IC50 sales manual

Version 0.3
Content

1. Introduction..........................................................................................3
2. Main functions of automation ..............................................................3
3. Technical information ..........................................................................6
4. Main features .......................................................................................7
5. Benefits................................................................................................8
6. Competitor comparison........................................................................9

Due to a policy of continuous development the right is reserved to make

changes in specifications and design without prior notice.

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1. Introduction
The Nordberg Intelligent Controller (IC50) has been designed to

• ease the usage of crusher

• ease service and fault diagnosis
• increase productivity and crusher's life-cycle
• protect users and equipment
• offer open link to various factory automation systems
• provide the operator necessary information and control functions for
optimized machine utilization.

IC50 has been developed for use on GP series crushers.

2. Main functions of automation

The main functions of the IC50 are:
1. protection of users and machine
2. diagnostics of control system and machine
3. monitoring of control system and machine
4. machine and process control
5. logging of control events and production data
6. data communication to other systems

How the machine is protected?

• AGAINST OVERLOADS: Feed is stopped, setting is opened or
crusher is stopped in case of overload situation (high power or
pressure).
• AGAINST DEVICE FAULTS: Operating system (lubrication unit,
crusher, feeding device) is stopped if any safety device of that
system has tripped.
• AGAINST ENVIRONMENT: Lubrication system is protected
against low/high temperature, low oil level and low oil pressure.
• AGAINST MISUSAGE: Operating systems are interlocked to
avoid incorrect starting/stopping order.

How the machine is diagnosed?

• CONTROL ACTIONS: The message field informs the operator
about the machine status and automated or operator actions. In
failure situations a pop-up window is displayed with information
about the failure; what has happened and why. Repairing
information can also be found.
• ACTION HISTORY: All the operationally necessary events are
displayed and listed with a time tag. All the alarms and warnings
are listed on a separate screen with additional information.
•
• DEVICE CONDITIONS: Sensor signal values, contactor and
switch statuses are available on a I/O window

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What is monitored?
• Power
• Crushing pressure
• Crusher setting
• Lubrication temperatures (tank and return)
• Material level inside the cavity
• Lubrication filter condition
• Lubrication pressure
• Running statuses of devices
• Oil level status
• Oil flow status
• Belt scale (if connected)
• condition of safety devices

What is controlled?
Lubrication system
Immersion heaters start when tank temperature is too low and stop
when it is high enough. Fan cooler operates as an opposite to heating.
All limit values are adjustable.

Lubrication pump is started and stopped by the operator requests

through the system. Starting/stopping of all devices is possible to do
sequentially and individually.

Crusher setting is controlled and adjusted according to setting presets

and load of the crusher.

All motors are protected from too high current by safety switches.
Operation of a device is disabled if safety switch is tripped.

Crusher
The crusher drive motor is interlocked with the lubrication system to
ensure crusher lubrication in all situations. Crusher is protected against
overloads and device faults.

Feeding device
Automation stops the feeder when high material level or crusher
overload situation is detected.
IC50 can control the variable speed feeder to optimize both cavity level
and power draw. PI controller is used for tuning the feeder speed.

What data is logged?

• 10 days of operating data is stored within the system. Running
time, crushing time, production, accumulated kWh above idle
point and energy consumption is available.
• Total crushing time is saved and shown on a display.

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 • Power, setting, pressure, temperatures, production, cavity level
and feeder speed can be trended. Trending is displayed in 6
minute, 60 minute, 6 hour and 24 hour views.
• 30 last calibrations are saved to calibration log.
• Parameter changes are also saved to the system.

What is needed for communication to other systems?

• Communication module (päätettävä miten nimetään)
• Configuration manual for communication set up
• ?

How the communication starts?

• Connect cables
• Configure network
• Map information to application

What can be communicated?

• Start/stop of all devices
• setting adjustment
• System diagnostics (system, device and sensor values and
statuses)
• History logs can be read
• Alarms can be read
• Parameters can be read and accessed
• and much more smaller details

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3. Technical information
IC50 system consists of three I/O modules and one display unit.

IC50 control cabinet Terminal box

of the
lubrication unit

Display
• Monochrome ¼ VGA LCD-display
• Embedded 486 microprocessor
• Operating voltage 24 VDC
• Dimensions 120 x 181 x 53
• Enclosure class IP65
• Operating temperature range -10°C … +45°C

I/O module
• Operating voltage 24 VDC
• Dimensions 147 x 113 x 35
• Enclosure class IP67
• Operating temperature range -40°C … +70°C

Communication protocol between display and I/O modules is

CANopen.

Higher level communication directly from the display is CANopen, other

protocols are also available through separate gateway (communication
module).

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4. Main features
Full machine protection
• Against overloads, misuse, cable breaks and sensor failures

Sequence start and stop

• System checks that the devices are in condition and starts/stops
them in the right order.

Manual mode
• Manual mode allows the operator to have complete control of
the crusher via display. Automation only ensures the machine
operates within safety limits.

Local mode
• Local mode allows the operator to adjust the setting from the
local control panel. Automation only ensures the machine
operates within safety limits.

Setting mode
• Adjusts the crusher to a desired setting.
• Opens the setting in overload situations and returns the main
shaft back to preset value after the load reverts to normal.

Load mode
• Automation adjusts the setting to get the crusher operate at the
wanted load level. Both power and pressure are monitored.

Feeder control modes

• High level detection where feeder is stopped on high material
level and restarted after a delay when acceptable level reached.
• PI controller controls variable speed feeder. Target level for
material or power draw can be set. Ultra sonic level sensor is
used for sensing material level in the cavity.
• Advanced logic is used for controlling the feeder speed to
maintain optimal cavity level. A digital (on/off) sensor is used to
detect the material level in the cavity.

Winter mode
• Winter mode function keeps the crusher warm when it is not
operating. Lubrication oil is heated and circulated through the
crusher to keep it ready for instant operation.

Calibrations
• Manual calibration (with lead)
• Contact calibration (metal to metal)
• Wear compensation

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 Password protection
• Parameters are categorized into 3 different levels. These levels
can be password protected.

Data log
• 10 days of operating data is stored within the automation system
• Last 50 alarms and events are recorded
• Last 30 calibrations are saved to the system
• Last 100 parameter changes are recorded

Other
• IC50 is capable of operating without display unit.
• Several languages are available.
• Pressure peak counter to avoid excessive crusher load.
• Liner wear indication

5. Benefits
Advanced diagnostic helps to track down problems
• Detailed alarms with online help
• System inputs and outputs shown
• Historical information of most important system activities

Total machine protection eliminates downtime

• Instant reaction to any abnormal and unsafe happening

Integrated feed rate control ensures a choke feed crusher, which

increases product cubicity
• Different feeder control modes available to ensure appropriate
solution for each crushing application
• Advanced level sensing technology used for accurate cavity
level monitoring

Liner wear surveillance helps to predict maintenance days

• Wear per cent displayed on screen

Crusher can operate at the maximum operational limits while still in full
protection of overload and component breakdowns
• power monitoring
• pressure monitoring

Readiness for instant operation in cold environment

• Winter mode function

Automatic functions eliminate the need for continuous human

surveillance

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6. Competitor comparison

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