Hasler Sound 2 Quick start guide

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SOUND2.943.001-E.e
Sound 2
Monitoring system for grinders
SOUND2.943.001-E.e

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SOUND2.943.001-E.e
REVISION
DATE
SOUND2.943.001-E.e
26/08/2020
This manual supposes the use of a version 1.0.0.1 or Higher of the Sound 2 software
It cannot be used for previous versions.
Service
If you need assistance, please call your local service center:
HASLER Group SA Tel. [phone]
F- 38780 Pont-Évêque Mail: [e-mail]
HASLER Suisse Sarl Tel. [phone]
CH-2000 Neuchâtel Mail: [e-mail]
HASLER Deutschland GmbH Tel. [phone]
D-48268 GREVEN Mail: [e-mail]
HASLER Industrial Equipment Tel. [phone]
CN-201801 Shanghai Mail: [e-mail]
Before you call...
➔Do you have alarm displays?
Are you able to eliminate the cause of the alarm displays?
➔Have you modified part of the system, Microphone, Cable, product or operating mode?
➔Have you tried to remedy the fault in accordance with the operating and service instructions?
➔Please note
The Job Number: _______________________________
The type of mill: _______________________________
The Part Number of Controler _______________________________
“No part of this publication may be reproduced or transmitted in any form or by any means electronic or
mechanical including photocopy, facsimile or computer-generated distribution without written permission from
HASLER Group. All translation rights are reserved by HASLER Group. HASLER Group has made every effort
to ensure the accuracy and validity of this document. However, errors or emissions cannot be excluded and may
be transmitted to HASLER Group, at the following number: [phone].
Information in this manual is correct as of the date of publication. HASLER Group assumes no responsibility for
damages resulting from misuse of the equipment or negligence on the part of operating personnel.
HASLER Group also reserves the right to modify equipment, products, programs, and procedures described in
this manual at any time without prior notice.

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Table of contents
1. INTRODUCTION.............................................................................................................5
2. CHECKING ON RECEIPT.............................................................................................5
3. CAUTION..........................................................................................................................5
4. SUPPLIES..........................................................................................................................6
5. MICROPHONE INSTALLATION................................................................................7
6. INSTALLATION OF THE ELECTRONIC HOUSING ..............................................9
7. MOUNTING SHIELDED CABLES IN THE CABLE GLANDS.............................10
7.1. CABLE PREPARATION.........................................................................................10
7.2. CABLE MOUNTING ..............................................................................................10
8. CONNECTION DIAGRAM..........................................................................................11
9. ELECTRICAL INTERFACE........................................................................................12
10. CONNECTION ..........................................................................................................13
10.1. POWER SUPPLY CONNECTION...................................................................................13
10.2. MICROPHONE CONNECTION ON EAR SIDE.................................................................14
11. INSTALLATION .......................................................................................................15
11.1. MICROPHONE DEFINITIVE POSITION.........................................................................15
11.2. MICROPHONE CONNECTION ON SOUND2SIDE..........................................................15
12. CALIBRATION .........................................................................................................17
12.1. MOVEMENT AND SELECTION KEYS...........................................................................18
12.2. SOUND 2CONFIGURATION........................................................................................19
12.3. CALIBRATION DISPLAY.............................................................................................21
12.4. CALIBRATION PROCEDURE.......................................................................................22
13. OUTPUTS SIGNALS.................................................................................................23
14. THRESHOLD SIGNALS..........................................................................................25
15. COMMUNICATION.................................................................................................26
15.1. SUBDCONNEXIONS (MODBUS RTU).....................................................................27
15.2. SUBDCONNEXIONS (PROFIBUS DP).........................................................................27
15.3. ETHERNET CONNEXION (MODBUS TCP) ................................................................28
16. TECHNICAL SPECIFICATIONS...........................................................................29
17. MAINTENANCE .......................................................................................................30
17.1. POWER SUPPLY CONNECTOR....................................................................................30
17.2. UPDATE SOFTWARE..................................................................................................30
17.3. UNDESIRABLE FREQUENCY INFLUENCE ...................................................................31
17.4. HOW TO REPLACE SOUND 1BY SOUND 2.................................................................32
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SOUND2.943.001-E.e
1. Introduction
Thank you very much for having chosen the monitoring system for mill Sound 2.
This system has been used successfully on mill all over the world and will certainly work to your
entire satisfaction and your plant.
Sound 2 meets the following European standards:
CEI61326-1(07/2012) for measure materials.
EN61010-1(2010) for security
The present manual should help to make you acquainted with the functions of the monitoring system
and will give you some advice as to installation in order to get the best possible information back
from your mill
2. Checking on receipt
Sound 2 is delivered to you in a specially adapted packing.
Check this packaging for traces of mechanicals shocks or other major damages.
Check the states of the contents and immediately announce any damage to the transport agent.
3. Caution
Warning!
Never connect a housing, which has been seriously mechanically damaged or
which is visibly humid.

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4. Supplies
Sound2 is composed of the followings elements:
[1]: A microphone in its adjustable support
[2]: A connector for the microphone cable
[3]: An electronic unit
[4]: A connector for the power supply cable
Connecting cables (not included):
oCable recommended: Standard Hasler reference: 0631.0007
(type LIYCY DIN47100 from NEXANS LIFLEX 2x0.22 or equivalent.)
•Microphone cable
Single pole, shielded type (Gauge A.W.G : 22-24)
Diameter between 2.5mm and 7mm.
Standard HASLER
Cross section: 0.25mm²
Outer diameter: 2.6mm
Weight: 11KG / km
Maximum length : 500m
Particularities: Excellent resistance to compression and to reverse bending, no flame
propagation
•Power Supply Cable
Type 3x 0.75mm²
Diameter between 6mm and 9.5mm
[1]
[2]
[3]
[4]

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5. Microphone Installation
The microphone fitted with two holes (diameter 13mm) 120mm spacing,
has to be set with a rigid support.
Firstly, the needed cable length has to be determined and the microphone interface must be
assembled.
The cable has to be protected by a sleeve up to the microphone connector.
It is advisable to set firstly the microphone on a temporary support in order to find the place, where
the maximum signal is obtained.
Picture 1 : Microphone system dimensions
Warning!
The microphone cable must be absolutely protected against electro magnetic
perturbation (avoid same cable path for power cable especially from motor).

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The microphone has to be placed under the mill at the ball’s impact point.
The impact point is situated more or less at the “four o’clock” position (120° to 140°).
Longitudinally, the area to monitor is situated at approximately 1 to 1.5m from the diaphragm,
or at 2/3 of the first chamber.
Figure 2 : Mill description
Figure 3 : Microphone placement (Ball’s impact)
The microphone interface must be installed closer to the mill in order to have the best capture
of the signal and in order to minimize the others mill influences when all mills are installed in
the same room.
The microphone support must be a solid construction because any accidental displacement
which could cause irremediable damage.
The microphone head is adjustable to 360°. A vertical or horizontal support can be used.
Material
Entrance
Output
Warning!
Set the microphone only after the mill has been running several hours
because of its dilatation.

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6. Installation of the electronic housing
The electrical housing can be installed:
•Near of the ball mill, on a wall of beam (remove the DIN rail mounting clip)
•In a cabinet.
The Sound 2 Electronic housing is guaranteed IP65.

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7. MOUNTING SHIELDED CABLES
IN THE CABLE GLANDS
7.1. CABLE PREPARATION
The interfaces are connected by shielded cables. These cables pass through shielded cable
glands.
Prepare the cable like below
7.2. CABLE MOUNTING
Contact disks (D): Nickel plated brass.
The threaded connector connects the shielding braid to the earthed unit.
12
D
D
Cable C
Cable characteristics: (c)
Shielding: braided copper
Maximum distance: 500 m
Wire resistance: < 40 /km
Important:
The cable shielding (c) must be connected
at both ends to the corresponding terminals
for the differential voltage to be lower than
30 V
OR
up to 9.5mm

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8. Connection diagram
Figure 4 : Connection diagram
P
EN P
Internal Power Supplies
Microphone
J1 (1) J1 (2)
Cross Talk In
J7 (1) J7 (2)
Cross Talk Out
J11 (1) J11 (2)
Filling Level
0-4 / 20 mA
J10 (1) J10 (2)
Filling Level
0 – 10 V
J3 (1) J3(2)J10 (1) J10 (2)
Digital Outputs
J2 (1-2) J2 (3-4) J2 (5-6) J2 (7-8)
J9
J4
J22
AC/DC Converter in 230V Version
DC/DC in 24V version
+
-
Service Port
J8

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9. Electrical interface
Unscrew and remove the lower cover to use the terminals.
J1: Microphone Input: Connected to
the microphone by a single pole
cable, shielded type (Gauge A.W.G:
22-24) diameter between 2.5mm and
7mm.
J2:Digital Outputs
J3: Analog
Output
0 / 10V
J10: Analog
Output
0/4-20mA
J11: Diaphony
OUT
J7: Diaphony
IN
J4:
Communication
Profibus DP
MODBUS RTU
J9:
Communication
MODBUS TCP
J22: Future
Connexions
Picture 5 : Sound 2 Interface
All the electrical cables must be shielded.
The shield must be connect to the ground reference (cable gland)

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10. Connection
10.1. Power Supply connection
Characteristics:
•Input : 88 –264 VAC Current: 0.4/0.7A
•Output : +12V 2.1A
Caution: The power supply cable is a non removable connector. It’s a permanent connection.
Deactivate the switching device before disconnect the equipment to prevent electrical shocks
The power supply is connected directly on AC/DC converter.
Check the serial number of the electronic box, it must be 2516.1000
Before connecting power supply, check the presence of a circuit breaker and
current protection (10A) upstream of Sound 2 supply line.
The protection devices (Switch and current protector) must be accessible
The name of the product :”Sound 2” Must be write visibly and near of the
protection devices
The power is fed through a round connector.
Disconnect the plug and attach a sector conductor at least 3 x 0.75mm² to the connector screws terminal.
Fix the cable with the holder, replace the covering cap and firmly tighten the rubber seal
1
L
2
PE
3
N
4
1 : L
2: PE
3: N
4 :NC

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10.2. Microphone connection on ear side
Reference connector is
DELTRON 592-0301
There is 6 elements
Insert the two plastic
pieces in the connector
body
Insert the cable into the connector
Then put the pins into the connector body and
connect the screw on the connector
Now you can connect the connector to the
microphone.
Check the microphone impedance
She must be < 50 ohms

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11. Installation
11.1. Microphone definitive position
As mentioned in chapter 5, the microphone is provisionally located at the “four o’clock” position, at
approximately 1m to 1.5m from the diaphragm, or 2/3 of the first chamber.
Important:
The position of the microphone must be checked and eventually
corrected in the following cases:
•For the first time, approximately after 3 months of
machine operation, when the grinding balls have stabilised
themselves and when the mill works at his maximum load.
•After any important changes of the grinding balls.
•At least once of years.
11.2. Microphone connection on Sound2 side
Sound
Input
J1
1
2
Sound 2
Board
Input +
Input –
(Ground)

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Cable recommended:
Input characteristics:
•Input level 0... 700mV on a resistive impedance of 35KΩ to J1
•EMI Immunity: 2KV
•Terminal Phoenix contact SPT2.5/2-V-5.0 (wire cross section: 0.14 to 2.5mm²)
•Hasler reference 0631.0007 screened 2x0.75 mmcable are used:
connect like this photo and connect the shield of this cable to the cable gland of the SOUND2

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12. Calibration
Filling Level
Wait Calibration 27.5°C
50%
Max Frequency : 1857 Hz
Max Power : 4560
Upper Threshold : 80%
Calibration
Alarm
Contextual
selection
Back
Escape
Menu
Home
Enter
Down
Up
Figure 7 : Functions keys on keyboard

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12.1. Movement and selection keys
The “Main” page which is the default page out of any selected menu,
can always be called directly with the key 'Home"
To call the menu page, press the key "menu"
To scroll up or down inside any list press the keys “Up” or “Down”
located on the right side of the screen.
The selected line appears with a grey background.
Once a menu selected, the access is given
by the key "Enter"
Some menus or lists may be longer than the maximum
number of lines available on the screen. An action on the
“Down” key when the last line is highlighted will move all the
lines upwards to show the following lines of the bottom.
With the same keys “Down” and “Up” the variable to reach will be
selected and displayed with enter .
Press to come back to the title of the menu or sub-menu

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12.2. Sound 2 configuration
-Power on the Sound2,
-Press the Menu key (see Figure 6), then select System and Security.
-The following pages appear successively. The current security level is Operator.
-Change to “Maintenance” level: Required password is “1000”
-Update software in 1.0.0.17 or higher are required as describe in §17.2.
-After updating with DSP software 1.0.0.17 or higher and CPU software 1.0.0.17 or higher,
the software version page will show the following information.
System 27.5°c
General
Security
Security 27.5°c
Password
Command Origin: Principal
Com. Orig.config
Security Level: Maintenance
Security 27.5°c
Security Level: Operator
CPU Board SW : 1.0.0.17
SW DSP : 1.0.0.17
CPU Board HW Type :3.0.0.0
Clean EEPROM Memory ?
Update DSP Soft
Software Versions 27.5°C
Update DSP Soft
Alarm
Parameters
Measures
Calibration
Cross Talk
Outputs
27.5°C
System

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-Press the Menu key (see Figure 6) , select parameters then Configuration
-Sound configuration parameters are
-Power used: This is the parameter used as reference to calibrate filling level.
A power is the amplitude of the sound signal at a given frequency. As reference we can used:
The sum of highest amplitude, the highest amplitude or the amplitude average in a defined
frequency range.
Every period of time, Sound2 perform the following operations:
-Acquire a continuous time signal from the mill
-Sample the signal in a set of 512 values in discrete time interval
-Compute 512 frequency components of the sound signal. Each component figures a power
value at a given frequency as shown below (Figure 7):
-The sum of these amplitudes(power) reflects mill filling level.
-Setting the parameter Power used to Highest powers means that only the highest values are
used in the sum.
-Setting Nb of Power to 100 means that, the 100 highest power values are used in the sum
-Rc Filter factor is the filter coefficient for the Filling level (smooth the fluctuation on filling
level)
-DspFilterLength is the filter coefficient for the power ( smooth the fluctuation on Power)
-Display mode: filling level or noise level
Figure 7: Power spectrum
Parameters 27.2°c
Power used : Highest Powers
Nb of Power : 100
Rc Filter Factor : 10
DspFilterLength : 10
Display Mode : Filling Level
Alarm
Measures
Measures
Calibration
CrossTalk
Outputs
System
27.5°C
Parameters
Measures
Inputs Sound Parameters 27.5°C
Configuration