IC600 Training Presentation v1 0
IC600 Training Presentation v1 0
IC600 Training Presentation v1 0
presentation
IC600 - Intelligent monitor and control
device for HP cone crushers in
Lokotrack applications
- LT200HP
- LT300HP
06.09.
2009
Benefits of IC
2 © Metso
IC600 system lay-out
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
5 © Metso
CAN bus connection in XM4 connector
PIN6 CAN 1L
XM4
PIN7 CAN 2H
PIN8 CAN 2L
6 © Metso
Connectors
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
- Don‟t press the control buttons • When main control center‟s key
with a screwdriver or any other switch is turn the control system
sharp object. It‟s best to press the starts for about 30 seconds,
control buttons with bear hands
without gloves.
then main window (0) is shown.
10 © Metso
IC600 display windows structure
0 - Main
window
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
Alarm number
<
Reset popup
13 © Metso
Unit information (1)
Process Hydraulics
Crusher Time counters
Engine Gearbox*
Active function is
highlighted with a
colour.
14 © Metso
Process window (1.1)
Values are process‟
measured data
<
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)
18 © Metso
clogged =
Hydraulics (1.5)
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)
Clutch slip %
slipping clutched
21 © Metso
Production data (1.8)
Crusher Power
Date consumption
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)
Engine load %
Crusher power
23 © Metso
Chart window (1.9.1-1.9.4)
24 © Metso
Info window
Press -button to
go back to the previous
window back up down
25 © Metso
Process control (3)
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.
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
Screen direction
29 © Metso
Crusher manual control (3.4)
Lubrication pump
Accessory devices
Crusher
<
Belt loosening
30 © Metso
Parameters menu (4)
31 © Metso
Parameters - display & adjusting
32 © Metso
Crusher setting calibration (4.1)
Calibration date
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
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
Selection down / up
or
Previous letter / next letter
37 © Metso
Loading a parameter file to the display – 4.2.4
File name
38 © Metso
Display settings (4.3)
Date
Time
Language
System of measures,
metric / imperial
< Display‟s contrast
39 © Metso
User level lock (4.4)
40 © Metso
Diagnostics menu (5)
41 © Metso
Module diagnostics (5.1)
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
45 © Metso
Track drive and remote control diagnostics
(5.2)
Feed off/on
Control position
< Tracking / process
Track movement selection
slow /fast
46 © Metso
Push-button diagnostics (5.3)
47 © Metso
Alarm log (5.4)
Alarm number
<
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
<
Alarm counter
49 © Metso
Engine‟s non-active alarms log (5.5.1)
Suspected Parameter
Number
<
Alarm counter
50 © Metso
Parameter changes log (5.6)
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
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**
53 © Metso
Operations with IC600
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
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.
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
• Integartion time is increased
only a one second
Measurement • Control is no longer vibratin, but
still undershooting clearly
Target
• 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
70 © Metso
Moving the unit
71 © Metso
Hydraulics, adjustments
Message field
73 © Metso
Diagnostics, Alarms
74 © Metso
Diagnostics, Engine
“Fault location”
(Suspected
Parameter Number)
Fault
events
75 © Metso
Diagnostics, modules
Module name
76 © Metso
* Depends from the pin type
77 © Metso
Diagnostics, module outputs
78 © Metso
Questions?