabinet. If any of the connectors is to be used, a cover plate
must first be removed.
If the cover plate is removed, the encapsulation cabinet no

Note ! longer meets the requirements of IP65. Make sure that the
gasket is correctly positioned when the cover plate is refilled.
The external monitor can be plugged in to the 15-pole D-sub connector at the top. The
resolution of the external monitor must be at least 800x600. The resolution cannot be
changed.
The mouse must be of the PS/2 type and it can be plugged in to the upper of the two PS/2
sockets.
The keyboard must also be of the PS/2 type and it can be plugged in to the lower of the two
PS/2 sockets.
The ASRi-OP control cabinet must be switched off while

Note ! external units are being connected.
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3. Commissioning a new system 2004-06-15 3
3. Commissioning a new system
3.1 Checking connections ...............................................................................2
3.2 System settings..........................................................................................3
3.3 A-range set-up – general ...........................................................................6
3.4 A-range set-up – metal-to-metal................................................................7
3.5 A-range set-up – with lead.......................................................................10
3.6 Extended system capabilities .................................................................12
3.6.1 Entering crusher parameters........................................................................12
3.6.2 Changing crusher parameters ......................................................................13
3.6.3 Ethernet communication...............................................................................17

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3.1 Checking connections
Switch on the ASRi system by pressing the switch at the far right on the bottom of the
control cabinet. In cold weather the system may need to warm up before it can start
operating. The blue pilot light on the front of the cabinet will flash while the system is
warming up. Start by checking that transducers, I/O units and cables are correctly
connected before the new system is put into operation.
Press the [Set-up] button at the bottom of the screen. Press the [Connections] button to
bring up the Connections picture.
The picture shows a schematic view of the connections. More detailed information is given
in Chapter 2.
The background in the cable designation is normally white when the cable is
connected and communication is active.
If the background in a cable designation is red, this is an indication that signals are
not being transmitted via the cable. This can be due to a fault in the cable or a fault
in one of the units which the cable links together.
ASRi manual S 223.468.00 en 3 (17)
3.2 System settings
When the system’s connections have been checked, a number of system settings must be
made.
Date and time

Press the [Set-up] button at the bottom of the screen. Press the [System] button to bring up
the System picture.
2.2
Press the [Date & time] button.

ASRi manual S 223.468.00 en 4 (17)
The Date & time picture displays the time and date which have been set in the system.
2.2.1
Press the [Adjust] button to change the date and/or time.
2.2.1.1
Highlight the field that is to be adjusted by touching it. Adjust the value displayed with the
help of the two spin buttons ( [▲] and [▼] ) on the right. Repeat the process with the other
fields that are to be adjusted. When the new settings have been made, press [OK].
ASRi manual S 223.468.00 en 5 (17)
Display
When the date and time have been correctly set, press the [System] button in the Menu
frame to return to the System picture. Press the [Display] button to bring up the Display
settings picture.
2.2.2
• Information level
Choose between the [Basic] button and the [Extended] button. For normal
operation, press the [Basic] button. To gain access to more advanced functions,
press the [Extended] button. See sections 3.6 and 5.6.
• Backlight luminance
Set the brightness of the screen.
• Language
Select the language with the help of the spin buttons and press [OK]. The languages
available in ASRi version 1.20 are:
Chinese English French Italian Polish Russian Swedish

Czech Finnish German Norwegian Portuguese (Brazilian) Spanish
• Units
Choose which measuring unit system is to be used in displays – European or
American. Press the [SI] button for European units or the [US] button for American
units.
ASRi manual S 223.468.00 en 6 (17)
3.3 A-range set-up – general
An A-range set-up must be carried out so that details of the mainshaft travel span are
available for the system. The position of the crusher’s mainshaft is expressed as an ”A-
dimension”. This is the name given to the smallest distance between the underside of the
crusher’s spider and the top of the headnut. An A-range set-up is required when the ASRi
system is first commissioned, or when the crusher is modified in such a way that the shaft
position measuring system is affected. There are two ways to carry out an A-range set-up:
• A-range set-up – metal-to-metal

This set-up procedure involves raising the mainshaft (with the crusher running
empty) until the mantle touches the concave ring, stopping the crusher, measuring
the A-dimension, entering this value, restarting the crusher and lowering the
mainshaft to its bottom position. When this has been done, the A-range set-up has
been completed.
• A-range set-up – with lead

This set-up procedure involves lowering a lump of lead through the crushing
chamber (with the crusher running empty), stopping the crusher, measuring the
thickness of the lead lump and entering this value, measuring the A-dimension and
entering this value, restarting the crusher and lowering the mainshaft to its bottom
position. When this has been done, the A-range set-up has been completed.
The metal-to-metal method is the easiest way to carry out the A-range set-up, and this is
the method normally used with H-type Hydrocones.
With an S-type Hydrocone, the design of the crushing chamber is such that it is usually
impossible to reach a metal-to-metal position. With a small S-type Hydrocone it may be
possible to reach this position, but the crusher will be subjected to a very high load. In the
case of an S-type Hydrocone, the A-range set-up should therefore always be carried out
with lead.
ASRi manual S 223.468.00 en 7 (17)
3.4 A-range set-up – metal-to-metal
To carry out an A-range set-up procedure using the metal-to-metal method, press the
[Set-up] button at the bottom of the screen. Press the [A-range] button in the Set-up menu.
2.3
Select the metal-to-metal method by pressing the [A & M-M] button.

ASRi manual S 223.468.00 en 8 (17)
To start the A-range set-up procedure, press that [Start] button. The procedure can be
halted at any stage by pressing the [Abort] button, which appears when the A-range
procedure has started.
The picture guides you automatically through the various stages of the set-up procedure.
Each step is displayed in green or black. A green colour indicates that the system is waiting
for you to do something.
1. Stop feeder
If the crusher is under load, the feed must be stopped.
2. Start crusher
If the crusher’s drive motor has not been started, a message comes up on the screen.
The system proceeds to the next step 30 seconds after the motor has been started. If the
crusher is loaded again, the A-range set-up procedure is automatically halted. This is
indicated by an error message: ”Crusher load too high, aborting”. In this case, press the
[OK] button to abort the set-up procedure.
ASRi manual S 223.468.00 en 9 (17)
3. Waiting for metal-to-metal contact

The ASRi system raises the mainshaft to reach the metal-to-metal position.
4. Detecting metal-to-metal contact

The ASRi system detects that the shaft cannot be raised further. If the pressure is too
high, the set-up procedure is halted and the message ”Pressure too high, aborting”
comes up. Press the [OK] button to acknowledge.
5. Stop crusher
Switch off the crusher’s drive motor.
6. Enter A-dimension and press [Continue]

Go out to the crusher and physically measure the A-dimension. Enter this value by
using the arrow buttons. When the correct A-dimension is displayed, press the
[Continue] button.
Do not move the shaft until you have entered the measured A-
Note ! dimension and pressed [Continue].
7. Start crusher
Restart the crusher’s drive motor. The system proceeds to the next step 30 seconds
after the motor has been started.
8. Waiting for A-Bottom position

The ASRi system lowers the mainshaft to establish the maximum A-dimension.
9. A-Bottom position detected, pumping up

The ASRi system has lowered the mainshaft to its bottom position and has registered
the maximum A-dimension. The shaft is then pumped back up half way.
10. Crusher Calibrated. Press [Finish]

The A-range set-up procedure has been completed. Press the [Finish] button.
ASRi manual S 223.468.00 en 10 (17)
3.5 A-range set-up – with lead
To carry out an A-range set-up procedure using a lump of lead, press the [Set-up] button at
the bottom of the screen. Press the [A-range] button and select the “with lead” method by
pressing the [A & Lead] button.
To start the A-range set-up procedure, press the [Start] button. The procedure can be halted
at any stage by pressing the [Abort] button, which appears when the A-range procedure has
started.
The picture guides you automatically through the various stages of the set-up procedure.
Each step is displayed in green or black. A green colour indicates that the system is waiting
for you to do something.
1. Stop feeder
If the crusher is under load, the feed must be stopped.
2. Start crusher
The system proceeds to the next step 30 seconds after the motor has been started. If the
crusher is loaded again, the A-range set-up procedure is automatically halted. This is
indicated by an error message: ”Crusher load too high, aborting”. In this case, press the
[OK] button to abort the set-up procedure.
ASRi manual S 223.468.00 en 11 (17)
3. Position the shaft. Measure the CSS.

Enter the value and press [Continue].
Go out to the crusher and measure the CSS. The size of the CSS can be adjusted by
using the L1 push button box or with the help of the arrow buttons in the small crusher
figure in the picture on the ASRi screen. To measure the CSS, use at least one lump of
lead, hanging in a steel wire, and lowered through the crushing chamber. If the CSS is
large, use some other suitable tool. Use a Vernier gauge to measure the thickness of the
lead lump after it has passed through the crushing chamber. This thickness corresponds
to the CSS. Enter this value by using the arrow buttons and then press the [Continue]
button.
After you have passed the lead through the crushing chamber,
Note ! do not move the shaft until you have entered the CSS and
pressed the [Continue] button.
When ASRi-L1 is used, there is no protective function to

Caution !! prevent the mainshaft being raised so far that there is metal-to-
metal contact between the crushing liners.
4. Stop Crusher
Switch off the crusher’s drive motor.
5. Enter A-dimension and press [Continue]

Go out to the crusher and physically measure the A-dimension. Enter this value by
using the arrow buttons and then press the [Continue] button.
Do not move the shaft until you have entered the measured A-
Note ! dimension and pressed [Continue].
6. Start crusher
Restart the crusher’s drive motor. The system proceeds to the next step 30 seconds
after the motor has been started.
7. Waiting for A-Bottom position

The ASRi system lowers the mainshaft to establish the maximum A-dimension.
8. A-Bottom position detected, pumping up

The ASRi system has lowered the mainshaft to its bottom position and has registered
the maximum A-dimension. The shaft is then pumped back up half way.
9. Crusher calibrated. Press [Finish]

The A-range set-up procedure has been completed. Press the [Finish] button.
ASRi manual S 223.468.00 en 12 (17)
3.6 Extended system capabilities
To gain access to more advanced features, the [Extended] button must be selected in the
Display settings picture. See under the heading Display in Section 3.2. To be able to make
changes, you must log in to the Configuration level. See Section 1.6.
3.6.1 Entering crusher parameters
If a system is moved from one crusher to another, several settings must be changed. To
make it easier to switch from one machine to another it is possible to enter a set of standard
values for various different crushers.
To enter standard parameter values, press the [Set-up] button at the bottom of the screen
and then press [Crusher data].
Select the type of crusher to which the ASRi system is to be connected and then press the
[Select] button to activate your selection. The “Custom” alternative can be used if none of
the listed crusher types matches the crusher with which the ASRi system is to be used.
“Custom” does not load or change any values – they must be entered manually. See the
next section.
ASRi manual S 223.468.00 en 13 (17)
3.6.2 Changing crusher parameters
It can occasionally be necessary to make certain changes in the standard parameter values.
This can be done using the Advanced menu.
Press the [Set-up] button at the bottom of the screen and then press [Advanced]. The
[Advanced] picture comes up.
ASRi manual S 223.468.00 en 14 (17)
A. User settings
The User settings picture contains information about the system. To view these User
settings, press the [User] button in the Advanced picture.
Mark the field where you want to make an alteration by touching it. A numerical keypad
will appear from the right-hand side of the screen. You can use this keypad to change the
value displayed in the field. The keypad automatically disappears when you exit from the
picture.
The following parameters can be changed in the User settings picture:
501.*) The total measuring span for the power transducer providing the power
signal.
502.*) The maximum permissible continuous power output from the motor.
503. The A-dimension at which a prompt about worn liners is to be activated.
When the A-dimension is less than the entered value, the “New liners
needed!” alarm is activated.
504. The total cycle time for a Multi-CSS crushing program (at least 60 seconds).
505. The selection of automatic or manual definition of the CSS-Start factor.
506. The activation or deactivation of the automatic wear compensation function
(IWC).
ASRi manual S 223.468.00 en 15 (17)
507. The alarm limit for the return oil temperature. If the measured temperature
exceeds this limit, the feed to the crusher is stopped. If a limit below 20 ºC is
selected, the alarm will not be activated.
In the Calculate power transmitter span picture, parameter 501 can be calculated with the
help of information about the power measuring equipment. To bring up the Calculate
power transmitter span picture, press the [Calculate] button in the User Settings picture.
The information needed for the calculation of the power measurement span is:
701.*) The nominal supply voltage to the power transducer. The power transducer
supplied by Sandvik Rock Processing has a nominal supply voltage of 110V
or 400V.
704.*) Primary current in current transformer.
705.*) Correction factor (Normally = 1).
If the power measurement set-up incorporates high-voltage transformers, the following

values must also be entered:
702.*) Primary voltage of voltage transformer.

703.*) Secondary voltage of voltage transformer.
*) See drawing 194.0408

ASRi manual S 223.468.00 en 16 (17)
When all of the information has been entered, the calculated result is displayed at the
bottom of the picture. Press [OK] to transfer the result to parameter 501 in the User Settings
picture. Press [Abort] to return to User Settings without transferring the calculated value.
B. Sandvik settings
In the Sandvik settings picture you can check other parameter values which can only be
changed by Sandvik personnel.
C. Log in
Used when “User settings” are to be changed.
D. The Service picture
The Service Picture displays information which can make fault-tracing easier. See section
11.1
ASRi manual S 223.468.00 en 17 (17)
3.6.3 Ethernet communication
Each ASRi system in a network must have its own unique IP-address. The IP-address of an
ASRi system can be changed.
The settings required for the two Ethernet connections can be made in the Communication
picture. This Communication picture is brought up by pressing the [Set-up] button at the
bottom of the screen and then pressing the [Com] button at the bottom of the column on the
left.
Fig 3.6.3 The ASRi system’s Communication picture.
Ethernet 1 refers to the 100 Mbit connection and Ethernet 2 refers to the 10 Mbit
connection.
Before delivery, the ASRi network cards are set to the addresses 192.168.30.200 and
192.168.31.201 respectively. If the ASRi system is to be put into a local network, these
addresses may need to be changed to avoid conflicts with existing systems on the network.
Contact your network administrator for a check on such addresses and any address changes
that are necessary.
When you have entered the desired address, press [Select].
For more information on communication possibilities, see the separate Communication

Manual S223.428 en.
ASRi manual S 223.468.00 en 1 (8)
4. Normal operation 2004-06-15 4
4. Normal operation
4.1 A guide to the normal picture.........................................................................2
4.2 Operating with automatic regulation, AUTO .................................................7
4.3 Operating under manual control, MAN..........................................................8

ASRi manual S 223.468.00 en 2 (8)
4.1 A guide to the normal picture
The Normal picture is the default picture – the picture normally shown on the screen. In the
following pages you will find descriptions of the figures and buttons which are shown in
the Normal picture.
5. 6.
7.
4.
3. 1
8.
2.
9.
1.
1. Menu buttons 6. Crusher symbol
2. Indication of Hydroset pressure 7. Operating mode

selector
3. Indication of operating mode
8. Button for opening
4. Indication of motor power draw Operator’s pad
5. Indication of CSS 9. Stop button

ASRi manual S 223.468.00 en 3 (8)
1. Menu buttons
1.d1
At the bottom of the screen is a row of six menu buttons which are always visible, no
matter which picture is shown in the window above. You can use these buttons to directly
access the picture in question. Blue highlighting on a button indicates which picture family
is currently being shown.
• Normal – The main picture, which shows the crusher’s operating status.
• Set-up – Connections, system settings and A-range set-up.
• Op. data – Information on power draw, Hydroset pressure, CSS, A-dimension, load,
combinations.
• Alarm – The Alarm list and the Alarm log.
• History – Historical data on power draw, Hydroset pressure, CSS, A-dimension,
temperature, ”mix” and occurrences.
• Help – An in-built ASRi manual.
2. Indication of Hydroset pressure
The instrument at the bottom-left corner displays the crusher’s

Hydroset pressure. The green area on the instrument is from 0 to
1.d2 100%, the yellow area from 100% to 120% and the red area from
120% to 150% of the crusher’s max. permitted Hydroset pressure.
The pressure is indicated by a sector where the average Hydroset

pressure is shown by the lower edge of the sector and the average
peak pressure by the upper edge of the sector. This information can be
used to determine how evenly the crusher is loaded and thus how well
it is operating. The narrower the sector, the better the crusher is
operating and the higher it can be loaded. Beneath the instrument, the
average peak pressure is shown numerically. If an Auto-Load
crushing program is active, this numerical field is highlighted in blue
and the relevant set point is indicated by a marking on the scale.
.
ASRi manual S 223.468.00 en 4 (8)
3. Indication of operating mode
1.d3
The Operating mode field indicates the regulation mode in which the ASRi system is
currently operating:
Line 1:
• Stop – no regulation is being carried out.
• Manual – the crusher is under manual control.
• Calibration – a calibration procedure is in progress.
• Auto – regulation is being carried out in accordance with the program indicated.
Line 2:
• Shows which crushing program has been selected and which regulation principle is
being used – ”Auto-CSS”,”Multi-CSS” eller ”Auto-load”.
Line 3:
• Shows the set points for the selected regulation crushing program.
On the right in the field is a ”traffic light” which provides a clear indication of any problem
in the system.
• Green light – everything is OK.
• Yellow light – there was previously an alarm which has now disappeared but has
not yet been acknowledged.
• Yellow/red light – there is at least one active alarm with severity degree B or C.
• Red light - there is at least one active alarm with severity degree A.
4. Indication of drive motor power
This instrument displays the power drawn by the crusher. The green
area on the instrument is from 0 to 100%, the yellow area from 100%
1.d4 to 140% and the red area from 140% to 150% of the crusher’s max.
permitted power. The measured power draw can exceed the crusher’s
or the drive motor’s max. power (whichever is lowest) by 10 % due to
losses in the motor. Beneath the instrument, the power draw is shown
numerically. If an “Auto-Load” crushing program is active, this
numerical field will be highlighted in blue and the relevant set point is
indicated by a marking on the scale.
ASRi manual S 223.468.00 en 5 (8)
5. Indication of CSS
The instrument at the top-left corner displays the crusher’s CSS. The
crusher’s current setting is displayed numerically beneath the
1.d5
instrument. If ”Auto-CSS” or ”Multi-CSS” regulation has been
selected, the numerical field will be highlighted in blue and the
deviation from the CSS Set point will be shown. The centre of the
scale corresponds to the desired CSS, which is shown at the top of the
instrument.
6. Crusher symbol
In the middle of the normal picture there is a crusher symbol

which contains information on the position of the mainshaft.
At the top, the current A-dimension is displayed numerically.
Beneath the figure is a column displaying the A-dimension
1.d6 in relation to the span of the probe’s working range. The
white portion of the column indicates the crusher’s operating
range. If the system needs calibrating, the column will be
yellow. The top of the column indicates the crusher’s ”metal-
to metal” position and the bottom indicates the ”A-Bottom”
position. As the crusher’s liners wear, the top of the column
moves upwards each time a calibration is carried out.
Two black arrows – one on either side of the column –

indicate the current position of the mainshaft.
Arrows above and below the column show when the

Hydroset pump is running. Pumping initiated by the ASRi
system is shown in blue whilst pumping initiated by the L1
push button box is shown in dark yellow.
The blue arrows above the crushing chamber give an

indication 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 fills with
material in the symbol.
ASRi manual S 223.468.00 en 6 (8)
7. Operating mode selector
[Auto] – starts regulation in accordance with the crushing program

1.d7 indicated in the Operating mode selector field.
[Man] – provides manual control of the mainshaft’s position.
With the arrow buttons in the Operating mode selector field you
can at any time manually pump the mainshaft up or down.
8. Button for opening Operator’s pad
When you press the [Open] button, the Operator’s pad comes up on the
1.d8 screen. With the Operator’s pad you can select crushing programs,
edit crushing programs and carry out calibration. When the [Open]
button is pressed to bring up the Operator’s pad, the text on the button
changes to [Close].
9. Stop button
With the [Stop] button you can stop regulation or calibration. If the
1.d9 crusher’s feed system is interlocked with the ASRi system, the feed is
also stopped, as indicated by the disappearance of the blue arrows.
Note that if the feed system is not interlocked with the ASRi system,
the feed indication arrows have no connection with reality.
ASRi manual S 223.468.00 en 7 (8)
4.2 Operating with automatic regulation, AUTO

To select a pre-configured crushing program, follow this sequence:
1. Press the [Open] button to open the Operator’s pad.

2. Touch the [Select program] tab.
3. Select one of the 20 crushing programs by pressing the arrow buttons at the
top-right of the Operator’s pad. Information about the selected program is
shown in the blue field. For an ”Auto-CSS” program, the CSS setpoint is
shown, whilst for a ”Multi-CSS” program both CSS setpoints are shown,
together with the time-share. In the case of an ”Auto Load” program, the
power and pressure setpoints are shown, together with the Min-CSS.
4. Select the crushing program you want to use by pressing the [Select] button.
The information displayed in the Operating mode selector will change to
reflect the newly selected program.
5. Close the Operator’s pad by pressing the [Close] button.
6. Start regulation by pressing the [Auto] button in the Normal picture.
2. 3.
1.1
4.
5.
For information about how to configure crushing programs, see Chapter 5.

ASRi manual S 223.468.00 en 8 (8)
4.3 Operating under manual control, MAN
If the crusher is under manual control, the drive motor’s power draw, the Hydroset
pressure, the CSS and the A-dimension can all be read off in the Normal picture. All alarms
and warning functions are operative. This means that warning lamps are lit (and, in some
cases, an alarm is also initiated) if a limit is exceeded but there is of course no automatic
regulation to counteract an overload.
To select manual control, press the [Man] button in the Operating mode selector.
Start manual
regulation
1.d7
Pump mainshaft
upwards
(i.e. decrease CSS)
Pump mainshaft
downwards
(i.e. increase CSS)
ASRi manual S 223.468.00 en 1 (7)
5. Configuring crushing programs 2004-06-16 5
5. Configuring crushing programs
5.1 General ........................................................................................................2
5.2 The configuration procedure.....................................................................3
5.3 An explanation of the Auto-CSS regulation mode...................................4
5.4 An explanation of the Multi-CSS regulation mode ..................................5
5.5 An explanation of the Auto-Load regulation mode .................................6
5.6 The Extended features ...............................................................................7
5.6.1 CSS-Start factor...............................................................................................7

ASRi manual S 223.468.00 en 2 (7)
5.1 General
If the crusher is to be operated with AUTO regulation, one or more crushing program(s)
must first be configured. 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 5.3

• Multi-CSS. See Section 5.4
• Auto-Load. See Section 5.5
Press the [Open] button to open the Operator’s pad. When the button has been pressed, the
text on it will change to [Close].
Open the
Operator’s pad
ASRi manual S 223.468.00 en 3 (7)
5.2 The configuration procedure
To configure a crushing program, follow this sequence:
1. On the Operator’s pad, select the [Edit program] tab.

2. Use the arrow buttons at the top-right to select the program to be configured.
3. Select the required regulation mode: Auto-CSS, Multi-CSS or Auto-Load. (Press a
second time to block the program so that it cannot be used.)
4. Enter the required values, as described in Sections 5.3, 5.4 and 5.5.
5. Press the [Save] button to save the changes made.
6. Select the next program to be configured, or press [Close] to finish the
configuration procedure.
3. 1. 2.
5.
1 1.2
6.
ASRi manual S 223.468.00 en 4 (7)
5.3 An explanation of the Auto-CSS regulation mode
With this type of regulation, the ASRi system strives 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 Hydroset pressure is excessive.
During the starting phase – before feeding to the crusher starts – the mainshaft will be
moved to a starting position. This starting CSS is normally calculated automatically by the
ASRi system.
When the feed to the crusher starts, automatic regulation commences as soon as the crusher
is loaded. The mainshaft will be moved towards the position which corresponds to the
desired CSS – the CSS setpoint. When the crusher is no longer loaded, the mainshaft will
be moved to the starting position again.
Configuration settings:
• Set the CSS setpoint at the desired CSS, i.e. a certain number of millimeters.
• The system checks that the CSS setpoint is not less than 2mm or larger than the
maximum CSS that the crusher can cope with. If the CSS setpoint you enter is too
small or too large, a red fault indication comes up.
1.2.1
ASRi manual S 223.468.00 en 5 (7)
5.4 An explanation of the Multi-CSS regulation mode
With 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
distribution between the two settings.
As an example, a smaller CSS can be selected as CSS Setpoint 1. The resulting crusher
product perhaps contains sufficient fine material, whilst there is a shortfall in coarser
material. Coarser material can be produced by entering a CSS Setpoint 2, which 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,
completely automatically. The result will be two different product curves which are
delivered one after the other on the crusher’s discharge conveyor. However, after a few
transition chutes the material which reaches the stockpile or storage bin will have a single
average grading and contain both the fines and the coarse material.
• CSS Setpoint 1: The first desired operating CSS.
• CSS Setpoint 2: The other desired operating CSS.
• Time-share (%): The operating time distribution between the two CSS Setpoints.
• The system checks that the CSS setpoint is not less than 2mm or larger than the
maximum CSS that the crusher can cope with. If the CSS setpoint you enter is too
small or too large, a red fault indication comes up.
ASRi manual S 223.468.00 en 6 (7)
5.5 An explanation of the Auto-Load regulation mode
With this type of regulation, the ASRi system regulates the setting so that the crusher
operates at a certain desired load level. The system continuously checks to see if it is the
power or the pressure which loads the crusher most. If the 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.
• Power setpoint: The highest drive motor power draw permitted for the crushing
program in question.
• Pressure setpoint: The highest Hydroset pressure permitted for the crushing
program in question.
• Min CSS: The smallest permitted setting.
The system checks that the Power setpoint does not exceed the maximum permitted
power, that the Pressure setpoint does not exceed the maximum permitted Hydroset
pressure and that the Min CSS is not less than 2mm nor larger than the crusher’s
maximum setting. If any of these values is outside the permitted limit, a red fault indication
comes up.
1.2.3
ASRi manual S 223.468.00 en 7 (7)
5.6 The Extended features

To be able to bring up the system’s more advanced features on the screen, press the
[Extended] button in the Display settings picture. See under the heading Display in Section
3.2.
5.6.1 CSS-Start factor

When the crusher’s crushing chamber empties and the ASRi system determines that the
crusher is no longer loaded, normal regulation ceases. The CSS is then changed to a
starting value, ready for the resumption of feeding. The starting setting is a factor times the
previous CSS. This factor can lie between 0.5 and 2.5. The CSS-Start factor can be
calculated automatically or can be set manually. See parameter No. 505 in Section 3.6.2.
To manually set a CSS-Start factor, the Extended information level must be selected. See
section 3.2.
Follow this procedure:
1. Press the [Open] button and select the [Edit program] tab.
2. Select the crushing program which is to be configured. Press the [Factor] button to
bring up the CSS-Start factor picture.
1.2.4e
3. Enter the desired CSS-Start factor with the help of the spin buttons, or by marking
the numerical field and using the keypad which appears.
4. Return to the selected crushing program with the altered value by pressing the [OK]
button. To return to the selected crushing program without changing the value,
press the [Cancel] button.
ASRi manual S 223.468.00 en 1 (4)
6. Calibration 2004-06-16 6
6. Calibration
6.1 Calibration – general .................................................................................2
6.2 Calibration – metal-to-metal ......................................................................3
6.3 Calibration – with lead ...............................................................................4

ASRi manual S 223.468.00 en 2 (4)
6.1 Calibration – general
”Calibration” is carried out when the CSS dimension of the crusher is to be checked. The
frequency with which the crusher is calibrated normally depends on the rate at which the
crushing liners wear. A more abrasive stone will require frequent calibration, whereas a
non-abrasive material will require only occasional calibrations. There are two ways of
carrying out a calibration – ”metal-to-metal” calibration or 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 Hydrocones.
We recommend regular inspection of the concave ring to make sure that it has not been
worn unevenly or has become oval. You should also look for any localized wear or other
damage in the crushing chamber. If the crushing liners are worn, the mantle (on the
mainshaft) cannot be raised so high that it comes into contact with the concave ring
without a risk of the mainshaft’s head nut contacting the underside of the crusher’s spider
hub. This occurs relatively early in the case of a coarse crusher which operates with a large
CSS. The ASRi system prevents further upward movement of the mainshaft if the
A-dimension is reduced to approx. 15mm. The system will then switch automatically to
”calibration with lead”.
In the case of an S-type Hydrocone, the design of the crushing chamber is such that it is
often impossible to reach a metal-to-metal position. With a small S-type Hydrocone it may
be possible, but the crusher will be subjected to a very high load. In the case of an S-type
Hydrocone, calibration should therefore always be carried out with lead.
1.3
The figure above shows the calibration tab in the operator’s pad in the Normal picture.
Select [M - M] or [Lead] to proceed with calibration.
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6.2 Calibration – metal-to-metal
With this calibration method the ASRi system raises the mainshaft as much as is possible
and then lowers the mainshaft a few millimeters. The crusher calibration procedure has
then been finished.
To carry out a metal-to-metal calibration, select the [Calibration] tab of the operator’s pad
and then press the [M - M] button. The calibration procedure starts automatically. You can
terminate the calibration procedure at any time by pressing the [Abort] button.
You will be guided automatically through the various stages of the calibration procedure:
1. Stop Feeder
If the crusher is under load, stop the feed to the crusher.
2. Start Crusher
The system proceeds to the next step 30 seconds after the motor has been started. If
the crusher is loaded again, the calibration procedure is automatically halted. This
is indicated by an error message: ”Crusher load too high, aborting”. Press the [OK]
button to abort the calibration procedure.
3. 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, a message comes up to indicate that the system
is switching to the ”with lead” calibration procedure. Accept this by pressing the
[OK] button, or terminate the calibration procedure by pressing the [Abort] button.
If the system indicates that the switch from ”metal-to-metal” to ”with lead” was
unsuccessful, the calibration procedure is terminated and the message ”Error,
aborting” comes up. Press the [OK] button to acknowledge.
4. Detecting metal-to-metal contact, pumping down

The ASRi system detects that the mainshaft cannot be raised further and pumps the
shaft down to the position corresponding to the starting setting for the selected
crushing program. If the pressure is too high, the calibration procedure is halted and
the message ”Pressure too high, aborting” comes up. Press the [OK] button to
acknowledge.
5. Crusher calibrated! Press Finished.

The crusher has now been calibrated. Press the [Finish] button to confirm that the
calibration procedure has been completed.
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6.3 Calibration – with lead
With this 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 a calibration with lead, select the [Calibration] tab of the operator’s pad and
then press the [Lead] button. The calibration procedure starts automatically. You can
terminate the calibration procedure at any time by pressing the [Abort] button.
You will be guided automatically through the various stages of the calibration procedure:
1. Stop Feeder
If the crusher is under load, stop the feed to the crusher.
2. Start Crusher
The system proceeds to the next step 30 seconds after the motor has been started. If
the crusher is loaded again, the calibration procedure is automatically halted. This
is indicated by an error message: ”Crusher load too high, aborting”. Press the [OK]
button to abort the calibration procedure.
3. Position the shaft and measure the CSS. Enter the value and press
[Continue].
Go out to the crusher and measure the CSS. To do this, use at least one lump of
lead, hanging in a steel wire, and lower it through the crushing chamber. If the CSS
is too large for the lead lump available, use some other suitable tool. Use a vernier
gauge to measure the thickness of the lead lump after it has passed through the
crushing chamber. The thickness corresponds to the CSS. Enter this value by using
the keypad that appears on the right.
Do not move the shaft until you have pressed the [Continue]
Note ! button.
4. Crusher calibrated! Press Finished.

The crusher has now been calibrated. Press the [Finish] button to confirm that the
calibration procedure has been completed.
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7. Operating data 2004-06-16 7
7. Operating data
7.1 Operating data – general ...........................................................................2
7.2 Power...........................................................................................................3
7.3 Pressure ......................................................................................................4
7.4 Position .......................................................................................................6
7.5 Temperature – Return oil ...........................................................................8
7.6 Combination ...............................................................................................9
7.7 Event list ...................................................................................................10
7.8 Reset..........................................................................................................11
ASRi manual S 223.468.00 en 2 (11)
7.1 Operating data – general
To make it possible for the operator to study in detail the various signals, values, events
and calculations, the ASRi system contains a feature which presents all of this information.
The calculations upon which the statistics and other values are based are carried out
continuously in the ASRi system’s CPU. The display of statistics and other information is
continuously up-dated on the screen. Whatever the operating mode, the operator can select
the display of operating data.
The information that is available is split into six different headings:
• Power – displays information on the power drawn by the crusher’s drive motor. See
Section 7.2.
• Pressure - displays information on the crusher’s Hydroset pressure. See Section 7.3.
• Position - displays information on the crusher’s CSS and A-dimension. See Section
7.4.
• Temperature - displays information on the temperature of the lubricating oil

returning to the crusher’s oil tank unit. See Section 7.5.
• Combination – a picture which displays the current measuring values and operating
times. See Section 7.6.
• Event list – a chronological list of the most important events. See Section 7.7.
In addition, there is another section which gives the operator the possibility of resetting
some of the statistical information calculated by the ASRi system. See Section 7.8.
ASRi manual S 223.468.00 en 3 (11)
7.2 Power
The Power picture displays more detailed information about the crusher’s power draw. To
bring up the picture, press the [Op. data] button at the bottom of the screen, and then the
[Power] button in the Operating data menu.
1.
2.
3.
3.1
1. The instantaneous and average power draws are displayed at the top of the picture,
both as numerical values and as an analog instrument.
2. In the middle part of the picture is an area where the two power draw values are
shown as trend curves. The curves move towards the left and show the latest 30
seconds.
3. At the bottom of the picture are two fields which present information on the
crusher’s power draw over the latest 30 minutes (on the left) and since the data
collection feature was reset (on the right). The information presented is based on
the “total operating time”, i.e. the time during which the crusher’s drive motor is
switched on.
Each column corresponds to 10 % of the permitted maximum input. The total

power range corresponds to 150 %, so there are 15 columns. An example: if the
permitted maximum input power is 200 kW, the first column corresponds to 0-20
kW. 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 power draw was
within the range represented by the respective column.
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7.3 Pressure
The Pressure picture displays more detailed information about the crusher’s Hydroset
pressure. To bring up the picture, press the [Op. data] button at the bottom of the screen,
and then the [Pressure] button in the Operating data menu.
1.
2.
3.
3.2
1. The instantaneous, peak average and average Hydroset pressure are displayed at the
top of the picture, both as numerical values and on an analog instrument.
2. In the middle part of the picture is an area where the three Hydroset pressure values
are shown as trend curves. The curves move towards the left and show the latest 30
seconds.
3. At the bottom of the picture are two fields which present information on the
crusher’s Hydroset pressure over the latest 30 minutes (on the left) and since the
data collection feature was reset (on the right). The information presented is based
on the “total operating time”, i.e. the time during which the crusher’s drive motor is
switched on.
Each column corresponds to 10 % of the permitted maximum Hydroset pressure.

The total pressure range corresponds to 150 %, so there are 15 columns. An
example: if the permitted maximum Hydroset pressure is 5 MPa, the first column
corresponds to 0-0.5 MPa. The total 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 red section at the top of each column represents an average
ASRi manual S 223.468.00 en 5 (11)
value of the size of the sector shown in the analog pressure display instrument in
the normal picture.
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7.4 Position
The Position picture displays more detailed information about the position of the crusher’s
mainshaft. To bring up the picture, press the [Op. data] button at the bottom of the screen,
and then the [Position] button in the Operating data menu.
1.
2.
3.
3.3
4.
5.
1. At the top-left of the picture there is information about how the crusher has been
calibrated. The displayed A-Cal values are:
• Final – The A-dimension corresponding to the mainshaft’s metal-to-metal
position with worn liners, when they were changed.
• Calculated - The A-dimension corresponding to the mainshaft’s metal-to-metal
position at the present moment, with calculated liner wear taken into
consideration.
• Latest - The A-dimension corresponding to the mainshaft’s metal-to-metal
position when the latest calibration was carried out.
• New liner - The A-dimension corresponding to the mainshaft’s metal-to-metal
position when the crusher was calibrated, with new liners fitted.
The A-dimension in the metal-to-metal position is the A-dimension at which the

liners come into contact with each other during a metal-to-metal calibration, or the
calculated A-dimension at which the liners would theoretically come into contact
with each other – if this were possible – during a calibration with lead.
ASRi manual S 223.468.00 en 7 (11)
2. At the top-right of the picture there is information about A-dimension values:

• Current – The A-dimension at that particular instant.
• A-start position, Load – an average value for the A-dimension at which the
crusher was most recently loaded.
Remaining mainshaft travel – the remaining amount of mainshaft travel, expressed

as a percentage of the total mainshaft travel when new liners were fitted. The
displayed value is calculated for the current CSS.
3. Between the values on the left and right there is a schematic figure which presents
the relative positions represented by the various values.
The figure also shows the minimum permitted A-dimension, A-Min, and the
maximum A-dimension, A-Bottom. A-Bottom is with the mainshaft 2 mm from the
absolute bottom position. This is to avoid the risk of running the Hydroset pump
dry.
4. In the central part of the picture is an area where information is given about the
CSS at which the crusher has operated during the latest 30 minutes and since the
feature was reset. The information displayed is based on data from time during
which the crusher has been loaded, i.e. while it is actually crushing.
5. At the bottom of the picture is a field where CSS values are displayed as curves.
The curves move towards the left and show the latest 30 seconds. The vertical scale
in the CSS display can be varied between 0-25mm, 0-50mm, 0-100mm and 0-
200mm with the help of the buttons on right of the presentation area.
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7.5 Temperature – Return oil
The Temperature Return oil picture displays more detailed information about the crusher’s
load. To bring up the picture, press the [Op. data] button at the bottom of the screen, and
then the [Temperature] button in the Operating data menu.
3.4
The temperature of the lubricating oil returning from the crusher to the tank is displayed in
the picture, both as a numerical value and as an instrument.
The picture also displays minimum, average and maximum temperature values from the
latest 30 minutes and since the system was reset. Equipment for measuring the lubricating
oil temperature is supplied as standard with the ASRi system. The information presented is
based on the “total operating time”, i.e. the time during which the crusher’s drive motor is
switched on.
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7.6 Combination
The Combination picture displays more detailed information about the crusher’s operating
times.To bring up the picture, press the [Op.data] button at the bottom of the screen, and
then the [Combination] button in the Operating data menu.
1.
2.
3.5
3.
1. At the top of the picture are five analog instruments, with a numerical presentation
field beneath each one. From the left, these instruments display power draw,
Hydroset pressure, return oil temperature, A-dimension and CSS.
2. In the middle of the picture, information is presented about the total operating time
– i.e. the time during which the crusher’s drive motor has been switched on – and
the time during which the crusher has been loaded. The times presented are, from
the top:
• Since the system was originally started up (can only be reset by Sandvik
personnel).
• Since the latest liner change (reset automatically when the first calibration is
carried out after new liners have been fitted).
• Since the latest calibration (reset automatically when a calibration is carried
out).
• Since resetting – can be reset in the Reset picture. See Section 7.8.
3. At the bottom of the picture is an area where information is presented about energy
consumption since the system was originally started up and since the system was
reset. The figures refer to power consumption during the time the crusher has been
loaded.
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7.7 Event list
The Event list picture displays information about changes which have occurred. The list is
presented in chronological order but can also be temporarily sorted in Group order or
Event text order by pressing the title bar at the top of the column in question. The Event
list can contain up to approximately 200 events depending on the type of event. When the
list is full, the oldest event is deleted to make room for the new one.
To bring up the Event list picture, press the [Op. data] button at the bottom of the screen,
and then the [Event list] button in the Operating data menu.
3.6
The following mode changes can be followed in the Event list:
• Activated stop mode – The system enters Stop mode.

• Activated manual mode – Manual regulation is activated.
• Crushing program X (Regulation mode Z) is activated.
• Activated calibration mode – A calibration procedure is initiated.
• A-range set-up activated – M-M.
• A-range set-up activated – Lead.
• New liners detected.
• Uncrushable object detected.
• System start.
• New crusher data loaded.
• Crushing program X saved.
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7.8 Reset
In the Reset picture it is possible to delete operating data based on the latest 30 minutes
and operating data that is collected during the period since the system was most recently
reset.
To bring up the picture, press the [Op. data] button at the bottom of the screen, and then the
[Reset] button in the Operating data menu.
3.7
Operating data can be deleted by pressing the [Reset] button. To prevent accidental
deletion, a question comes up to check that you really do want to delete all operating data.
Press [OK] to confirm or press [Cancel] to exit without deleting data.
ASRi manual S 223.468.00 en 1 (14)
8. Alarms 2004-06-16 8
8. Alarms
8.1 Alarms – general ........................................................................................2
8.2 Alarm status................................................................................................4
8.3 The Alarm list..............................................................................................5
8.4 The Alarm log .............................................................................................6
8.5 Explanations of alarms ..............................................................................7
8.5.1 A-alarms .......................................................................................................8
8.5.2 B-alarms......................................................................................................10
8.5.3 C-alarms .....................................................................................................13

ASRi manual S 223.468.00 en 2 (14)
8. Alarms 2004-06-16 8
8.1 Alarms – general
The ASRi system incorporates a general alarm system which monitors a number of analog
and digital signals. The system monitors signals from transducers and values which 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.
To bring up the Alarm page, press the [Alarm] button at the bottom of the screen.
1. 2. 3. 4.
Alarm list
Alarm log
4.1
The Alarm list and the Alarm log have the same appearance:
1. At the far left of the display frame is a column in which is shown a symbol that
indicates the current status of the alarm. See Section 8.2.
2. To the right of the alarm status column is the Severity column, in which a figure is
displayed. The lower the figure, the more important is the alarm.
3. The next column to the right, Time, shows the time at which the alarm was initiated
(after any applicable delay).
4. At the far right is the Alarm text column, in which a short description of the alarm
is displayed.
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8. Alarms 2004-06-16 8
Alarm list
The Alarm list shows all alarms which have any status other than ”inactive”. The Alarm
list is arranged in chronological order.
The order in which the alarms are displayed can be changed manually by touching the title
bar of the column which is to determine the order of display. The displayed list can be
switched between descending or ascending order by touching the title bar.
Alarm log
The Alarm log shows all status changes for all alarms. Each line in the display symbolizes
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 the new one.
The Alarm log displays the status changes in descending order of time, i.e. with the latest
status change at the top. This can be changed manually in the same manner as the Alarm
list display, as explained above.
ASRi manual S 223.468.00 en 4 (14)
8. Alarms 2004-06-16 8
8.2 Alarm status
Each alarm exists in one of the following statuses:
Inactive: This is the normal condition, i.e. there is no fault.
Active and unacknowledged: The signal in question has assumed an abnormal value.
The operator has not yet noticed the fault, which is indicated in the Alarm list and the
Alarm log by an icon which shows a yellow triangle with a red border and a black
exclamation mark.
Active and acknowledged: The fault condition persists but the operator has
acknowledged the alarm. The icon 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 somewhat
smaller green triangle with a red border and a black exclamation mark.
Blocked.
This icon is used only in the Alarm log and indicates that an alarm has returned to the
”Inactive” status. It consists of a white triangle with a green border and the text ”OK”.
ASRi manual S 223.468.00 en 5 (14)
8. Alarms 2004-06-16 8
8.3 The Alarm list
4.1
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.
To acknowledge an alarm, mark the line that displays information about the alarm. When
the line has been marked, a dialog box comes up. Press the [Ack.] button to confirm that
you want to acknowledge the alarm. If it is possible to block the alarm, this can be done by
pressing the [Block] button instead.
4.1.1
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8. Alarms 2004-06-16 8
8.4 The Alarm log
4.2
If you mark a line in the Alarm log, a dialog box comes up with a description of the status
change in question. In this box you can determine the time period for which the Alarm log
is to display status changes. This setting does not affect the number of items saved in the
log – only the number that are displayed.
4.2.1
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8. Alarms 2004-06-16 8
8.5 Explanations of alarms
There are three degrees of severity for alarms – A-, B- and C-alarms.
• An A-alarm is the most serious. 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 should be stopped in
some other way. Regulation cannot be restarted until the fault has been corrected.
An active A-alarm is indicated by red in the “traffic light” in the Operating mode
field in the normal picture.
• A B-alarm results in a feed shut-down, if the feed interlock output from the ASRi
system is used, but regulation continues whilst the fault persists. When the fault has
been corrected, the feed is restarted and regulation continues as before. An active
B-alarm is indicated by red/yellow in the “traffic light” in the Operating mode field
in the normal picture.
• A C-alarm is more a type of warning than an alarm. Regulation and feeding

continue as before. An active C-alarm is indicated by red/yellow in the “traffic
light” in the Operating mode field in the normal picture.
Alarms which are no longer active but which have not been acknowledged are indicted by
yellow in the “traffic light” in the Operating mode field in the Normal picture.
ASRi manual S 223.468.00 en 8 (14)
8. Alarms 2004-06-16 8
8.5.1 A-alarms
Alarm A01: No pressure signal!

If this fault persists, the alarm indicates a sustained loss of signal in the pressure
measurement system. The fault can be due to a break in the communication cable (K5), a
break in the signal cable from the pressure transducer (K2) or a faulty pressure transducer
B2N.
If the fault is only temporary, the alarm indicates that the pressure measurement system has
suffered a loss of signal, but the signal has reappeared. If this is the case, acknowledge the
alarm. If the alarm comes up frequently, check the cable connections since it is likely that
they are loose. Check also that the average pressure displayed in the [Op. data/Pressure]
picture corresponds to the reading on the Hydroset pressure gauge on the oil tank unit.
If the fault persists:

1. Check that the communication cable (K5) is not damaged.
2. Check that the pressure signal cable (K2) is not damaged.
3. If both cables are undamaged, replace the pressure transducer (B2N).
4. Check that the I/O unit functions correctly.
5. Press [Alarm] to bring up the Alarm list on the screen. Check that the alarm is
inactive and acknowledge it.
All automatic regulation is blocked as long as the fault persists.
Alarm A02: No A-dimension signal!

If this fault persists, the alarm indicates one of the following faults in the shaft position
sensing system:
• A break in the communication cable (K5).
• A short-circuit between the negative and signal conductors in the sensor cable (K1).
• A break in the position sensor cable (K1).
• A faulty position sensor (B1N).
• A fault in the I/O unit.
If the fault is only temporary, the alarm indicates that the mainshaft position sensing
system has suffered a loss of signal, but the signal has reappeared. If this is the case,
acknowledge the alarm. If the alarm comes up frequently, check the cable connections
since it is likely that they are loose.

1. Check that the communication cable (K5) is not damaged.
2. Check the position sensor cable (K1) for the faults described above as B and C and
correct any fault.
3. If both cables are undamaged, replace the position sensor (B1N).

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8. Alarms 2004-06-16 8
Alarm A03: High power signal!

An abnormally high value is shown in the display instrument. This indicates that the power
measurement converter (U1N) is faulty and sends far too high a signal to the ASRi system.
Follow this sequence:
1. Change the power measurement converter (UlN).
Alarm A04: High pressure signal!

This alarm indicates that the pressure transducer (B2N) is faulty.
1. Change the pressure transducer (B2N) .
Alarm A05: High A-dimension signal!

This alarm indicates that the shaft position sensor (B1N) is faulty.
1. Change the shaft position sensor (B1N) .

ASRi manual S 223.468.00 en 10 (14)
8. Alarms 2004-06-16 8
8.5.2 B-alarms
Alarm B10: High oil temp. signal!

This alarm indicates that the temperature transducer (B3N) is faulty.
1. Change the temperature transducer (B3N).
Alarm B11: No power signal!

If this fault persists, the alarm indicates a sustained loss of signal in the power
measurement system, or a short-circuit. The fault can be due to:
• A break in the communication cable (K5).
• A faulty power measurement converter (U1N).
• A blown fuse (F11). This fuse protects the inputs to U1N from the crusher drive
motor’s supply voltage (terminals 5, 6 and 7).
• A faulty current transformer (T11).
• A faulty I/O unit.
The feed to the crusher is stopped (if the feeding system is connected to the ASRi system)
but is automatically restarted when the power signal is restored. If the fault has
disappeared, the alarm indicates that the power measurement system has suffered a loss of
signal, but the signal has been restored. If this is the case, acknowledge the alarm. If the
alarm comes up frequently, check the cable connections since it is likely that they are
loose.
If the fault persists, follow this sequence:
These actions must only be made by a qualified electrician. The

Warning ! crusher’s drive motor must be stopped.
1. Check with a voltmeter that the control voltage (110 or 230 V) is present between
terminals 9 and 12 on the power measurement converter (U1N).
2. Check that there is no break or short-circuit in the communication cable (K5).
3. Check that the current transformer (T11) is not faulty by first disconnecting the
cables from terminals S1 and S2 and then measuring the resistance between S1 and
S2 with an ohmmeter. The meter should indicate almost zero ohms.
4. If no fault is found, change the power measurement converter (U1N).
Check that the fault has disappeared and acknowledge the alarm.
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8. Alarms 2004-06-16 8
Alarm B12: Shaft at bottom – overload!

The mainshaft is in its bottom position and the power draw and/or the Hydroset pressure
are above the limits for maximum permitted power draw and Hydroset pressure
respectively. The feed to the crusher is stopped (if the feeding system is connected to the
ASRi system) but is automatically restarted when the load has dropped back below the
permitted limits, even if the mainshaft is still in its bottom position.
Alarm B14: Pump motor tripped!

This alarm indicates that the Hydroset pump motor’s overload protector (in the L3
component box) has tripped out. The feed to the crusher is stopped (if the feeding system is
connected to the ASRi system) but is automatically restarted when the motor protector is
reset.
1. Reset the motor protector by pressing the reset button on the thermal overload relay
in the L3 component box.
2. Check in the Alarm list that the alarm is inactive and then acknowledge the alarm.
If the fault reoccurs when the Hydroset pump motor is started, the reason may be that the
thermal overload relay is incorrectly set or that the Hydroset pump motor (M6) is
overloaded or damaged.
Alarm B15: Lub. oil too hot!

This alarm indicates that the lubrication oil returning to the tank is hotter than the
permitted level. The feed to the crusher is stopped (if the feeding system is connected to
the ASRi system) but is automatically restarted when the return oil temperature has
dropped back below the permitted level.
1. Consult the crusher’s maintenance instruction manual for information about
possible causes and remedies.
2. Check in the Alarm list that the alarm is inactive and then acknowledge the alarm.
Alarm B16: L1 pumped up too long

The feedback signal from the contactor which pumps the mainshaft up has been active too
long. The feed to the crusher is stopped (if the feeding system is connected to the ASRi
system) but is automatically restarted when the contactor feedback signal disappears.
1. Check the Hydroset system.
2. Check that the 1/0 module in the L3 cabinet functions correctly.
Alarm B17: L1 pumped down too long

The feedback signal from the contactor which pumps the mainshaft down has been active
for too long. The feed to the crusher is stopped (if the feeding system is connected to the
ASRi system) but is automatically restarted when the contactor feedback signal disappears.
ASRi manual S 223.468.00 en 12 (14)
8. Alarms 2004-06-16 8

Alarm B18: ASRi pumped up too long

The ASRi computer has been trying to pump up the mainshaft for too long a time. The feed
to the crusher is stopped (if the feeding system is connected to the ASRi system) but is
automatically restarted when the contactor feedback signal disappears.
Alarm B19: ASRi pumped down too long

The ASRi computer has been trying to pump down the mainshaft for too long a time. The
feed to the crusher is stopped (if the feeding system is connected to the ASRi system) but
is automatically restarted when the contactor feedback signal disappears.
Alarm B20: No communication with I/O module CB-U!

This alarm indicates a constant loss of communication with the I/O module in the power
measurement system (ASRi-CB-U1N).
Alarm B21: No communication with I/O module CB-T!

This alarm indicates a constant loss of communication with the I/O module in the
connection box on the oil tank unit (ASRi-CB-T).
Alarm B22: No communication with I/O module L3!

This alarm indicates a constant loss of communication with the I/O module in the L3
component cabinet.
Alarm B23: Power too low compared to pressure

This alarm indicates a possible fault in the power measurement system or in the pressure
measurement system. The fault results in the indicated power being unreasonably low in
comparison with the pressure.
Alarm B24: Pressure too low compared to power

This alarm indicates a possible fault in the power measurement system or in the pressure
measurement system. The fault results in the indicated pressure being unreasonably low in
comparison with the power.
ASRi manual S 223.468.00 en 13 (14)
8. Alarms 2004-06-16 8
8.5.3 C-alarms
Alarm C21: No oil temp. signal!

If this fault persists, the alarm indicates a constant loss of signal in the temperature
measuring system.
The fault can be due to:
• A break in the temperature signal cable (K3).
• A faulty temperature transducer (B3N).
• A faulty I/O unit.
Crushing can continue. The fault does not affect automatic regulation. It is only the
automatic feed shut-down feature (due to an excessive return oil temperature) that does not
function.
If the fault is only temporary, the alarm indicates that the temperature measuring system
has suffered a loss of signal, but the signal has reappeared. If this is the case, acknowledge
the alarm. If the alarm comes up frequently, check the cable connections since it is likely
that they are loose.
1. Check that the temperature transducer cable (K3) is not damaged.
2. If the cable is not damaged, change the temperature transducer (B3N).
Alarm C23: Shaft at bottom!

This alarm indicates that the mainshaft is in its bottom position. Crushing can continue, but
it is not possible to lower the shaft further.
Alarm C24: Shaft at top!

To ensure that the headnut does not come too close to the spider hub and thus cause
damage, the ASRi system does not permit the mainshaft to rise higher than a position
where a certain minimum A-dimension remains. This distance is approx. 15 mm for most
H-type and S-type Hydrocones, and approx. 25 mm for H8800 crushers. The distance is
only approximate because the headnut does not end up in exactly the same place on the
mainshaft after each liner change. In addition, the mainshaft will gradually drop slightly
over a long period because of wear in the crusher’s step bearing assembly.
The liners can of course be worn out long before the A-dimension has decreased so much
that this alarm is activated. Crushing can continue, but it is not possible to raise the shaft
further.
ASRi manual S 223.468.00 en 14 (14)
8. Alarms 2004-06-16 8
Alarm C27: New liners needed!

This alarm indicates that the mainshaft has risen above the position where the A-dimension
is less than the value you have entered as the limit where a warning is to be given that the
liners are worn and need changing.
For more information on this alarm limit, see Section 3.6.2, parameter 503.
ASRi manual S 223.468.00 en 1 (7)
9. Historical data 2004-06-17 9
9. Historical data
9.1 Historical data – general ............................................................................2
9.2 The historical data picture.........................................................................3
9.3 The historical data menu ...........................................................................5

ASRi manual S 223.468.00 en 2 (7)
9.1 Historical data – general
The ASRi system continuously monitors the various signals and values. These are logged
in historical data log files. The values and signals which are logged are:
• Instantaneous power draw, average power draw and max. permitted power
• Instantaneous pressure, average pressure, average peak pressure and max. permitted
pressure
• Current CSS and CSS-setpoint
• Current A-dimension, A-dimension for the ”metal-to-metal” position with new
liners, A-dimension for the ”metal-to-metal” position during the latest calibration
and the calculated A-dimension for the current ”metal-to-metal” position.
• The return oil temperature
• Digital status signals for feeding ON/OFF and mainshaft pumping UP/DOWN.
To view historical data, press the [History] button at the bottom of the screen.
Curve presentation
Historical
data menu
Legend for
analog and
digital
signals
On the left of the picture is the historical data menu which gives access to six different sets
of historical data curves, etc.
ASRi manual S 223.468.00 en 3 (7)
9.2 The historical data picture
The historical data picture is built up in the following way:
1. 2. 3.
4.
5.
6.
10.
7.
8.
9.
1. At the top of the curve presentation frame are four buttons for the selection of the
resolution of the displayed curves. A higher resolution means a shorter signal
storage time. The four buttons give the following choices:
• The [12 seconds] button stores information for approx. 1 hour and displays
information covering 12 seconds (power and pressure) or 1 minute (other
signals). The button changes automatically to a [1 minute] button if the CSS,
Temperature, Position or Combination picture is to be displayed.
• The [10 minutes] button stores information for approx. 24 hours and
displays information covering 10 minutes.
• The [1 hour] button stores information for approx. 1 week and displays
information covering 1 hour.
• The [12 hours] button stores information for approx. 4 weeks and displays
information covering 12 hours.
The information 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.
ASRi manual S 223.468.00 en 4 (7)
2. The upper frame is the curve presentation area where the analog curves are
displayed. Each curve has its own vertical scale (y-axis), at the left or the right of
the presentation area.
3. At the top of the presentation frame is a ”handle” with a cursor which stretches
down over all of the curves. The cursor can be moved left and right by ”grabbing”
the handle and moving it sideways to indicate the value(s) of the variable(s) at any
particular time. This time is indicated in the cursor’s ”handle”.
4. When CSS curves are presented (See next Section), the vertical scale can be set on
the right of the curve presentation area. The scales available are 0-25mm, 0-50mm,
0-100mm and 0-200mm.
5. To the right of the time scale there is a button with which the right-hand end of the
time scale can be set to ”now”.
6. To the right of the time scale there is also a button which is used to scroll forwards
in time. Each time the button is pressed, the time scale is moved ”one page”
forwards.
7. Beneath the analog curves in the presentation frame is the horizontal time scale (the
x-axis) which is common for all of the curves displayed. For space reasons, the
markings on the time scale show only hours, minutes and seconds. The exact time
can be read off in the cursor’s ”handle”.
8. Beneath the time scale is an area where the digital signals are displayed.
9. At the bottom of the picture is the legend frame where names and values of all of
the curves can be found. The colors of the various curves are shown and the values
at the intersection with the cursor are also displayed.
10. To the left of the time scale there is a button which is used to scroll backwards in
time. Each time the button is pressed, the time scale is moved ”one page”
backwards.
Above each value scale (y-axis) for the analog curves there is an identification designation
(A1, A2, A3 and A4). A corresponding identification designation (D1, D2 and D3) is
displayed to the left of each digital signal. These designations are also given in the legend
frame at the bottom of the picture.
ASRi manual S 223.468.00 en 5 (7)
9.3 The historical data menu
In the historical data menu you can select the curve(s) to be displayed. The choices are
described individually below:
1.
2.
3.
4.
5. 5.1
6.
1. Power
Analog signals
Average
power - setpoint: 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 lowest.
Average power: The average value of the power draw signal.
Power: The instantaneous value of the power draw signal. This is only
displayed if [12 seconds] resolution has been selected.
Digital signals
Pump up: Indicates that the mainshaft is being pumped upwards.
Pump down: Indicates that the mainshaft is being pumped downwards.
Feed: Indicates that the ASRi system permits feeding to the crusher.
ASRi manual S 223.468.00 en 6 (7)
2. Pressure
Analog signals
Average peak
pressure - setpoint: The maximum permitted pressure for the crusher 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
cases it is the same as the maximum permitted pressure for the
crusher.
Average pressure: The average value of the pressure signal.
Average peak pressure: The calculated average value of the peaks in the pressure signal.
Pressure: The instantaneous value of the pressure signal. This is only
displayed if [12 seconds] resolution has been selected.
Digital signals
3. CSS
Analog signals
CSS: The gap between the crusher’s mantle and concave ring on the
closed side.
Latest CSS-setpoint: 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.
Digital signals
ASRi manual S 223.468.00 en 7 (7)
4. Temperature
Analog signals
Temperature: The temperature of the lubrication oil returning to the tank.
Digital signals
No digital signals are displayed.
5. Position
Analog signals
Shaft position: The A-dimension for the current position of the mainshaft.
A-Cal-Calculated: The calculated A-dimension for the current ”metal-to-metal”
position.
A-Cal-New liners: The A-dimension corresponding to the actual or calculated
”metal-to-metal” position with new liners.
A at latest calibration: The A-dimension corresponding to the latest calibrated or
calculated ”metal-to-metal” position.
Digital signals
6. Combination
Analog signals
CSS: The gap between the mantle and the concave ring on the closed
side.
Average power: The average value of the power draw signal.
Average peak pressure: The calculated average value of the peaks in the pressure signal.
Digital signals
ASRi manual S 223.468.00 en 1 (15)
10. POT – the Product Optimization Tool 2004-06-17 10
10. POT – the Product Optimization

Tool
10.1 POT – the Product Optimization Tool – general ......................................2
10.1.1 Configuring Material Assumption Forms (Conf. MAF)..............................4
10.1.2 Material Assumption Forms (MAF) ..............................................................7
10.2 The Fraction Distribution Diagram (FDD)...............................................10
10.2.1 Configuration of Fraction Distribution Diagram .......................................12
10.3 Product Curve Diagram (PCD) ................................................................13
10.3.1 Entering product limit curves.......................................................................15

ASRi manual S 223.468.00 en 2 (15)
10.1 POT – the Product Optimization Tool – general
The Product Optimization Tool (POT) helps you, the user, to decide at which CSS the
crusher should operate in order to provide the maximum quantity of the product you want,
whilst the quantity of unwanted material is as small as possible.
The POT is based on the collection of information about your crushing plant and the input
of this information to the ASRi system. The system needs information about the particle
size distribution of the product, the output in t/h and the product quality when the crusher
is run at various different CSS values. The more information that you put into the system,
the better the results of the calculations.
The POT consists in principle of three components:

• The Material Assumption Form (MAF)
• The Fraction Distribution Diagram (FDD)
• The Product Curve Diagram (FCD)
Each of these components also has an associated configuration procedure:

• Configuration of MAF
• Configuration of FDD
• Input of Product Limit Curves
ASRi manual S 223.468.00 en 3 (15)
To gain access to the POT-feature, the [Extended] button must be selected in the Display
settings picture. See under the heading Display in Section 3.2. To be able to make changes,
you must log in to the Configuration level. See Section 1.6.
Press the [Set-up] button at the bottom of the screen and then the [POT] button to bring up
the Product Optimization Tool picture.
2.6e
Press the [Conf. MAF] button to configure the MAF or the [MAF] button to edit various
MAF functions.
ASRi manual S 223.468.00 en 4 (15)
10.1.1 Configuring Material Assumption Forms (Conf. MAF)
Before the POT can be used, the MAF must be configured to suit your crushing plant. In
this configuration you define the aperture sizes you use in your laboratory test sieves and
which product fractions are used in product quality determination. Make sure that you
include all of the aperture sizes and fractions that are used in connection with the products
from the crusher – not just the ones that happen to be used in the first laboratory test report
you enter. If sieve aperture sizes or fractions must be altered later, all previously entered
information will be lost.
Configuration is carried out in three steps.
Step 1:
• As soon as you start the configuration procedure, a warning text comes up.
(Warning! If you change the MAF configuration and press OK, all Material
Assumption Forms that you have previously saved will be erased!).
• To continue, press [Next]. If you want to exit from the configuration procedure,
press [Abort].
2.6.1e
ASRi manual S 223.468.00 en 5 (15)
Step 2:
• In step 2, you define the sieve aperture sizes which are used in your laboratory test
reports. Touch the desired field to bring up a keypad on the screen. Use this keypad
to enter the sieve aperture sizes. These aperture sizes need not be given in any
special order since they will automatically be sorted in descending order when the
configuration is saved. Fields that are not needed can be left blank.
• If you want to exit from the configuration procedure, press the [Abort] button. No
changes will be saved.
• Press [Next] to proceed to the next step. Changes are saved first after step 3.
2.6.1.1e
ASRi manual S 223.468.00 en 6 (15)
Step 3:
• The last step is to define the fractions for which product quality data is to be given.
These are given as intervals between two different sieve aperture sizes. The sieve
aperture sizes do not need to be exactly the same as the ones entered in the previous
step, but the smaller one must be entered in the “From” column and the larger one
in the “To” column. When the configuration is saved, the fractions will
automatically be sorted in descending order.
• Press the [Previous] button to go back to Step 2 if you want to make changes in the
sieve aperture table.
• Press the [Abort] button to exit from the configuration procedure. No changes will
be saved.
• Press [OK] to complete the configuration.
All previously entered information concerning the POT function

Note ! will be erased.
2.6.1.1.1e
ASRi manual S 223.468.00 en 7 (15)
10.1.2 Material Assumption Forms (MAF)
When the Material Assumption Form (MAF) has been configured, laboratory test results
can be entered. The system can store 20 different MAFs. Each MAF can contain data from
between two and five test reports from different crusher settings. The screen analysis for
each test can contain “percentage passing” figures for up to 16 different sieve aperture
sizes and up to 5 different product quality fractions can be included.
2.6.2e
The table in the MAF consists of the following:
• At the top, the CSS at which the crusher was operating when the sample was taken.
• In the second line is the flow rate – i.e. the crusher’s capacity when the sample was
taken. The flow rate can be given in any desired units, but must be the same for
each column in the table.
• Beneath the flow rate is an area where product quality data is entered for the
fractions in the table. The product quality data can also be given in whatever units
you desire, but again, the units used must be the same in all of the columns in the
table.
ASRi manual S 223.468.00 en 8 (15)
• The bottom part of the table is where you enter the “percentage passing” value for
each sieve aperture size. The percentage passing value at any sieve aperture size
must be smaller than (or the same as) the percentage which passes through the next
larger aperture. An empty field indicates that the percentage passing through that
sieve aperture is the same as the percentage which passes through the next larger
sieve aperture.
If a MAF is to be used, it must contain data for at least two different crusher settings. The
maximum number of settings for which data can be entered on a single MAF is five.
There are a number of functions available for editing the MAF:
2.
1.
5.
2 6 2e 6.
3.
4.
7.
1. Select the MAF to be edited by using the spin buttons at the top right of the picture.
There are 20 different MAFs.
2. Enter the value by touching the field and then using the numerical keypad which
comes up on the right of the picture.
3. To add more columns for additional CSS values, press [Add CSS]. An empty
column appears to the right of the existing columns. The CSS values do not need to
be given in order as they are sorted in ascending order when the data is saved.
ASRi manual S 223.468.00 en 9 (15)
4. If you want to delete a column, mark a field in the column in question and then
press [Delete CSS].
5. The table can be restored to the previously saved version by pressing [Restore].
6. All data can be deleted from the table by pressing [Clear all].
7. Save the alterations you have made by pressing the [Save] button.
When you press the [Save] button, you save all of the changes
Note ! that you have made in all MAFs – not just in the MAF which
happens to be displayed.
If the program discovers a logic error in a MAF, or if important information is

missing, an error message comes up above the [Save] button and the MAF which
contains the error is displayed. If there are other errors, only the first to be
discovered is displayed.
ASRi manual S 223.468.00 en 10 (15)
10.2 The Fraction Distribution Diagram (FDD)
The Fraction distribution diagram gives you the opportunity to use the information you
have stored in a Material Assumption Form to select the optimum CSS value(s) for the
duty in question. When you change the CSS in a Fraction Distribution Diagram, you can
study the effects of changing the CSS setpoint(s) and – with Multi-CSS – also the time-
share value.
The bar chart presents the expected total product distribution, based on the data in the
Material Assumption Form you have selected. The MAF provides product size distribution
curves, product quality figures and crusher throughputs at different CSS values. In the
FDD – if you have selected a crushing program with Auto-CSS regulation - you select the
CSS setpoint. The FDD presents the expected product distribution in the form of a bar
chart. Another bar chart presents the expected product quality in each fraction.
If you have selected a crushing program with Multi-CSS regulation, you select the two
CSS setpoints and the time-share value. Again, two bar charts are displayed, presenting the
expected product distribution and product quality.
To open the FDD function, follow this sequence:
1. Press the [Open] button and select the [Edit program] tab.
2. Select the crushing program which is to be configured or studied, then press the
[FDD] button to open the FDD picture. This feature is only available in crushing
programs based on Auto-CSS or Multi-CSS regulation.
FDD-
button
1.2.2e
ASRi manual S 223.468.00 en 11 (15)
The FDD picture contains two diagrams:
The diagram on the left displays the product distribution between different fractions with
the selected CSS value(s) and – in the case of a crushing program which uses Multi-CSS
regulation – also the selected time-share value, with the feed material and CSS values
which were used when the tests on which the selected MAF is based were made.
In the same way, the diagram on the right displays the product quality figures for the
different fractions. Settings and time-share values are the same as the ones used to edit
normal crushing programs.
1.
Fraction Product
distribution quality
data
1.2.1.1e
3.
2.
4.
To use the FDD, follow this sequence:
1. Select the MAF which is to be used for the study. Use the spin buttons at the top
left of the picture.
2. Press the [Conf. FDD] button to select the fraction limits which are to be presented
in the two diagrams. See Section 10.2.1.
3. Change the CSS Setpoint value(s) and/or the time-share value to find the optimum
set-up. See Sections 5.3 and 5.4.
4. Return to the selected crushing program with the new value(s) by pressing the [OK]
button. To return to the selected crushing program without changing the value(s),
ASRi manual S 223.468.00 en 12 (15)
10.2.1 Configuration of Fraction Distribution Diagram
The size fraction limits and the fractions for quality data can be configured in the picture
shown below. Open the Configuration of Fraction Distribution Diagram picture by pressing
the [Conf.FDD] button in the Fraction Distribution Diagram picture.
2. 4.
1.2.1.1.1e
1.
3.
5.
The Fraction Distribution Diagram can be modified in the following way:
1. Beneath the left-hand diagram field there are a number of fields, corresponding to
test sieve aperture sizes. Decide which fraction limits are to apply for each of the
fractions to be shown by marking fields. In the example shown, the first fraction
stretches from the first marked field (0.0) to the second (2.0). This bar thus
describes the amount of 0-2mm material which will be produced when the crusher
is run under the selected conditions.
2. See the picture above for an example of a typical Fraction Distribution Diagram.
3. Select or deselect the fields under the right-hand diagram to display or delete the
product quality bars.
4. See the picture above for an example of a typical Product Quality Diagram.
5. Save the changes you have made and return to the Fraction Distribution Diagram
picture by pressing the [OK] button. You can ignore the changes and return to the
Fraction Distribution Diagram picture by pressing the [Cancel] button.
ASRi manual S 223.468.00 en 13 (15)
10.3 Product Curve Diagram (PCD)
The Product Curve Diagram gives you the opportunity to use the information you have
stored in a Material Assumption Form to select the optimum CSS value(s) for the duty in
question. When you change the CSS in a Product Curve Diagram, you can study the effects
of changing the CSS setpoint(s) and – with Multi-CSS - also the time-share value.
To open the Product Curve Diagram picture, press the [PCD] button in the Operator’s Pad in
the Normal picture. This feature is only available in crushing programs based on Auto-CSS
or Multi-CSS regulation.
The Product Curve Diagram shows a theoretical size distribution curve for the selected
picture, based on the data in the Material Assumption Form you have selected. The MAF
provides product size distribution curves and crusher throughputs at different CSS values.
In the PCD – if you have selected a crushing program with Auto-CSS regulation - you
select the CSS setpoint. The PCD presents the expected product size distribution in the
form of a curve. The PCD also displays a pair of limit curves – max. and min. limits –
which can be used as a guide when you make adjustments.
If you have selected a crushing program with Multi-CSS regulation, you select the two
CSS setpoints and the time-share value.
ASRi manual S 223.468.00 en 14 (15)
1. 2.
Product
size
distribution 1.2.1.2e
curve
4.
3.
To use the PCD, follow this sequence:
1. Select the MAF which is to be used for the study. Use the spin buttons at the top-
left of the picture.
2. Select the product limit curves with the spin buttons at the top-right of the picture.
The limit curves can be edited by pressing the [Input] button.
3. Change the CSS Setpoint value(s) and/or the time-share value to find the optimum
set-up. See Sections 5.3 and 5.4.
4. Return to the selected crushing program with the new value(s) by pressing the [OK]
button. To return to the selected crushing program without changing the value(s),
ASRi manual S 223.468.00 en 15 (15)
10.3.1 Entering product limit curves
The limit curves can be edited in the Input of Product Limit Curves picture. To open this
picture, press the [Input] button in the Product Curve Diagram picture.
1.
2.
1.2.1.2.1e
3.
4.
The limit curves can be edited in the following way:
1. Select which Product Limit Pair is to be displayed with the help of the spin buttons
at the top-left of the picture. Up to ten Limit Curve Pairs can be stored.
2. Fill in the left-hand column with suitable test sieve aperture sizes. Fields can be left
empty. There is no in-built check on the plausibility of the values entered.
3. The diagram at the bottom-left of the picture shows the limit curves in question.
4. Save all of the changes you have made in all of the Product Limit Pairs and return
to the Product Curve Diagram picture by pressing the [OK] button. You can cancel
all of the changes you have made in all of the Product Limit Pairs and return to the
Product Curve Diagram picture by pressing the [Cancel] button.
ASRi manual S 223.468.00 en 1 (4)
11. The service picture and Power 2004-06-17 11

measurement
11. The service picture and Power

measurement
11.1 The service picture .................................................................................2
11.2 Power measurement...............................................................................4

ASRi manual S 223.468.00 en 2 (4)

measurement
11.1 The service picture
The Service picture displays information that can make it easier to trace faults in the
system. To bring up the Service picture, press the [Service] button in the Advanced
picture.
Under the heading “Analog signals”, the current measured values for the analog signals
are displayed in three different ways. First in the appropriate measuring unit, then as a
number between 0 and 32 767 and finally in mA.
Beneath the analog signals are displayed also the CSS, the current calculated wear rate in
mm/kWh, the current shaft movement speed and a value that describes the size of the
sector in the Hydroset pressure display. The calculated wear rate is displayed irrespective
of whether or not wear compensation has been selected. The shaft movement speed is
presented as a positive value if the mainshaft is moving upwards and a negative value if it
is moving downwards.
Under the heading “Digital signals” there are two figures that correspond to the LEDs on
the 1/0 modules in the L3 cabinet. On the left are the digital inputs and on the right the
outputs. When an output should be activated and when an input is activated, this is shown
by a green field. It is also possible to manually pump the mainshaft up or down by pressing
the [Pump up] or [Pump down] buttons.
ASRi manual S 223.468.00 en 3 (4)

measurement
At the bottom of the picture there is information about communication with the three 1/0
modules. An active alarm is displayed for the appropriate module by a red field in the
“Current status” column. On the right is a counter for each module. This displays the
total number of communication faults for the module in question since the system was put
into operation or since the operator reset the counters to zero by pressing the [Reset]
button on the right.
ASRi manual S 223.468.00 en 4 (4)

measurement
11.2 Power measurement
The power measurement components supplied with the ASRi system must be installed in
the correct way. See Section 2.3.
Three components are used to measure the input power to the motor. The instruments that
display power on the ASRi-OP control cabinet’s screen – both analog and digital – display
the measured input power to the motor. Similarly, the curves presented in Op. data and
History pictures also display the measured power.
When the system is commissioned, the motor’s maximum output power must be entered –
see Section 3.62. Enter the rated output power, as given on the motor’s identification plate.
See drawing 194.0408.
ASRi internally corrects this maximum output power to the corresponding power measured
by the power measuring components. The correction factor used by ASRi is 1.1, which
approximately corresponds to the power losses in the motor and the transmission between
the motor and the crusher.
The value entered as “Parameter 502 – Motor’s max. output power” in the User
Settings picture must be the rated output power of the crusher’s drive motor. Similarly, the
value entered as “Parameter 601 – Max. input power to crusher” (a Sandvik setting) is
also a mechanical input power to the crusher. ASRi internally corrects this value as well
into a measured electrical input power.
Apart from parameters 502 and 601 – which present maximum mechanical power values –
all other power values are measured electrical input powers. This means that the power set-
point for an Auto-load crushing program can be up to 1.1 times greater than the motor’s
maximum output power or the crusher’s maximum input power, whichever is lowest.
If, for example, User setting parameter 502 has been entered as 220 kW and Sandvik
parameter 601 is not smaller, ASRi will internally correct the maximum power for an
Auto-load program to 1.1*220=242 kW. This power corresponds to 100%, the transition
between the green and yellow areas on the analog power display instrument.
Electrical safety 13
1 (1)
S 050.014.00 en 2005-05-27
Electrical safety
1. Permit only trained and competent personnel to work on

Warning !!! electrical components, in the plant or on any equipment.
2. Always assume that an electrical circuit is live until it is proven dead by proper
testing procedures.
3. Lock out the appropriate safety isolating switch or the main breaker, and display the
”Work in progress” warning sign in an appropriate place before performing any
inspection, maintenance, lubrication or adjustment procedure on a machine.
4. Repair or replace electrical wires, cables and connectors that are broken or damaged
in any way.
5. Check that electrical earth wires, motor and power cable connections are properly
and securely connected before starting any equipment.
6. Make sure you know the location of all power lines and underground cables. Use
extreme caution when working around these areas. Memorize the location of all main
electrical isolating switches.
7. Never work on electrical equipment while it is raining or while standing in water or

on wet surfaces unless you know that the power is disconnected.
8. Be alert when working around or with electricity. Report any electrical hazard
immediately to your supervisor.

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S 223.468.

2 Connecting up a new system S 223.468-2

2006-03-13 4 Normal operation S 223.468-4

5 Configuring crushing programs S 223.468-5

7 Operating data S 223.468-7

9 Historical data S 223.468-9

10 POT (the Product Optimization Tool) S 223.468-10

The service picture and Power

13 Safety regulations S 050.014 en

Appendix A 14 Components R 223.1252

16 Mainshaft position sensor R 223.1319

1.2 A presentation of the ASRi system...........................................................3

1.3 How the ASRi system is built up...............................................................4

1.4 The ASRi system in comparison with previous systems .......................5

1.4.1 In comparison with previous versions of ASRi .............................................5

1.4.2 In comparison with the ASR Plus system......................................................5

1.5 A general description of the ASRi control cabinet ..................................8

1.6 Information levels.......................................................................................9

1.7 A guide to using this manual ..................................................................10

1.7.1 Typographical conventions ...........................................................................10

Voltages above 100V can be present in the following units:

1.2 A presentation of the ASRi system

1.3 How the ASRi system is built up

1.4 The ASRi system in comparison with previous systems

1.4.1 In comparison with previous versions of ASRi

1.4.2 In comparison with the ASR Plus system

• The ASRi system incorporates an improved Auto-cycle function, now called

• The ASRi system permits the storage of 20 different crushing programs.

• The crusher‘s Hydroset pressure is displayed as a sector, to illustrate the crusher’s

• The ASRi system incorporates a built-in instruction manual.

1.5 A general description of the ASRi control cabinet

1.6 Information levels

1.7 A guide to using this manual

1.7.1 Typographical conventions

Note ! This manual describes a standard ASRi system. Various

2. Connecting up a new system 2004-06-15 2

2. Connecting up a new system

2.1 General ........................................................................................................2

2.2 ASRi bus cables (k5) ..................................................................................4

2.3 Components which are supplied ..............................................................6

2.4 Components which are not supplied........................................................9

2.5 Cables which are supplied ......................................................................10

2.6 Cables which are not supplied................................................................11

2.7 Connection of external monitor, mouse and keyboard.........................12

2. Connecting up a new system 2004-06-15 2

A lot of effort has been put into reducing to a minimum the

2. Connecting up a new system 2004-06-15 2

System overview for the ASRi system (194.0397, sheet 1)

Sandvik Rock Processing

2. Connecting up a new system 2004-06-15 2

2.2 ASRi bus cables (K5)

• “ASRi” – The ASRi control cabinet (ASRi-OP)

An example of a system configuration is shown below:

2. Connecting up a new system 2004-06-15 2

Each cable has a male connector at one end and a female

2. Connecting up a new system 2004-06-15 2

2.3 Components which are supplied

ASRi-OP control cabinet

Outside dimensions: 350 mm wide, 291 mm high and 81 mm deep

Component cabinet ASRi-L3

Position sensor ASRi-B1N

Pressure transducer ASRi-B2N

Temperature transducer ASRi-B3N

Connection box ASRi-CB-T