Sandvik Asri 2.0: Installation Manual

installation manual Doc. no. S 223.
513 en
SANDVIK ASRi 2.0

This document is valid for:
Serial no. / Machine no. Sign.
SANDVIK ASRi 2.0
© Copyright 2007 Sandvik SRP AB.

All rights reserved. No parts of this document may be reproduced or copied in any form or by
any means without written permission from Sandvik SRP AB. All data and information in this
manual may be changed without further notice. Reservations for misprints.
Document number: S 223.513 en

Issue: 20071207
Version: 1
Sandvik
Stationsplan, SE-233 81 Svedala, Sweden
Tel: +46 (0)40 409000, Fax: +46 (0)40 409260
www.sandvik.com
IM Sandvik ASRi 2.0
1. Introduction
1.1 Equipment information.......................................................... 6
1.1.1 Document information.............................................. 7
1.2 Operating principles of a cone crusher ................................. 8
1.3 Function and benefits of the ASRi ...................................... 10
1.3.1 ASRi system description ........................................ 11
1.3.2 Hydroset pressure definitions ................................ 14
1.4 Information levels................................................................ 15
2. Safety precautions
2.1 Hazard information ............................................................. 18
2.1.1 Warning signs ........................................................ 18
2.1.2 Risk levels.............................................................. 18
2.1.3 Prohibition signs..................................................... 19
2.1.4 Mandatory signs..................................................... 19
2.2 Personnel............................................................................ 19
2.2.1 Personal protection ................................................ 20
2.3 General safety precautions................................................. 21
2.3.1 Machine safety guards........................................... 22
2.3.2 Machine access ..................................................... 22
2.3.3 Electrical safety...................................................... 22
2.3.4 Welding .................................................................. 23
2.3.5 Hydraulic system.................................................... 23
2.3.6 Lubrication system ................................................. 23
2.3.7 Lifting and moving loads ........................................ 24
2.3.8 Feed and jams ....................................................... 25
2.4 Emissions ........................................................................... 26
2.4.1 Dust........................................................................ 26
2.4.2 Noise...................................................................... 27
2.4.3 Radioactivity........................................................... 27
© 2007 Sandvik SRP AB Doc. no. S 223.513 en Ver. 1 1

IM Sandvik ASRi 2.0
3. Hardware installation
3.1 General description............................................................. 30
3.2 Installation preparations ...................................................... 32
3.2.1 Unpacking and checking ........................................ 32
3.2.2 System layout......................................................... 32
3.3 Placement and installation .................................................. 33
3.3.1 Control unit OP and power supply unit PS ............. 33
3.3.2 Power measurement unit U1N ............................... 36
3.3.3 Hydroset drive unit L3 ............................................ 39
3.3.4 Tank measurement unit (CBT) ............................... 43
3.3.5 ASRi bus cables W5 .............................................. 46
3.3.6 Final connections ................................................... 48
3.3.7 Ethernet communication ........................................ 49
3.3.8 Level monitor.......................................................... 49
3.4 Testing the system .............................................................. 50
4. Set-up: Installation
4.1 General settings.................................................................. 54
4.1.1 Units ....................................................................... 55
4.1.2 Crusher model........................................................ 55
4.2 Crusher settings.................................................................. 55
4.2.1 Power transducer span .......................................... 58
4.3 A-dimension range set-up................................................... 60
4.3.1 Metal-to-metal A-dimension range set-up .............. 60
4.3.2 A-dimension range set-up with lead....................... 63
4.4 Ethernet communication ..................................................... 66
5. ASRi update
5.1 General ............................................................................... 70
5.1.1 Connection ............................................................. 70
5.1.2 Configuring the IP address..................................... 71
5.1.3 Establishing contact with the ASRi......................... 71
5.1.4 Updating................................................................. 74
2 Doc. no. S 223.513 en Ver. 1 © 2007 Sandvik SRP AB

IM Sandvik ASRi 2.0
Appendix A:
Technical references
A.1 Circuit diagrams................................................................. A-2
A.2 Mechanical installation and dimensions ............................ A-3
A.2.1 Control unit OP: wall mounted .............................. A-3
A.2.2 Control unit OP: cabinet mounted......................... A-3
A.2.3 Power supply unit PS............................................ A-4
A.2.4 Power measurement unit U1N.............................. A-4
A.2.5 LV current transformer T11 ................................... A-5
A.2.6 HV current transformer T11 .................................. A-5
A.2.7 Voltage transformer T12 ....................................... A-6
A.2.8 HV voltage transformer T12.................................. A-6
A.2.9 Power transducer span ......................................... A-7
A.2.10 Hydroset drive unit L3 ........................................... A-9
A.2.11 Tank measurement unit CBT ................................ A-9
A.2.12 Pressure transducer B2N with mounting kit ....... A-10
A.2.13 Temperature transducer B3N with mounting kit .. A-10

IM Sandvik ASRi 2.0
This page is intentionally left blank

1. Introduction
IM Sandvik ASRi 2.0 5

IM Sandvik ASRi 2.0 1. Introduction
1.1 Equipment information

Purpose
The purpose of this Sandvik equipment is to regulate and protect a cone
crusher from overloads. The system also helps improve production and
achieve better control and use of the cone crusher. Sandvik SRP AB will not
accept any liability for damage to equipment or injury to personnel caused by
unauthorised or improper use or modification of this equipment.
Manufacturer
This Sandvik equipment has been manufactured by:
Sandvik SRP AB
Stationsplan 1
SE-233 81 Svedala
Sweden
www.sandvik.com
For maintenance
Contact the nearest Sandvik company, agent, representative or the
manufacturer directly:
Sandvik SRP AB
Service Dept.
SE-233 81 Svedala
Sweden
Telephone +46-40-40 90 00
Telefax +46-40-40 92 64
Identification
The ASRi serial number decal is located on the side of the control unit and
contains the serial number which is needed when contacting Sandvik SRP
AB concerning this specific equipment.
1 Serial number decal

1.1.1 Document information

Purpose of this Installation manual
The purpose of this Installation manual is to provide the technicians with
information on how to safely install this Sandvik equipment.
It is important to:
• read through the whole of this manual before you start the installation
work
• keep the manual for the lifetime of the equipment
• pass the manual on to any subsequent holder or user of the equipment
Design modifications
The instructions in this document are in accordance with the design and
construction of the equipment at the time it was delivered from the Sandvik
SRP manufacturing plant.
Technical publications
The technical publications for the customer are for this equipment:
• Installation manual (IM)
• Operator’s manual (OM)
• Spare parts catalog (SPC)
When ordering technical publications, always specify the language and quote
the ASRi serial number.
Number of pages
This document contains a total of 76 pages, excluding Appendix A.
Feedback
If you have comments on this Installation manual or problems connected to
the ASRi 2.0 documentation, send an e-mail to: manuals.srp@sandvik.com.

1.2 Operating principles of a cone crusher

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

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

1.3 Function and benefits of the ASRi

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

– The distance A (mm or in.) between the underside of the spider hub
and the top of the headnut. This is also referred to as the A-dimension,
and is used to describe the position of the mainshaft. The A-
dimension is also used to calculate the cone crusher’s setting, also
referred to as the CSS, and the wear on the manganese. If the mantle
is raised in order to reduce the setting or compensate for wear, the A-
dimension will decrease.
Regulation of the crusher’s performance can be carried out in accordance
with two basic principles:
– maintaining a constant, predetermined setting
– maintaining a constant, predetermined crusher load.
The system checks the input information and compares it with the permitted
levels. The system detects and registers repetitive pressure peaks and reacts
by running the Hydroset pump in order to increase or decrease the setting.
The system will also give warnings and alarms of different kinds, such as an
indication that the manganese is nearing the end of its life or that a sensor is
faulty.
1.3.1 ASRi system description

The computer in the control unit monitors and regulates the crusher. The
computer stores the statistics, historical data, and crushing programs etc. The
control unit provides a variety of possibilities for communication with other
systems in the plant.
The ASRi system consists of the following subsystems:
• Power supply unit (PS)
• Control unit with a colour touch screen (OP)
• Power measurement unit (U1N)
• Tank measurement unit (CBT)
• Hydroset drive unit (L3)
(Continued)

The figure below shows an example of how the system can be arranged.
-PS -OP
Power supply unit Control unit
=PM =OT/HT
-U1N -CBT -L3
Power measurement unit Tank measurement unit Hydroset drive unit
NOTE! The power supply unit (PS) must be installed close to the control unit (OP).
The other units can be installed in the most convenient positions as they are
connected by a bus system.
The system incorporates a number of transducers that provide the

measurement values and signals that the control unit needs in order to
monitor and regulate the crusher:
– A pressure transducer measures the pressure in the crusher's Hydroset
system.
– A position transducer measures the position of the crusher's
mainshaft.
– A temperature transducer measures the temperature of the lubricating
oil returning to the tank from the crusher.
(Continued)

The signals from these transducers are fed to a distributed I/O unit
designated as HT.CBT. This distributed I/O unit forwards the measurements
to the control unit via an RS485 Modbus serial bus, also referred to as the
ASRi bus.
There is a second I/O unit:
– A power transducer with an associated current transformer and if
necessary, a voltage transformer, that measures the power drawn by
the crusher’s drive motor.
The signal from the power transducer is forwarded to the control unit via the
ASRi bus. If the motor is of the high-voltage type, the voltage measurements
needed by the power transducer are made via appropriate high voltage
transformers.
In addition to the analog transducer signals, the system incorporates the
following digital inputs:
– Hydroset pump contactor status signals that tell the system that the
pump motor is pumping the mainshaft up or down.
– An overload protector signal that trips out if the Hydroset pump
motor is overloaded.
and the following digital outputs:
– A signal to other equipment that the crusher is able to receive feed
material.
– Hydroset pump contactor control signals. The contactors open and
close to provide power to the pump motor that moves the mainshaft
(and the mantle) up and down.
– An alarm signal that indicates that the system has detected an alarm
condition.
All of the digital signals are routed through a third distributed I/O unit in the
L3 cabinet and forwarded to or sent from the control unit via the ASRi bus.

1.3.2 Hydroset pressure definitions

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

1.4 Information levels

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


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

IM Sandvik ASRi 2.0 2. Safety precautions
2.1 Hazard information

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

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

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

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

before any work
2.2 Personnel
All work on the equipment is to be carried out only by trained or authorized
personnel.
– “Trained” means that the person in question has been given practical
instruction by an authorized person on how the various tasks are to be
carried out.
– “Authorized” means that a person has undergone a theoretical and
practical test of knowledge, organized by Sandvik SRP AB. He/she is
therefore judged to have the knowledge and competence to carry out
the tasks assigned to the appropriate role.
All expected work tasks on this production equipment have been defined by
Sandvik SRP AB as belonging to one of three categories – work roles –
based on different competence profiles. These three work roles are:
• Installation
• Operation
• Maintenance

Sandvik SRP AB provides technical documentation appropriate to all three

work roles:
• Installation manual
• Operator’s manual and Wear parts catalog
• Maintenance manual and Spare parts catalog
Sandvik SRP AB can provide adequate training for all three work roles and
can carry out authorization of trained personnel.
The technical documentation from Sandvik SRP AB covers only work on the
production equipment itself – it does not cover work tasks associated with
other equipment or routines at the site.
It is the responsibility of the plant management to assign responsibility for:
• The production equipment and the work area around the equipment
• All personnel in the vicinity of the equipment
• Compliance with national and local safety regulations
• Checking that all safety devices are fully operational
Sandvik SRP AB declines all responsibility for injury or damage resulting
from non-compliance with the instructions in this manual.
2.2.1 Personal protection

Sandvik SRP AB strongly recommends that personal protective equipment is
always worn when working in the vicinity of the equipment.
Sandvik SRP AB strongly recommends to use a safety harness when
working above, inside and under the equipment.
The Sandvik SRP AB recommendation for personal protective equipment
includes:
Ear protection Safety helmet Eye protection
Protective gloves Safety boots Mask or breathing

apparatus

2.3 General safety precautions

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

2.3.1 Machine safety guards

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

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

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

2.3.4 Welding
CAUTION! Welding on the crusher is only permitted when and as described in the
manual. For all other welding operations on the crusher local service
personnel must be consulted.
CAUTION! Only welders qualified according to European Standard EN 287 or

similar are permitted to perform welding operations on the crusher.
If welding an item to the crusher, the grounding cable must be attached to the
item itself. If a crusher component is to be welded, the grounding cable
should be attached as near to the welding area as possible.
Toxic gases
Inhalation of welding fumes can be dangerous to health. Always follow
instructions provided by the welding equipment supplier.
WARNING! Some parts of the crusher are made of manganese steel. Long-term
exposure to manganese oxide can affect the nervous system.
2.3.5 Hydraulic system

CAUTION! Only personnel certified in hydraulics are permitted to perform
maintenance on the hydraulic system (except bleeding air from the
Hydroset system).
Oil pressure
Pressurized oil is dangerous if released incorrectly. Relieve all
pressure before carrying out maintenance or repair work on the
WARNING! hydraulic system.
CAUTION! Never adjust pressure relief valves beyond the recommended values.
Oil temperature
Hydraulic oil can get very hot in operation. Allow the oil to cool before
working on the hydraulic system. Equipment and hoses/pipes
WARNING! containing hydraulic oil may be hot on surface.
CAUTION! Make sure all defective hoses, valves or fittings are checked, repaired
and replaced before starting the equipment.
2.3.6 Lubrication system

CAUTION! Equipment and hoses/pipes containing lubrication oil may be hot on
surface.
CAUTION! Make sure all defective hoses, valves or fittings are checked, repaired
and replaced before starting the equipment.
CAUTION! Always remove oil stains to avoid skidding risk.

2.3.7 Lifting and moving loads

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

2.3.8 Feed and jams

CAUTION! When the crushing chamber is empty, avoid feeding solitary round
rocks.
CAUTION! Never feed combustible process material into the crusher.
Flying fragments
Never use wedges etc. to clear jams in the feed opening. Stones and
fragments can be thrown out at high speed from the crushing
WARNING! chamber.
Explosives
Never remove blocking boulders from the crusher by blasting.
Blasting may cause personal injury and seriously damage bearings or
WARNING! other parts. Sandvik SRP AB takes no responsibility for injury to
personnel or damage to the equipment when blasting is used.
Risk of crushing
Never stand inside the crusher when a blockage is removed. You might
be pulled forcefully and suddenly downwards together with the
DANGER! material in the crushing chamber and be crushed.
In some cases it is possible to increase the CSS (closed side setting)

temporarily to clear a jam.
Always follow local regulations when attempting to clear a jam.

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

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

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

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

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


3. Hardware installation
This section describes the installation of the ASRi system hardware. Read
the whole section before performing any tasks regarding the ASRi
installation.
To ensure maximum safety, always read section 2. Safety precautions before
doing any work on the equipment or making any adjustments.

IM Sandvik ASRi 2.0 3. Hardware installation
3.1 General description

The physical arrangement of the ASRi system's major components and the
distances between them vary from plant to plant. The major components are:
– ASRi control unit (OP) with power supply unit (PS)
– Power measurement unit (U1N)
– Tank measurement unit (CBT)
– Hydroset drive unit (L3).
– ASRi bus cables (W5)
The ASRi system’s major components can be installed in the most
convenient locations in the plant. They are linked by an ASRi bus, so their
relative positions are not critical. The ASRi bus implements a daisy chain
serial communication typology. The ASRi bus cables are designated W5, see
section 3.3.5 ASRi bus cables W5. Typically, the control unit OP is placed in
the control room and the power measurement unit U1N in the electrical
switchgear cabinet. The tank measurement unit CBT is mounted on, in, or
near the crusher’s oil tank unit, which in turn is placed by the crusher. The
Hydroset drive unit L3 can be installed in the most convenient place, for
example close to the switchgear cabinet or close to the crusher’s oil tank unit.
All of the components in the ASRi system, including the cables W1-W6, are
tested before the system is delivered.
The customer decides the relative positions of the major components and
specifies the lengths of the ASRi bus cables needed to connect them. If this
information has been provided, the appropriate cables will be supplied by
Sandvik. Check with your supervisor if this information is available.
The figure below shows an example of how the system can be arranged:
W5 W5 W5
T L=40 m L=30 m L=20 m T
X1 X2 X1 X2 X1 X2 X1 X2
OP CB U1N L3
(Continued)

If no information on the required cable lengths has been supplied to Sandvik,

the ASRi system will be delivered with a standard ASRi bus cable kit, see
section 3.3.5 ASRi bus cables W5. If you have no information on how the
major components are to be placed relative to each other, this must be
decided before installation starts. See section 3.2.2 System layout.
If the ASRi bus cables supplied are sufficiently long, use these. If the cables
supplied are not long enough, order the lengths required. See section
3.3.5 ASRi bus cables W5.
Sandvik sets up the ASRi system, with the appropriate parameters for the
crusher type, before the system is delivered.
If you have any questions about connections etc., always be prepared to give
the serial number of the ASRi system (the serial number can be found on a
decal on the side of the control unit OP).

3.2 Installation preparations

3.2.1 Unpacking and checking
Open the packing case containing the components of the ASRi system and
check the contents against the packing list. If there are any discrepancies,
notify Sandvik immediately.
3.2.2 System layout

As the major components of the ASRi system are connected by an ASRi bus,
they can be placed in the most convenient positions. Use the information in
section 3.1 General description, section 3.2 Installation preparations, and
section 3.3 Placement and installation when planning the system layout.
The ASRi bus cables must be long enough to link the four major
components.
a) Make a sketch of the layout of the major components and establish
where the ASRi bus cables W5 will be installed. See the example below,
and the example in section 3.1 General description.
b) Measure the length of the cable runs and check that the ASRi bus cables
supplied are long enough.
W5 W5 W5
T L=55 m L=50 m L=35 m T
X1 X2 X1 X2 X1 X2 X1 X2
CB OP L3 U1N

3.3 Placement and installation

3.3.1 Control unit OP and power supply unit PS
Control unit OP
Parameter Value
Dimensions 350 mm × 291 mm × 71 mm (H × W × D)
Weight 6.5 kg
Operational temperature -10 ºC to +40 °C
Storage temperature -25 ºC to +60 °C
Protection class IP65
Power supply 18–32 VDC
The control unit of the ASRi system incorporates an industrial computer with
a screen and various ports for connection to other systems. The control
unit OP is fed with 24 VDC from the power supply unit delivered by
Sandvik. The computer has a 12" SVGA touch screen. The enclosure is of
acid-proof stainless steel and has protection class IP65.
There are seven M12 connectors at the bottom of the control unit. There is an
additional USB connector beneath a panel on the left-hand side. If this
additional connection is used, the cabinet no longer has protection class
IP65.
8
1 RS232
2 X1 ASRi bus
3 X2 ASRi bus
4 X4 Ethernet 2, 10 Mbit
5 X5 Ethernet 1, 100 Mbit 9
6 X7 Power supply 24 VDC
7 On / Off switch
8 USB
9 Pilot light 1 2 3 4 5 6 7
(Continued)

The control unit OP is available in two versions–one with four pivoted

attachment lugs on the back of the cabinet, and the other with a flange for
recessed mounting. In addition, a wall mount is available that enables both
wall and bench mounting.
The control unit OP is best placed in a control room. However, in some cases
it may be desired to mount the control unit elsewhere, for example when
several ASRi systems are controlled through an Ethernet link.
Power supply unit PS
Parameter Value
Dimensions (without connectors) 217 mm × 120 mm × 72 mm (H × W × D)
Weight 2.7 kg
Power supply 100–240 VAC
The power supply unit PS has a robust metal housing that is water-tight and
it has LEDs to indicate that the corresponding output is supplied. The power
consumption is 100 W and the voltage supply can lie between 100 and
240 VAC.
3
1 X1 AC power supply input 1 2
2 X2 DC power supply output
3 LEDs
The power supply unit PS should be mounted near the control unit.
(Continued)

Cable W4
Cable W4 is a cable with M12 connector ends that connects the control
unit OP and the power supply unit PS. The standard cable length is 5 m.
Cable W101 (not supplied by Sandvik)
Cable W101 is needed to connect the power supply unit PS to its
corresponding AC supply. It has to be dimensioned according to local
regulations. Sandvik supplies a suitable 4-pole plug for the end of cable
W101 that fits the socket (X1) in the power supply unit PS.
Connections
Always refer to the appropriate circuit diagram in appendix A: Technical
references when connecting ASRi units.
a) Place the control unit OP and the power supply unit PS in their positions.
NOTE! Mount the power supply unit PS in such a way that the ventilation slots
are vertical and not covered, and air can circulate without restriction.
b) Connect cable W4 between the control unit OP and the power supply
unit PS, see the appropriate sheet in circuit diagram 194.0550 in
appendix A: Technical references.
CAUTION! Do not connect the units to the power supply until all other cables and
units are connected, see section 3.3.6 Final connections.
100-240VAC
W4
W101
X1 X2 X7
PS OP

3.3.2 Power measurement unit U1N

Parameter Value
Weight 0.6 kg
Power consumption 3 VA
The power measurement unit U1N has an I/O unit (in the connection block)
and two ASRi bus connections. U1N requires a separate 85/250 VAC supply.
1
2
1 X1 ASRi bus
2 X2 ASRi bus
The power measurement unit U1N is generally supplied separately for

installation in an existing switchgear cabinet, containing the starter for the
crusher’s drive motor, or in a switchgear room. However, U1N may be
installed prior to delivery if the order also covers other electrical equipment
from Sandvik.
If you intend to use non-Sandvik components for power measurement we
recommend that you contact Sandvik and discuss the question of the
compatibility of the proposed components.
(Continued)

Current transformer T11

The current transformer T11 is generally supplied separately for installation
in an existing switchgear cabinet or switchgear room. However, T11 may be
installed prior to delivery if the order also covers other electrical equipment
from Sandvik.
Circuit breaker F11
The power measurement unit U1N is protected by the supplied 3-pole 1A
circuit breaker F11.
Equipment for high-voltage motor
If the ASRi system is ordered for a crusher driven by a high-voltage motor,
suitable high-voltage transformers must be used. See the appropriate sheet of
circuit diagram 194.0550 in appendix A: Technical references.
Cable W102 is the power supply cable for the power measurement unit U1N
and has to be dimensioned according to local regulations. The power
consumption of the power measurement unit is approximately 3VA
Connections
a) Place the power measurement unit U1N, in its position.
CAUTION! Due to the low degree of encapsulation (protection class), the power
measurement unit U1N must be installed inside a cabinet of some kind.
(Continued)

b) Connect the current transformer T11 plus, if applicable, T12 and the
circuit breaker F11 according to the appropriate sheet of circuit diagram
194.0550 in appendix A: Technical references.
NOTE! The 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 the voltage measurement inputs to
U1N must be connected on the same side of the starting equipment.
CAUTION! Do not connect the unit to the power supply until all other cables and
units are connected, see section 3.3.6 Final connections
90-260VAC
W102
15, 16
U1N
10, 11, 12 3, 4
T12
T11
M1

3.3.3 Hydroset drive unit L3

Characteristics Data
Weight 9.5 kg
Operational temperature 0 °C to +50 ºC
Storage temperature -25 °C to +60 °C
The Hydroset drive unit L3 is the contactor/component box for the Hydroset
pump motor. The Hydroset drive unit L3 is delivered separately. The
Hydroset drive unit contains motor protectors and contactors for the forward/
backward connection of the Hydroset pump, an I/O-unit with an ASRi bus
communication interface, a single-phase power supply unit (100-240 VAC
input/24 VDC 2.1 A output) plus an alarm relay, and a relay for the
interlocking of the crusher's feed arrangement (feeder and/or conveyor).
1
1 X3 L1
2 X1 ASRi bus 2
3 X2 ASRi bus
4 W1M6 3
5 W103
6 W2M6
7 W104, W105
4 5 6 7
The Hydroset drive unit L3 can be installed in the most convenient place, for
example close to the switchgear cabinet or close to the crusher’s oil tank unit.
(Continued)


Cable W103 is the control voltage supply cable for the Hydroset drive
unit L3. The power consumption of the Hydroset drive unit is 50 W and the
control voltage can lie between 100 and 240 VAC.
Cable W104 is the interlock cable to the feed system control equipment and
must be dimensioned in accordance with local regulations, to suit the voltage
and the power rating of the feeder or conveyor interlock signal. The cable
must be connected to terminals 201 and 202 in the terminal block X4 inside
L3, see the L3 circuit diagram in appendix A: Technical references. The
maximum permissible current (-K21A) is 6 A at 250 VAC.
Cable W105 is the interlock cable for the alarm lamp (if fitted). The cable
must be connected to terminals 203 and 204 in the terminal block X4 inside
L3, see the L3 circuit diagram in appendix A: Technical references. The
maximum permissible current (-K24A) is 6 A at 250 VAC.
Cable W1M6 (not supplied by Sandvik)
Cable W1M6 is the power supply cable to the L3 cabinet and runs from the
switchgear to L3. It must be dimensioned in accordance with local
regulations to suit the voltage and the power rating of the motor. Also use the
list of cables in the crusher’s Installation manual when dimensioning
cable W1M6.
Cable W2M6 (not supplied by Sandvik)
Cable W2M6 is the power supply cable that runs from the L3 cabinet to the
Hydroset pump motor M6. It must be dimensioned in accordance with local
conditions to suit the voltage and the power rating of the motor. Also use the
list of cables in the crusher’s Installation manual when dimensioning
cable W2M6.
Push button box L1
The push button box L1 can be used for manual control of the crusher's
mainshaft if there is a fault with the ASRi system. However, the L1 is
normally not active. The push button box is directly connected to the
contactors of the Hydroset pump motor and is used for raising and lowering
the mainshaft independently of the ASRi system.
NOTE! Sandvik recommends that the L1 box is stored well away from the L3 cabinet.
(Continued)

Cable W6
Cable W6 is the cable between the push button box L1 (used for direct
control of the Hydroset pump motor) and the Hydroset drive unit L3.
Hydroset pump motor M6 (not delivered with ASRi system)
The Hydroset pump motor M6 is mounted in the Hydroset tank unit HT. The
Hydroset pump motor is not part of the ASRi system delivery but is
delivered as part of the crusher’s auxiliary equipment.
Feeder FC (not delivered with ASRi system)
FC is the designation used for the system that feeds material to the crusher.
The feeder is not part of the ASRi system delivery but is either installed
already or can be ordered as an optional item of equipment.
Sandvik strongly recommends that the feed to the crusher is interlocked with
the ASRi system through relay -K21A in the Hydroset drive unit L3, as
shown in circuit diagram 194.0550 in appendix A: Technical references. 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 a type A or B alarm and will simultaneously stop the feed
to the crusher.
Alarm lamp H1 (not delivered with ASRi system)
H1 is the designation used for an external alarm lamp. In the Hydroset drive
unit L3 there is a relay (-K24A) that is energized when an A or a B alarm is
initiated. The output contact of relay -K24A can be utilized to connect an
external indicating lamp to draw the attention of plant personnel or to
transmit an alarm to a higher-level plant control system. This alarm lamp is
not usually part of the ASRi system delivery.
Connections
a) Place the Hydroset drive unit L3 in its position.
NOTE! Protect the Hydroset drive unit against falling material.
b) Connect interlock cables W104 and W105 to the feed system control
equipment and the alarm system respectively.
(Continued)

c) Connect cable W1M6 between the switchgear and the Hydroset drive
unit L3.
d) Connect cable W2M6 between the Hydroset drive unit L3 and the
Hydroset pump motor M6.
CAUTION! Do not connect the unit to the power supply until all other cables and
units are connected, see section 3.3.6 Final connections.
100-240VAC L3
W1M6
W103
X4 X4
X4 W104
L3 X4 W105
X3 X4
W2M6
W6
M6
L1
NOTE! If L1 is to be used, terminal blocks 205 and 206 in the terminal 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 W6 from L3 and
remove the linking plug.
CAUTION! When L1 is used, there is no protective function to prevent the

mainshaft from being raised so high that there is metal-to-metal contact
between the crushing liners.

3.3.4 Tank measurement unit (CBT)

Characteristics Data
Dimensions 211 mm × 30 mm × 26.5 mm (H × W × D)
Weight 0.266 kg
Operational temperature 0 ºC to +55 ºC
Storage temperature -25 ºC to +85 ºC
Power supply 24 VDC via ASRi bus
The tank measurement unit CBT receives inputs from three transducers,
B1N, B2N, and B3N.
1
2
3
4
1 X1 ASRi bus
2 X2 ASRi bus
5
3 X3 B1N
4 X4 B2N
5 X5 B3N
B1N is mounted in the bottom of the crusher, while B2N and B3N are
mounted in the oil tank unit and the Hydroset tank unit OT/HT. The
measurement unit CBT is therefore installed on, in, or near the oil tank unit.
Position transducer B1N
The position transducer B1N 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 with a new crusher, the position transducer is
installed in the crusher before delivery.
(Continued)

Cable W1
Cable W1 connects the position transducer B1N and the tank measurement
unit CBT. Cable W1 consists of two sections, a standard cable of 3 m and an
extension cable, the length of which depends on the installation. Sandvik
selects the appropriate cables for the crusher with which the system is to be
used.
Pressure transducer B2N
The pressure transducer B2N measures the Hydroset pressure and is installed
in the oil tank unit OT/HT.
Cable W2
Cable W2 connects the pressure transducer B2N and the measurement
unit CBT. The cable is available in lengths from 3 m to 7 m.
Temperature transducer B3N
The temperature transducer B3N measures the temperature of the lubricating
oil returning to the oil tank unit. It is installed in the oil tank unit OT.
Cable W3
Cable W3 connects the temperature transducer B3N and the measurement
unit CBT. The cable is available in lengths from 1 m to 7 m.
NOTE! Cables W1, W2, and W3 used with ASRi 2.x systems are different from the
equivalent cables in preceding ASRi systems. If you need to order any of
these cables, be sure to give the serial number of the ASRi system. ASRi 2.x
systems have serial numbers from 2000 and upwards.
Connections
a) Place the tank measurement unit CBT in its position.
NOTE! Protect the tank measurement unit from falling material.
(Continued)

b) Connect cables W1, W2, and W3 between the transducers (B1N, B2N,
and B3N) and the tank measurement unit CBT.
CB
X3 X4 X5
W2
W3
W1
S P
I I I
B1N B2N B3N

3.3.5 ASRi bus cables W5

The ASRi bus cables W5 are used to link all the four major components. A
total of three W5 cables are required. All of the ASRi bus cables use the
same connectors so they can be interchanged or coupled together to make
longer cables.
If Sandvik has been given information about the lengths required for the
ASRi bus cables, the closest standard length cables will have been supplied
with the ASRi system. The ASRi bus cables W5 are available in the
following standard lengths:
Length
250 m
200 m
150 m
100 m
80 m
60 m
50 m
40 m
30 m
20 m
10 m
7m
5m
2m
If Sandvik has not received information about the lengths required, a

standard cable kit will be supplied. This standard kit consists of:
Qty. Length
1 40 m
1 30 m
2 20 m
1 10 m
A
NOTE! ASRi bus cables can be joined together and you can connect them in
whichever sequence suits the site best.
(Continued)

Connections
a) Install the ASRi bus cables between the control unit OP, the power
measurement unit U1N, the Hydroset drive unit L3, and the tank
measurement unit CBT.
W5 W5 W5
T T
X1 X2 X1 X2 X1 X2 X1 X2
CB U1N L3 OP
NOTE! Install the ASRi bus cables W5 well away from items that can generate
interference, for example frequency converters and power cables.
NOTE! Each ASRi component has a male connector, always designated X1 and a
female connector, always designated X2. Make sure that you install the
cables the right way round.
NOTE! The ASRi bus requires a termination plug at each of the two extremities. Two
termination plugs are supplied, one male and one female.

3.3.6 Final connections

a) Connect the power supply cable W102 to the power measurement unit
U1N, see section 3.3.2 Power measurement unit U1N and the
appropriate sheet in circuit diagram 194.0550 in appendix A: Technical
references.
a) Connect the power supply cable W103 to the Hydroset drive unit L3, see
section 3.3.3 Hydroset drive unit L3 and the appropriate sheet in circuit
diagram 194.0550 in appendix A: Technical references.
a) Connect the power supply cable W101 to the power supply unit PS and
the power grid, see section 3.3.1 Control unit OP and power supply unit
PS and the appropriate sheet in circuit diagram 194.0550 in appendix
A: Technical references.
b) Switch on the power supply to PS.
CAUTION! The connection between the power supply unit to the power supply
must be made last, or components might be damaged.
NOTE! A qualified electrician must make and inspect the electrical connections on
the site.
The figure below shows an example of an ASRi system installation when all
the connections have been made.
100-240VAC 85-250V AC/DC 100-240VAC L3
W4 W5 W5 W5
W1M6
W101
W102
T T W103
15, 16
X1 X2 X7 X5 X4 X1 X2 X1 X2 X1 X2 X1 X2 X4 X4
X4 W104
PS OP CB U1N L3 X4 W105
X3 X4 X5 10, 11, 12 3, 4 X3 X4
W2M6
W2
W3
W6
T12
W1
T11
S P M6
M1
I I I
B1N B2N B3N L1

3.3.7 Ethernet communication

If the ASRi system is to be connected to an Ethernet network, a
communication cable must be connected to one of the two Ethernet sockets
on the bottom of the control unit OP.
Since every communication network is unique, there must be a discussion
with Sandvik about which ASRi communication components are required.
This must be done in advance so that the components can be ordered in good
time.
3.3.8 Level monitor

Most cone crushers have a level monitor installed in the feed hopper. The
level monitor is used to control the feeding of material to the crusher. If there
is a blockage in the crusher’s feed opening, for example, the level monitor’s
output signal is used to stop the feed.
The type of level monitor and the control logic employed vary from plant to
plant, so the electrical connection of the level monitor is part of the plant’s
general electrical system. There is no connection between the level monitor
and the ASRi system, but it is important to keep in mind that the interlocks to
the feeding system should include both the level monitor and the ASRi
system. See more about the feed interlock in section 3.3.3 Hydroset drive
unit L3.

3.4 Testing the system

Switch on the power to the various components in the ASRi system. Use the
control unit OP to check that the connections are correct and that the system
functions correctly. See also Service in the Operator’s manual.
Testing communication
a) Switch on the power to the control unit OP. The system will start up and
perform an automatic check of the computer. When the start-up is
completed, the Main picture will appear on the screen.
b) Check that each end of the ASRi bus daisy chain is terminated by a
termination plug. One end of the ASRi bus daisy chain is terminated by a
male plug and the other by a female plug.
c) Press the [Set-up] button, and then [Service] to open the Service
picture.
d) Press the [Connections] button to open the Connections picture.
e) Check that none of the circles are red. Cable W6 to L1 is always white.
– If any of the circles marked W5 are red, there is a communication
fault between the control unit OP and the other major components
(L3, CBT, or U1N).
– If any of the circles marked W1, W2, or W3 are red, the tank
measurement unit CBT, the cables, or the transducers are faulty.
Testing the Hydroset drive unit L3
and the Hydroset pump
f) Open the L3 box.
g) Press the [up] button on the push button box L1. The contactor K6MF
should be energized.
h) Press the [down] button on the push button box L1. The contactor
K6MB should be energized.
i) Open the inspection door in the crusher’s feed hopper.
j) Check that the mainshaft moves up and down by pressing the
corresponding buttons on the push button box L1.
(Continued)

k) Press the [up] and [down] buttons respectively on the main picture of
the control unit OP display. When pressing the [up] button, the A-
dimension should decrease and when pressing the [down] button, the A-
dimension should increase. If the Hydroset pump does not run correctly,
the ASRi will indicate this with an alarm.
Testing the power measurement unit U1N
In order for the power measurement to work, all components must be
connected correctly and the correct range of measurement must be set in the
ASRi
l) Check that three phases are connected to terminals 10, 11, and 12 in the
power measurement unit U1N.
m) Check that the current transformer T11 is mounted in the same phase as
terminal 10 in U1N.
n) Check that the cable that runs through the current transformer to the
motor goes through the large hole marked P1 and out through P2.
o) Check that the secondary side of the current transformer, marked S1 and
S2, is connected to terminals 3 and 4 respectively in U1N.
p) Check that the correct range of measurement is set in the ASRi (Power
transducer span, parameter 501). See section 4.2 Crusher settings.
Checking the control values
q) Start the crusher motor.
r) Check the Hydroset pressure. It should normally lie between 0.3 and 0.6
MPa depending on crusher model. See the manuals for the crusher.
s) Check the power draw. The approximate power consumption for
different crushers when the lubrication oil is warm are listed in the table
below.
Crusher model Power
CH/CS420 10-15 kW
CH/CS430 15-20 kW
CH/CS440 20-30 kW
CH/CS660 30-40 kW
CH870 40-60 kW
CH880 50-80 kW
NOTE! If the oil is cool, the power consumption is higher.
Finishing off
t) The ASRi system is now ready for commissioning and calibration.


4. Set-up: Installation

IM Sandvik ASRi 2.0 4. Set-up: Installation
4.1 General settings

Before operation of the ASRi can begin, some parameters must be set
concerning the crusher, its calibration, and the communication settings etc.
See Operation set-up in the Operator’s manual for instructions on how to set
up the display.
NOTE! The installation picture is password protected. The password is only needed
when changing the settings and can be obtained from Sandvik.
Follow the instructions below to open the Installation picture.

a) Press the [Set-up] button in the menu bar, and then the [Installation]
button in the pop-up menu.
b) Enter User name and Password.
c) Press the [OK] button. If you press the [Cancel] button, you will still be
able to see the basic settings, but not change them.
RUNNING: NEW PROGRAM User:
Set-up: Installation
Units
SI US
A-dim. range
Lead M-M
Crusher model
Select
Settings Reset all

Settings Reset
Communication Update
Com. Update
Operator password
Change
Main Op. data Alarm History Set-up Help

4.1.1 Units
The ASRi can display information according to the International system of
units (SI) or US units (US).
a) Press the [SI] button to select SI units or the [US] button to select US
units.
4.1.2 Crusher model

If an ASRi system is moved between crushers, several settings must be
changed. To facilitate switching from one machine to another it is possible to
enter a set of standard values for various different crushers. The Custom
alternative can be used if none of the listed crusher types matches the new
crusher in the ASRi system. The Custom alternative does not load or change
any values, but new values must be entered manually. See section
4.2 Crusher settings.
a) Scroll [S] or [T] in the Crusher model menu to select a crusher model.
b) Press the [Select] button to apply.
4.2 Crusher settings

Occasionally it may be necessary to change the standard parameter values.
a) Press the [Settings] button to open the Settings picture.
b) Touch the field value(s) you want to change. Use the numerical keypad
that pops up to change the value displayed in the field. The numerical
keypad automatically disappears when you exit the picture.
(Continued)

Set-up: Installation: Settings
Power
501 Power transducer span Calculate
502 Motor output power
508 Power supply frequency
A-dimension
503 A-dim for liner change alarm
CSS
504 Multi-CSS cycle time
505 CSS factor mode Manual Auto
506 Automatic wear compensation Enabled Disabled
Temperature
507 Lub. oil temperature limit

Close
Crusher name
509 Crusher name
c) Enter the information needed for the parameters on the picture:

Power
501 Power transducer span:
The total measuring span of the power transducer that provides the
power signal.
502 Motor output power:
The maximum permissible continuous power output from the
motor. Enter the rated output power, as it is labelled on the
identification plate of the crusher’s drive motor.
508 Power supply frequency:
The frequency at which the crusher’s drive motor operates.
(Continued)

A-dimension
503 A-dimension for liner change alarm:
The A-dimension at which a warning about worn liners shall be
activated. When the A-dimension is less than the entered value, the
“New liners needed!” warning is activated.
CSS
504 Multi-CSS cycle time:
The total cycle time for a Multi-CSS crushing program (at least
60 seconds).
505 CSS factor mode:
The selection of automatic or manual definition of the CSS-Start
factor.
506 Automatic wear compensation:
The activation or deactivation of the automatic wear compensation
function (IWC).
Temperature
507 Lub. oil temperature limit:
The alarm limit for the return lubrication 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.
Crusher name
509 Crusher name:
The name of the crusher for which the parameters are valid. If
entering a new crusher into the ASRi menu, write the new crusher’s
name.

4.2.1 Power transducer span

If you need to calculate the value that is to be entered for parameter 501, you
can access the Power transducer span picture.
a) Press the [Calculate] button in the Settings picture to enter the Power
transducer span picture.
Set-up: Installation: Settings: Power transducer span
Power transducer
701 Nominal input voltage
Voltage transformer
702 Primary voltage
703 Secondary voltage
Current transformer
704 Primary current
Correction factor
705 C =
Power transducer span
Cancel OK
b) Enter the information needed for the calculation of the power

measurement span:
Power transducer
701 Nominal input voltage:
The nominal measurement span voltage to the power transducer.
The power transducers supplied by Sandvik have nominal input
voltages of 110V or 400V.
(Continued)

Voltage transformer
If the power measurement set-up incorporates high-voltage transformers, the
following values must be entered:
702 Primary voltage:
The primary voltage of the voltage transformer, if used.
703 Secondary voltage:
The secondary voltage of the voltage transformer, if used.
Current transformer
704 Primary current:
The primary current of the current transformer.
Correction factor
705 C = The correction factor. The normal factor value is C = 1.000.
Power transmitter span
When all of the information has been entered, the calculated result is
displayed here in the picture, see also the calculation diagram of the power
transducer span in appendix A: Technical references.
c) Press [OK] to transfer the result to parameter 501 in the Settings picture.
Press [Cancel] to return to the Settings picture without transferring the
calculated value.
CAUTION! If you press [OK] and the values are incorrect, the ASRi will not
function correctly.

4.3 A-dimension range set-up

The position of the crusher's mainshaft is defined by the “A-dimension”. It
refers to the smallest distance between the underside of the crusher's spider
and the top of the headnut. See the cone crusher Operator’s manual for
further details.
An A-dimension range set-up is required when the ASRi system is first
commissioned, or when the crusher is modified in such a way that the
mainshaft position measuring system is affected, for example when replacing
a defective position transducer B1N. It must be carried out so that details of
the mainshaft travel span are available for the system and there are two ways
to carry it out. They are metal-to-metal A-dimension range set-up and A-
dimension range set-up with lead. The first is the easier method of the two
because it does not require the physical measurement of the crusher´s CSS.
4.3.1 Metal-to-metal A-dimension range set-up

A metal-to-metal A-dimension range set-up 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 procedure is finished, the A-dimension range set-up has been
completed
The information in the M to M calibration picture guides you through the
various stages of the A-dimension range set-up procedure. Each step is
displayed in green or black. The green text colour indicates that the system is
awaiting action on the instruction given on the picture.
a) Press the [M-M] button in the Installation picture.
b) Press the [Start] button to start the metal-to-metal A-dimension range
set-up procedure.
c) The procedure can be cancelled at any stage by pressing the [Cancel]
button.
1. Stop feeder
If the crusher is under load, stop the feed.
CAUTION! If the feed arrangement is not interlocked with the ASRi, the operator
has to stop the feed to the crusher.
(Continued)

2. Start crusher
If the crusher's drive motor is off, this is indicated by a message in the
picture. The system proceeds to the next step 30 seconds after the motor
starts. If the crusher is loaded again, the A-dimension range set-up procedure
is automatically cancelled. This is indicated by an error message: “Crusher
load too high, aborting”. In this case, press the [OK] button to cancel the
procedure.
d) Check that there is no material in the crusher.
3. Waiting for metal-to-metal contact
The ASRi system raises the mainshaft to reach the metal-to-metal position.
4. Metal-to-metal contact detected
The ASRi system detects that the shaft cannot be raised further. If the
pressure is too high, the set-up procedure is cancelled and the message
“Pressure too high, aborting” pops up. Press the [OK] button to
acknowledge.
CALIBRATION: NEW PROGRAM User:
Set-up: Installation: A-dim. range: M to M calibration
1. Stop feeder
2. Start crusher
3. Waiting for metal-to-metal contact
4. Metal-to-metal contact detected
5. Stop crusher
6. Enter A-dimension and press [Continue]
7. Start crusher
8. Pumping down mainshaft
9. Bottom position detected, pumping mainshaft up
10. Crusher calibrated! Press [Finish]
Start Back
(Continued)

5. Stop crusher
Switch off the crusher's drive motor.
e) Measure the A-dimension on the crusher. See also Topshell assembly in
the crusher’s Operator’s manual.
f) Enter this value by using the arrow buttons.
g) Press the [Continue] button.
NOTE! Do not move the shaft until you have entered the measured A-dimension
and you have pressed [Continue].
7. Start crusher
h) Restart the crusher's drive motor. The system proceeds to the next step
30 seconds after the motor starts.
The ASRi system lowers the mainshaft to establish the maximum A-
dimension.
The ASRi system lowers the mainshaft to its bottom position and registers
the maximum A-dimension. The shaft is then pumped up.
10. Crusher Calibrated. Press [Finish]
The A-dimension range set-up procedure is completed.
i) Press the [Finish] button.
The system is now ready for start-up.

4.3.2 A-dimension range set-up with lead

An A-dimension range set-up with lead 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 procedure is
finished, the A-dimension range set-up has been completed.
The information in the Lead calibration picture guides you through the
various stages of the A-dimension range set-up procedure. Each step is
displayed in green or black. The green text colour indicates that the system is
waiting for action on the instruction given in the picture.
Follow the instructions below to perform an A-dimension range set-up with
lead.
a) Press the [Lead] button in the Installation picture.
b) Press the [Start] button to start the calibration with lead.
c) The procedure can be cancelled at any stage by pressing the [Cancel]
button.
1. Stop feeder
If the crusher is under load, stop the feed.
CAUTION! If the feed arrangement is not interlocked with the ASRi, the operator
has to stop the feed to the crusher.
2. Start crusher
If the crusher's drive motor is off, this is indicated by a message in the
picture. The system proceeds to the next step 30 seconds after the motor
starts. If the crusher is loaded again, the A-dimension range set-up procedure
is automatically cancelled. 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.
(Continued)

d) Check that there is no material in the crusher.

CALIBRATION: NEW PROGRAM User:
Set-up: Installation: A-dim. range: Lead calibration
1. Stop feeder
2. Start crusher
3. Position the mainshaft. Measure the CSS.

Enter the value and press [Continue]
4. Stop crusher
6. Start crusher
9. Crusher calibrated! Press [Finish]
Start Back
3. Position the mainshaft. Measure the CSS.

Enter the value and press [Continue].
e) Measure the CSS inside the crusher.
The CSS can be adjusted by using the L1 push button box or by using the
arrow buttons in the small crusher figure in the ASRi picture. 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.
f) Enter the value by using the arrow buttons
(Continued)

g) Press the [Continue] button.

NOTE! Do not move the mainshaft after the lead has passed through the
crushing chamber until you have entered the CSS and pressed the
[Continue] button.
CAUTION! When ASRi-L1 is used, there is no protective function to prevent the

mainshaft from being raised so far that there is metal-to-metal contact
between the crushing liners.
4. Stop Crusher
h) Switch off the crusher's drive motor.
i) Measure the crusher’s A-dimension. See also Topshell assembly in the
crusher’s Operator’s manual.
j) Enter the value by using the arrow buttons.
k) Press the [Continue] button.
NOTE! Do not move the mainshaft until you have entered the measured A-
dimension and pressed [Continue].
6. Start crusher
l) Restart the crusher's drive motor. The system proceeds to the next step
30 seconds after the motor starts.
The ASRi system lowers the mainshaft to establish the maximum A-
dimension.
The ASRi system lowers the mainshaft to its bottom position and registers
the maximum A-dimension. The shaft is then pumped half way up.
9. Crusher calibrated. Press [Finish]
The A-dimension range set-up procedure is completed.
m) Press the [Finish] button.
The system is now ready for start-up.

4.4 Ethernet communication

If the ASRi system is to communicate with an external system, it must be
configured and 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 for
the two Ethernet connections are made in the Communication picture.
a) Press the [Com.] button on the Installation picture to open the
Communication picture.
Set-up: Installation: Communication
Ethernet 1
OFF
IP address
Subnet mask
Ethernet 2 OFF
IP address
Subnet mask
Select
Gateway
Comli
ASRPlus id
Close
Ethernet 1 100 Mbit connection

Ethernet 2 10 Mbit connection
(Continued)

Before delivery, the ASRi network cards are set to the addresses
192.168.30.200 and 192.168.31.201. If the ASRi system is to be part of a
local network, these addresses may need to be changed to avoid conflicts
with existing systems in the network. You can contact your network
administrator to check if any address changes are necessary.
NOTE! The first three fields of the computer’s IP address and the first three fields of
the ASRi IP address must match. The fourth fields must differ.
Check your computer’s IP address as follows:

b) Make sure the Ethernet cable between the control unit OP and the
computer is connected.
c) Go to the Start menu in Windows 95/98/ME/NT/2000/XP and click on
[Run].
d) For Windows 95/98/ME enter winipconfig and click [OK].
e) For Windows NT/2000/XP enter cmd and click [OK].
f) In the prompt window, enter ipconfig and press the enter key.
(Continued)

g) The computer’s IP address will be shown in the prompt window.
Example: In the window above, the IP address is 164.4.69.152, so the ASRi

system should have the same numbers in the first three fields, and be
concluded with any number between 000 and 255 with the exception of 152,
since this is the last field number of the computer’s IP address.
h) Enter the desired address in the Communication picture by first pressing
the corresponding [IP] button for the card to be used.
i) Enter the desired address by pressing the address fields and change the
numbers using the numerical keypad.
j) Press [Select].
k) If the other card is not in use, press its corresponding [OFF] button.
If there is a DHCP server in the local network, you can press the [DHCP]
button in order to dynamically assign an IP address to the ASRi system. In
this case you do not have to select the IP address and subnet mask manually.
If neither Ethernet connection is to be used, switch the cards off by pressing
the [OFF] button.
If connecting the ASRi system to units outside the local network, it is
necessary to assign a Gateway address. This requires a manual IP address
set-up.

5. ASRi update

IM Sandvik ASRi 2.0 5. ASRi update
5.1 General
When purchasing an ASRi system that accompanies a crusher, the ASRi
software is installed prior to delivery. However, it is necessary to perform the
steps of updating or installing the ASRi software when an existing ASRi
2.xx system is to be updated with new software.
The updating process consists of four steps:
a) Connection
b) Configuring the IP address
c) Establishing contact with the ASRi
d) Updating software
In order to update your ASRi software you need the following parts and
equipment:
• Updating program CD (included in the updating package)
• Ethernet cable (included in the updating package, but not required if
there is already a connection to a network)
• Computer with an Ethernet port
5.1.1 Connection
When updating the ASRi software there must be an Ethernet connection
between the computer and the control unit. This connection can either be
permanent or temporary. Follow the instructions below in order to set up a
temporary Ethernet connection between the computer and the control unit.
a) Connect the Ethernet cable between the computer’s network port and
one of the Ethernet ports on the control unit.
There are two Ethernet ports on the control unit. Ethernet 1 is a 100 Mbit
connection and Ethernet 2 is a 10 Mbit connection. It is recommended to
use the Ethernet 1 connection, if possible.

5.1.2 Configuring the IP address

The settings for the Ethernet connection are made in the Communication
picture. See section 4.4 Ethernet communication.
5.1.3 Establishing contact with the ASRi

The ASRi system has an integrated web server. When connected to a
network, the system can be accessed through a web browser such as Internet
Explorer.
Connecting through WINi
a) Locate the IP address at the left corner of the WINi view and note it
down.
b) Proceed to item g.
Connecting by cable to the programming computer
First you must disconnect the Proxy server.
c) Press [Start] on the start menu, select Settings, then Control Panel and
click the [Internet Options] icon.
(Continued)

d) Click the Connections tab and then the [LAN Settings] button.
e) Make sure the Use a proxy server... box is unchecked.
f) Click [OK] twice.

g) Start the web browser (e.g. Internet Explorer).
(Continued)

h) Enter the ASRi system address in the address field:

http://xxx.xxx.xx.xxx (the IP address of the control unit).
i) Press the enter key and the web page of the ASRi system, that contains
links to new version uploads, backups, history export and the manual,
will appear.

5.1.4 Updating
a) Click Upload new program version in the ASRi system web page to
update the program.
b) The new program is supplied on a CD. Load that disc into the CD drive.
c) Go to Windows Explorer, locate the CD disc, and press the Upgrade.exe
icon.
d) Enter the serial number of the ASRi system in the ASRi serial number
box. The serial number sign is located on the left hand side of the ASRi
panel.
e) Click the [Get code] button.
f) The update code appears in the Code box.
g) Enter the code in the Password box.
h) Browse the CD to locate the update_prog.upd file.
i) Enter the full path to the update_prog.upd file in the Path and filename
box.
j) Click the [Submit File] button to send the update to the ASRi system.
k) Go to the Control unit and press [Set-up] and then [Installation] to
open the Installation picture.
l) Press the [Update] button and then the [Yes] button to upgrade the
ASRi system.
m) Then new software is installed and if the installation is successful, the
ASRi system will reboot. This confirms that the update has been
completed.
n) Reset the Proxy server when the upgrade procedure is finished.
o) You can check which version of the ASRi you have by pressing the
[Set-up] button and then the [Service button]. The name of the
current program version is shown in the upper right corner of the Service
picture.

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installation manual Doc. no. S 223.

SANDVIK ASRi 2.0

Serial no. / Machine no. Sign.

SANDVIK ASRi 2.0

© Copyright 2007 Sandvik SRP AB.

Document number: S 223.513 en

© 2007 Sandvik SRP AB Doc. no. S 223.513 en Ver. 1 1

2 Doc. no. S 223.513 en Ver. 1 © 2007 Sandvik SRP AB

© 2007 Sandvik SRP AB Doc. no. S 223.513 en Ver. 1 3

This page is intentionally left blank

4 Doc. no. S 223.513 en Ver. 1 © 2007 Sandvik SRP AB

IM Sandvik ASRi 2.0 5

1.1 Equipment information

1 Serial number decal

6 Doc. no. S 223.513 en Ver. 1 © 2007 Sandvik SRP AB

1.1.1 Document information

© 2007 Sandvik SRP AB Doc. no. S 223.513 en Ver. 1 7

1.2 Operating principles of a cone crusher

8 Doc. no. S 223.513 en Ver. 1 © 2007 Sandvik SRP AB

setting decrease = finer product setting increase = coarser product

© 2007 Sandvik SRP AB Doc. no. S 223.513 en Ver. 1 9

1.3 Function and benefits of the ASRi

10 Doc. no. S 223.513 en Ver. 1 © 2007 Sandvik SRP AB

1.3.1 ASRi system description

© 2007 Sandvik SRP AB Doc. no. S 223.513 en Ver. 1 11

Power supply unit Control unit

-U1N -CBT -L3

Power measurement unit Tank measurement unit Hydroset drive unit

The system incorporates a number of transducers that provide the

12 Doc. no. S 223.513 en Ver. 1 © 2007 Sandvik SRP AB

© 2007 Sandvik SRP AB Doc. no. S 223.513 en Ver. 1 13

1.3.2 Hydroset pressure definitions

14 Doc. no. S 223.513 en Ver. 1 © 2007 Sandvik SRP AB

1.4 Information levels

© 2007 Sandvik SRP AB Doc. no. S 223.513 en Ver. 1 15

This page is intentionally left blank

16 Doc. no. S 223.513 en Ver. 1 © 2007 Sandvik SRP AB

IM Sandvik ASRi 2.0 17

2.1 Hazard information

General danger Dangerous voltage Risk of crushing

Hanging load Risk of crushing Flying fragments

2.1.2 Risk levels

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

18 Doc. no. S 223.513 en Ver. 1 © 2007 Sandvik SRP AB

2.1.3 Prohibition signs

2.1.4 Mandatory signs

Disconnect current Read the manual

© 2007 Sandvik SRP AB Doc. no. S 223.513 en Ver. 1 19

Sandvik SRP AB provides technical documentation appropriate to all three

2.2.1 Personal protection

Ear protection Safety helmet Eye protection

Protective gloves Safety boots Mask or breathing

20 Doc. no. S 223.513 en Ver. 1 © 2007 Sandvik SRP AB

2.3 General safety precautions

© 2007 Sandvik SRP AB Doc. no. S 223.513 en Ver. 1 21

2.3.1 Machine safety guards

2.3.2 Machine access

2.3.3 Electrical safety