IC600 series

presentation
IC600 - Intelligent monitor and control
device for HP cone crushers in
Lokotrack applications
- LT200HP
- LT300HP

06.09.
2009
 Benefits of IC

• Standard electrical system in all

LT-units
- main control center
- engine control center
- hydraulic control center
• Same SW in all machines
• System language selectable
parameter
• All I/O modules are the same
-> one spare part with
automatic program
downloading
• Improved diagnostics
• Online help system

2 © Metso
 IC600 system lay-out

• IC600 controls Lokotrack‟s:

- Feeder

SAE
- Conveyors
• Lifting, main, re-circulating,
DCM HUB ECM
by-pass and side conveyors
- Screen
- Engine
< UCD HCM SCM - Crusher
• Lubrication
- Tracks
Module: Location:
DCM = Device Control Module Main control center, inside
HUB = Power supply unit & hub junction module Main control center, inside
ECM = Engine Control Module Engine module
UCD = Unit Control Display Main control center
HCM = Hydraulics Control Module Hydraulics center
SCM = Screen Control Module Screen

3 © Metso
 Control module

XM1 XM2
• I/O module has four male
connectors.
• XM4 is in use for CAN bus and
the operating voltage for the
module.
• In electric drawings the inputs
< and outputs are named
according to connector.
- Example:
DCM XM1.14 = DCM module,
Connector XM1, pin14. Pins are
numbered in the bottom of the
XM4 XM3 connector.
-CAN-bus
-Operating voltage

4 © Metso
 Hub junction module

• Hub junction module has five

male connectors.
• XH1, XH2, XH3, XH5
XH5 XH1 distributes CAN-bus &
operating voltage to display
and I/O modules.
<
XH2
• XH4 is the socket to power the
control system & emergency
XH4 XH3
stop identification.

5 © Metso
 CAN bus connection in XM4 connector

• XM4 connector connects each

module to CAN bus and
PIN1 GND
deliveries power for modules.
Each module power and CAN PIN2 CAN 1H

bus connection (XM4) is similar. PIN3 CAN GND

PIN4 +24 Vdc

< PIN5 +24 Vdc

PIN6 CAN 1L
XM4
PIN7 CAN 2H

PIN8 CAN 2L

6 © Metso
 Connectors

Plug and header assembly colors Header assembly

are mechanically keyed to mate (inside a module)
only with identical colors.

Mating
seal

<

Wedge lock

Housing

7 © Metso
 Unit Control Display

Connector
labels and
• XM1, 8 pins
XM1 part number - operating power to display
- CAN connection
- CAN2 connection for upper level
automation
• XM2, 23 pins
- service key connection
< - USB connection for program
downloading

XM2

8 © Metso
 Main Control Center
4 5 6 7

1. Emergency stop

2. Lubricating unit

3. Radio key

4. Water pump

5. Display

3 8 6. Process start
<
7. Key switch
2 9
8. Signal horn
11 9. Process stop
1
10. Working light
10
11. Driving light

9 © Metso
 Using Unit Control Display

• Five control buttons

- Control symbols on display shows
the function of the control button in
current window
• if no symbol, then no function
Symbols - 2nd button always opens info
Control window
buttons
Info

- Don‟t press the control buttons
with a screwdriver or any other
sharp object. It‟s best to press the
control buttons with bear hands
without gloves.
• When main control center‟s key
switch is turn the control system
starts for about 30 seconds,
then main window (0) is shown.

10 © Metso
 IC600 display windows structure
0 - Main
window

1 - Unit 2 - Info 3 - Process 4 - Parameters 5 - Diagnostics

11 © Metso
 Main window (0) User level
= 0, operator level
Active control device (radio = 1, technician level
or cable image) in window 0
Fuel level = 2, Metso Minerals service level
(In any other window)
Time
Symbol describing the
window
Feed speed Cavity level *

Crusher power

Crusher setting
Engine RPM
< Values are shown
Crusher RPM
numerically and with Message field
graphic bar. Colors are
according to system * If digital level sensor
settings. is selected symbol
Unit information Process Diagnostics is shown when cavity
level is high
blue = idle Info Parameters
green = normal
yellow = high
orange = max.
red = excessive
12 © Metso
 Alarm popup

In any window the alarm

popup is shown on top of
the window.

Alarm number

<

Reset popup

Alarm specified information

13 © Metso
 Unit information (1)

Process Hydraulics
Crusher Time counters

Engine Gearbox*

< Crusher info charts Production

Active function is
highlighted with a
colour.

* The symbol is showed if Press ok to Use arrow buttons to

gearbox drive is selected. enter to the choose the function
active function

14 © Metso
 Process window (1.1)
Values are process‟
measured data

Feeder control % * Crusher setting

Feeder speed * Crusher speed
Feed hopper
material level * Crusher power
Lifting conveyor control % Generator statuses
& speed *
< Crusher cavity
Generator frequency /
voltage
level

* optional equipment Generator statuses

= normal temp
= high temp
= voltage OK
= frequency OK
= no voltage
15 © Metso
= no frequency
 Crusher window (1.3)
Values are crusher‟s
measured data

Feed status and feed Crusher cavity

control % material level*
Clamping and release
pressure switch state
Crusher‟s setting
Cooler status
Crusher‟s status and
Lubrication oil tank rpm
< status
- level - heater Main conveyor‟s
- pump - tank temp status
- pressure Crusher power

Lubrication functions Status symbols: stop

(see next slide) pause * If digital level sensor
is selected symbol
feed with min speed
is shown when cavity
running, normal speed level is high
running, fast speed
16 © Metso
 Lubrication oil tank status

Lub. Pump speed and

status Oil pressure status
arrow=on, no arrow=off pressure symbol = pressure OK
no pressure symbol = no pressure
Lub. oil level ! = switch fault
black=ok
red blinking=low level) Oil line to crusher
blue = pump not ready
Heater green = ok to start
(red=on, white=off)

<
Oil temperature in tank
Return oil temperature,
numeric and color
blue = crusher not ready
green = normal temp
red = high temp

17 © Metso
 Engine (1.4)

Engine coolant temp Engine actual rpm

Engine load % Engine target rpm

Engine oil pressure Coolant level

Hourmeter Charged air temp

Fuel consumption Air filter status
<
Voltage Cooler‟s control
current
Coolers speed is
control current
Coolant level
0 = no coolant conversely
1 = coolant ok

Air filter status

ok =

18 © Metso
clogged =
 Hydraulics (1.5)

Hydraulic oil temp Crusher pressure ***

Hydr. oil filter status * Pump pressure
current ***
Hydr. oil level ** Engine load %
Device pump pressure Icons are shown
if hydraulic drive is
< selected

* Filter status ** Hydr oil level *** optional equipment

ok = ok =
clogged = low =

19 © Metso
 Counters (1.6)

Process equipment
hourmeters, category 1

Track-drive Feed
Process
Crusher
Lubrication pump Fuel consumption
Lubrication pump
Engine
< Crusher
Clutch‟s operating times * Engine

Hourmeters, category 2
* Optional for service interval

20 © Metso
 Distribution gear & clutch (1.7)

Hydraulic control pressure

Clutch slip %

Clutch shaft rpm

Crusher v-belt pulley rpm

Distribution gear oil temp
<
Clutch status
no image = unclutched

slipping clutched

21 © Metso
 Production data (1.8)

Crusher Power
Date consumption

Process on -hourmeter Crusher on load

-hourmeter

< Production data log will be

stored for eight weeks (56
days).
After this it will be erased
by new production data.

Erase log
(User level 2 = service mode only. Press
buttons 4 & 5 for 3 seconds to change
button 3 to Erase log -button)

22 © Metso
 Crusher charts menu (1.9)

Chart of four different

value measured can be
choosed.
Feed control %

Engine load %

Crusher power

< Lubrication temperatures

23 © Metso
 Chart window (1.9.1-1.9.4)

Chart is being scaled

according the highest
measured value. Chart line color
indication

< Chart based on

measured data Time axis
is set to 60 min

24 © Metso
 Info window

Info window can be

opened by pressing
-button Info text and it‟s
number.
Each window has it‟s own Texts are according to
info text. selected language.

Use arrow buttons

< to scroll up / down the info

text.

Press -button to
go back to the previous
window back up down

25 © Metso
 Process control (3)

Manual feed control Feed automatic /

Target feed control *** manual mode
Crusher speed
control
Lubrication oil Lokotrack manual
heating control
Crusher manual
controls
<

Screen (with can control)** Process options

***Target feed modes
** optional equipment
Target power mode:

Target level mode:

26 © Metso
 Manual use of Lokotrack (3.1)
Engine and generator‟s Main conveyor
voltage status

Feeder * Screen
Screen‟s undersize
Lifting conveyor
conveyor*
By-pass conveyor * Screens side conveyor
Side conveyor * Screens hydraulic
support legs
Re-circulating conveyor * Hydraulic outlet
Engine rpm control
<
Dust removal unit on *
Hydr oil cooler on
Engine cooler on Dust removal unit
- If engine is off devices can be manually controlled. vibrating on *
- If engine is running hydraulic devices can be manually controlled. Safety devices will affect. Generators
output voltage status has to be OK to control electrical devices manually.

Device statuses: = OFF = running

= ON = not running
Power supply: = Engine stopped = Electric power OK
= Engine running = Electric power disabled
27 © Metso
 Screen module manual control (3.2)

Screen‟s direction
Side conveyors speeds
and control % Screen speed and
control %

<
Undersize conveyor
speed and control %

Side conveyors and discharge conveyor have same maximum oil flow. Conveyors
speeds can be changed, but if control value is increased over 100%, then the other
conveyor(s) control value is decreased by the same amount.

28 © Metso
 Process options (3.3)

Hydraulic outlet

Side conveyor

Dust removal
Return conveyor

< Bypass conveyor

Screen direction

29 © Metso
 Crusher manual control (3.4)

Heater Belt tensioning

Cooler

Lubrication pump
Accessory devices
Crusher
<
Belt loosening

* Showed icons are depended

from the crusher drive types

30 © Metso
 Parameters menu (4)

General (G) Setting calibration

Feed (F) Parameter tools
Crusher (C) Display settings
Tracking (T) User level
< Engine (E) Programming

Distribution gear, Katsa (K)

Hydraulics (H) Screen (S)

Lubrication (L) Alarms (A)

31 © Metso
 Parameters - display & adjusting

Parameter selection Display and adjusting

Parameter letter and metric / imperial
number.
- Adjusting is done
with metric system
General, G
Feed, F
Crusher, C
< Tracking, T Parameter description
Engine, E
Distribution gear, K
Hydraulics, H
Lubrication, L
Screen, S
Alarms, A

32 © Metso
 Crusher setting calibration (4.1)

Crushing time since

last calibration

Calibration date

Used crusher power

Current crusher setting since last calibration
<

Calibration value

33 © Metso
 Parameter tools (4.2)

Save parameters

Load parameters
Save parameters
to USB memory
< Load parameters
from USB memory

34 © Metso
 Data transfer of parameters from system to a
file – 4.2.1

File name
Rename file
New file Delete file

File transfer progress

bar, percentage value
< Save parameter group
0–100%

Selection down / up
or
Previous letter / next letter

35 © Metso
 Parameter data transfer from file to system –
4.2.2

File name
Rename file
Delete file

File transfer progress

bar, percentage value
< Parameter data transfer
0–100%

Selection down / up
or
Previous letter / next letter

The new parameter settings replace the old

settings, unless the old parameters were not
previously saved.
36 © Metso
 Saving parameters to USB memory – 4.2.3

File transfer progress

bar, percentage value
< Parameter data transfer
to USB memory
0–100%

37 © Metso
 Loading a parameter file to the display – 4.2.4

File name

File transfer progress

bar, percentage value
< Parameter data transfer
from USB memory
0–100%

Parameter data transfer is possible only when the

machine engine is switched off or the external
power source is switched off.

38 © Metso
 Display settings (4.3)

Date

Time

Language
System of measures,
metric / imperial
< Display‟s contrast

39 © Metso
 User level lock (4.4)

Input frame of user level 1

Input frame of user
level 1 lock code
Input frame of user level 2

< Display frame of the

generated level 2 lock
code

To open / close user levels User level

it is possible to use user = 0, operator level
level codes or a tool to
open the lock. N02495935 = 1, technician level
= 2, Metso Minerals service level

40 © Metso
 Diagnostics menu (5)

Modules Engine fault codes

Tracking, radio Parameter log

Push buttons Calibration log

< Alarms log Temperature log

41 © Metso
 Module diagnostics (5.1)

Modules and connectors

< Modules program

version info

42 © Metso
 Module pins diagnostics
How to read input / output data

<
Select module and the involved Value / status Module
connector from module diagnostics internal temp
window
I/O‟s pin number

43 © Metso
 Modules program version info (5.1.1)

Module
Version number
Publication date
Runtime version
(module low level
operating system)

<

44 © Metso
 Module program loading window

Module program loading

window will open
automatically if needed

Estimated remaining time

Loading progress bar

and percentage
When loading is ready,
< this image will appear
-> turn key switch to 0-
position

Do not cancel in the

middle of loading.

45 © Metso
 Track drive and remote control diagnostics
(5.2)

Cable remote / radio

Engine rpm - +
remote control active
Target rpm & rpm
increasing, decreasing
Track control %
Feed - +

Feed off/on
Control position
< Tracking / process
Track movement selection
slow /fast

46 © Metso
 Push-button diagnostics (5.3)

Radio key switch

Feed start Engine start
Feed stop Horn / beacon
Feed speed decrease Process stop
Feed speed increase
Process start
<

47 © Metso
 Alarm log (5.4)

Alarm number

Date Alarm counter.

Number of times the
Time alarm of this number
is activated

<

Erase log
(User level 2 = service mode only. Press
buttons 4 & 5 for 3 seconds to change
button 3 to Erase log -button)

48 © Metso
 Engine‟s active alarms log (5.5)

Suspected Parameter
Number

Failure Mode Identifier

<
Alarm counter

To non active engine

alarms log

49 © Metso
 Engine‟s non-active alarms log (5.5.1)

Suspected Parameter
Number

Failure Mode Identifier

<
Alarm counter

50 © Metso
 Parameter changes log (5.6)

Date Parameter‟s previous

and changed value
Time

Changed parameter

<

Erase log
(User level 2 = service mode only. Press
buttons 4 & 5 for 3 seconds to change
button 3 to Erase log -button)

51 © Metso
 Calibration log (5.7)

Time
Date Change to crushers
setting value caused
by calibration

Crushing time since last

calibration
<
Used crusher power
since last calibration

Erase log
(User level 2 = service mode only. Press
buttons 4 & 5 for 3 seconds to change
button 3 to Erase log -button)

52 © Metso
 Temperature history log (5.8)
Alarm limit counter
Warning limit counter

4 weeks average
temperature
Hydraulic oil
Engine coolant
Lubrication return oil
Lubrication tank oil
< Distribution gearbox oil**

** log is shown if gearbox Erase log

drive is selected (User level 2 = service mode only. Press
buttons 4 & 5 for 3 seconds to change
button 3 to Erase log -button)

53 © Metso
 Operations with IC600

NOTE! Read unit‟s user manual for safety issues

before operating the machine in any way!

54 © Metso
 Basic use
1. Start engine

2. Start Process
3.Control / Tune / Monitor the Process

55 © Metso
 Feed control, basic control
Feeder can be started by the user
or automatically by the IC system
Lifting
conveyor F27
control range After start the control
is restricted value is set by manual or
between automatic feed control
parameters
F26 & F27
F26
(F35 & F36)
F31

Lifting conveyor
acceleration and
Lifting conveyor min deceleration speed is set
speed running time is set with parameter FS25
with parameter F31 (F41) (FS78)

56 © Metso
 Feed control, Manual feed control
Feed speed: lifting conveyor and feeder speed can be manually
controlled from the IC. Feed start and stop buttons are same
regardles of control mode.
Increase/Decrease feed speed from the display, remote control or
from the service platform control box.
Set feed control to ‟M‟ (Manual)
Start feed if not already running

Feed control percent

Select for to increase feeder speed
Select for to decrease feeder speed

NOTE! There is interlocking between control positions. Control can be always made
from the display, if display‟s page 3 is open, then other devices are not enable. Service
platform control buttons are enbled only when display is not on page 3 and remote control
is not selected. Feed can be always stopped from all positions.
57 © Metso
 Feed control, Automatic (Target) control
TARGET POWER (Parameter FS97 = 1)
Feed speed is changed for to gain wanted crusher load. Target value
can be changed same way as feed control percent with manual control.

TARGET LEVEL (Parameter FS97 = 2)

Feed speed is changed for to gain wanted crusher cavity level. Target
value can be changed same way as feed control percent with manual
control.

Set feed control to ‟A‟ (Automatic)

Increase or decrease target value

58 © Metso
 Automatic Feed control, PID-Controller basics

Measurement
(level, power or Process
pressure)

Lifting conveyor
Target value
PID Controller / feeder
From the user
control

P = Proportional value
Parameters
I = Integration time
P, I (and D)
D = Derivation time

59 © Metso
 Automatic Feed control, PID Parameters
100% 100% P-Control
Target parameter value Feed control value

P * Difference
Measured signal Difference

t t

100% PI-Control
100% PID-Control

P * dM
I-time
D-time
P * Difference

t
t
60 © Metso
 Automatic Feed control, PID Tuning
P = 0.3, I = N/A, D = N/A
• Controller is set only for P
control
• P value is too low because
Target control reacts too slowly

• Signals
Measurement
- Target: Display‟s parameter value
set by the operator

Control
- Measurement: Cavity level or
crusher power
- Control: Feed control percent

40s

61 © Metso
 Automatic Feed control, PID Tuning
P = 0.6, I = N/A, D = N/A
• P value is now increased to 0.6
• Control is faster and starts to
slightly undershoot
Target

Measurement

Control

40s

62 © Metso
 Automatic Feed control, PID Tuning
P = 1.0, I = N/A, D = N/A
• P value is now increased to 1.0
• Control reacts too fast
• Control is undershooting and
causing too much load to the
Target
lifting conveyor and feeders
Measurement
motor
• Measurement is also far from
the target value, thereby
Control intgration is needed
• P value should be set to
previous value, set P to 0.6

40s

63 © Metso
 Automatic Feed control, PID Tuning
P = 0.6, I = 15s, D = N/A
• Controller is now set to PI mode
by setting the integration time to
20s
Target • Integration time is too long.
Measurement
Measurement is gaining target
too slowly

Control

40s

64 © Metso
 Automatic Feed control, PID Tuning
P = 0.6, I = 1s, D = N/A
• Integration time is now set to 1
second
Measurement • Control starts to vibrate. This
will cause excessive load to
lifting conveyor and feeders
motor and feed will be paused
Target
due high load.
• Increase integration time

Control
40s

65 © Metso
 Automatic Feed control, PID Tuning
P = 0.6, I = 2s, D = N/A
Measurement
Target
• Integartion time is increased
only a one second
• Control is no longer vibratin, but
still undershooting clearly
• Increase integration time

Control

40s

66 © Metso
 Automatic Feed control, PID Tuning
P = 0.6, I = 5s, D = N/A
• Integration time is now
increased to 5 seconds
Control
• Control is behaving very well
Target

Measurement

40s

67 © Metso
 PID-Controller, Tuning
P = 0.6, I = 5s, D = 0.1s
• Controller is now set to PID
mode with setting the Deritative
Control time to 0.1s
Target • Deritative time is so small so it
Measurement does not affect to the control

40s

68 © Metso
 Automatic Feed control, PID Tuning
P = 0.6, I = 5s, D = 0.5s
• Deritative time is no increased
to 5 seconds
• Control starts to
over/undershoot in the start
• D feature does not improve
control, so set it to 0,1s
• Controller should be now tuned
- P = 0.6, I = 5s
• Default values are:
- P = 0.8, I = 15s, D = 0.1s
• Note! The measured signal
filttering is also a key parameter
40s (see parameters CS88, FS85)

69 © Metso
 Changing crusher speed

Crusher speed can be changed by selecting the speed slider and

moving the slider from process control page. With clutch driven crusher
the slider changes engine rpm. With hydraulic driven crusher the target
speed is changed.

70 © Metso
 Moving the unit

• Unit has three driving speeds that is selected by increasing or

decreasing the engine revolutions (requested rpm)
• Unit movements can be controlled by using remote control (via radio)
or drive box (via cable)
• I/O module controls the proportional valve with voltage (Danfoss)

71 © Metso
 Hydraulics, adjustments

A. Set control from the IC system to moderately low level

B. Open the valve restriction screw
C. Start the device and measure the speed
D. Heat up the hydraulic oil to at least 40°C (?)
E. Increase IC‟s control value (current / control percent) untill the
maximum speed (specified in the hydraulic diagrams) is
achieved.
A. Lifting conveyor: Make sure that feed control (and F27 value) is in 100%
value.
B. Feeder: Make sure that feed control (and F36 value) is in 100% value.
C. Screen module: Increase side conveyors and undersize conveyor speed in
turns from the screen control page for to adjust maximum speeds. Set both
controls back to 100% and adjust nominal speed current values from the
parameters.
F. Tighten the valve restriction screw
72 © Metso
 Diagnostics, Messages
Engine start
• “Ask” from the system
what is wrong:
- Switch key switch to
start position
Process start - Press process start
• System gives a
message for to notify
why engine or process
is disabled

Message field

73 © Metso
 Diagnostics, Alarms

• System activates an alarm

when malfunction appears or
user attention is needed
• Press 2nd button for to
receive information regarding
the alarm (reason / result /
recover)
• Reset popup with 1st button
• Alarms does not have to be
Reset popup acknowledged

Alarm specified information

74 © Metso
 Diagnostics, Engine

“Fault location”
(Suspected
Parameter Number)

“ Fault mode” (Failure

Mode Identifier)

Fault
events

75 © Metso
 Diagnostics, modules
Module name

Select module and the involved Value / status Module

connector from module diagnostics internal temp
window
I/O‟s pin number
Software and
firmware versions

76 © Metso
 * Depends from the pin type

Diagnostics, module inputs

• DI (Digital Input), 2 stages, „0‟ (<1V* or <4.2V*), „1‟ (>2V* or >4.8V*)

• PI (Pulse Input), Frequency and Pulse count, <0.5/2.5kHz, „0‟

(<4.2V), „1‟ (>4.8V)

• AI (Analog Input), 16bit (65535 values), 0-22.7mA / 0-5V

• AI (Analog Input,+5Vsupply), 16bit (65535 values), 0-5V

• FB (Current Feedback), 15bit (32767 values), 0-1000mA

77 © Metso
 Diagnostics, module outputs

• DO (Digital Output), 2 stages, „0‟  0V, ‟1‟ 24V (Ubat)

• PWM (Pulse Width Modulated),Analog output based on PWM

signal‟s pulse ratio. 40-500Hz (max 2,5kHz)

• PWM + FB (Current control circuit)

78 © Metso
Questions?