IC5XXIC6xx Instruction Manual v3 En

IC500 / IC600 INSTRUCTION MANUAL

IC500 / IC600 Instruction Manual

Introduction This Instruction Manual refers to the controller used in LT units, manufactured by Metso Minerals (Tampere) Oy. To obtain the best performance from this product, please read this manual carefully. It will guide you in operating the IC500 / IC600 system. This Instruction Manual is valid for IC500 / IC600 controller. Because of the continuous development of the product, the manufacturer reserves the right to alter the technical specifications written in this manual, without any advance information.

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IC500 / IC600 Instruction Manual TABLE OF CONTENTS 1

PRECAUTIONS ...............................................................................................................................................5 1.1 HANDLING INFORMATION ...............................................................................................................................5 1.1.1 Storage..................................................................................................................................................5 1.1.2 Transport ..............................................................................................................................................5 1.1.3 Function Keys.......................................................................................................................................5 1.2 WELDING OF THE UNIT ...................................................................................................................................5 1.3 BATTERY CHARGING ......................................................................................................................................5 1.3.1 Quick Chargers ....................................................................................................................................5 1.3.2 Jump Starting .......................................................................................................................................6 1.4 CLEANING THE DISPLAY .................................................................................................................................6

2

GENERAL.........................................................................................................................................................7 2.1 2.2 2.3 2.4

3

IC500 / IC600 SYSTEM ...................................................................................................................................7 RUN MODE .....................................................................................................................................................8 ADMINISTRATION MODE .................................................................................................................................8 SERVICE MODE ...............................................................................................................................................8

DISPLAY WINDOWS .....................................................................................................................................9 3.1 STRUCTURE AND ORDER OF THE DISPLAY WINDOWS .....................................................................................9 3.1.1 Tracks movement ................................................................................................................................10 3.2 GENERAL INFORMATION ...............................................................................................................................11 3.3 DISPLAY SCREEN ..........................................................................................................................................11 3.3.1 Choosing the Language......................................................................................................................12 3.3.2 Adjusting the Display Contrast and Brightness .................................................................................12

4

STARTING THE PROCESS.........................................................................................................................12

5

STOPPING THE PROCESS .........................................................................................................................13

6

MAIN WINDOW (RUN MODE WINDOW)...............................................................................................14 6.1

HELP-WINDOW ..............................................................................................................................................17

7

UNIT INFORMATION..................................................................................................................................18

8

FEEDER ..........................................................................................................................................................19

9

CRUSHER.......................................................................................................................................................20

10

ENGINE...........................................................................................................................................................22

11

HYDRAULICS ...............................................................................................................................................23

12

TIME COUNTERS.........................................................................................................................................24

13

PROCESS OPTIONS .....................................................................................................................................25

14

MANUAL CONTROL OF DEVICES ..........................................................................................................27 14.1 14.2 14.3 14.4

15

TRACK-DRIVING WINDOW (OPERATION IN SERVICE MODE ONLY)........................................31 15.1

16

STARTING THE PROCESS WITH MANUAL CONTROL (JAW CRUSHER / IMPACT CRUSHER) ..........................28 STOPPING THE PROCESS WITH MANUAL CONTROL (JAW CRUSHER / IMPACT CRUSHER)............................28 CONE CRUSHER MANUAL CONTROLS ........................................................................................................29 STOPPING THE PROCESS WITH MANUAL CONTROL WITH CONE CRUSHER ..................................................30

TRACK DRIVE SPEED.................................................................................................................................32

PARAMETERS / SERVICE WINDOW ......................................................................................................33 16.1 16.2

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EDITING CONTRAST, TIME, DATE OR UNITS ...............................................................................................34 PARAMETERS ...........................................................................................................................................34 3/93

IC500 / IC600 Instruction Manual 16.2.1 Service parameter adjustment ............................................................................................................34 16.2.2 User editable parameters ...................................................................................................................35 16.2.3 Parameters .........................................................................................................................................36 16.3 ALARM PARAMETER .................................................................................................................................58 16.4 THIS CHAPTER IS RESERVED FOR FUTURE USE ..........................................................................................58 16.5 CONE CRUSHER SETTING CALIBRATION WINDOW (CONE CRUSHERS ONLY) ..............................................59 16.6 DIAGNOSTICS ...........................................................................................................................................61 16.7 TRACK DRIVE DIAGNOSTICS ....................................................................................................................62 16.8 PUSH BUTTON TEST .................................................................................................................................63 17

LOG FILES.....................................................................................................................................................64 17.1 ALARM LOG .............................................................................................................................................65 17.1.1 Alarm list ............................................................................................................................................66 17.2 DIESEL DIAGNOSTIC TROUBLE CODES (ACTIVE AND STORED) ................................................................72 17.3 TEMPERATURE HISTORY LOG ..................................................................................................................73 17.4 PARAMETER LOG .....................................................................................................................................73 17.5 FACTORY PARAMETERS ............................................................................................................................74

18

MODULE PROGRAM VERSIONS .............................................................................................................75

19

READING INPUT/OUTPUT MODULES DATA .......................................................................................76

20

REPLACING A MODULE............................................................................................................................77 20.1 REPLACING A CONTROL MODULE .............................................................................................................77 20.2 REPLACING A DISPLAY MODULE (UCD) ...................................................................................................77 20.2.1 Updating the HUB and I/O modules ..................................................................................................77

21

TROUBLESHOOTING .................................................................................................................................78

Appendices

1 2

Engine diagnostics codes SAE J1939 Input/Output list

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1

Precautions

1.1

Handling Information

1.1.1

Storage

Store the device control module (DCM), power supply unit and hub junction module (Hub), hydraulic control module (HCM) and engine control module (ECM) at a temperature between –50 oC and +85 oC (-58 oF and + 176 oF). Store the unit control display (UCD) at a temperature between –25 oC and +60 oC (-13 oF and +140 oF). (See Chapter 2.1 IC500 / IC600 system: Explanations of Abbreviations). 1.1.2

Transport

DCM, Hub, HCM and ECM: Dimensions: 147 x 136 x 46 mm. Weight: 0.7 kg (1.5 lbs) UCD: Dimensions: 182 x 120 x 53 mm Weight: 1.2 kg (2.6 lbs) 1.1.3

Function Keys

Always press the function keys with bare fingers. Do not press the keys with a screwdriver or any other sharp tool, as it will break the keys. Do not use gloves as you may by mistake press many buttons simultaneously. 1.2

Welding of the Unit

If any welding is to be done on the unit, care must be taken to protect the control system. ƒ ƒ ƒ ƒ

Stop the engine. Disconnect the earth cable from the batteries. Disconnect engine wire harness sockets from engine control module (Ref. Engine instructions) Fasten the earth cable of the welding device as close to the part to be welded as possible. Make sure that no welding current is able to pass through any bearings or electrical equipment.

1.3 1.3.1

Battery Charging Quick Chargers Do not use quick chargers or start boosters. The rough voltage control and interference of the above-mentioned devices may damage the components of the control system. If unit batteries need to be charged, remove the + and – cables from the batteries during charging.

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IC500 / IC600 Instruction Manual 1.3.2

Jump Starting

Jump-starting can be used to help the engine start if the batteries of the unit are unable to start the engine. Make sure that the power source voltage level corresponds to the control system (24 VDC).

Make sure the polarity is correct.

1.4

Cleaning the Display

Wipe the display with a damp, soft cloth.

Do not use material that may scratch or otherwise damage the surface of the window. Do not direct a jet of water on to the IC500 / IC600 display screen when washing the unit with a pressure washer.

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2 2.1

General IC500 / IC600 System

The IC500 / IC600 controller is used to control LT functions. IC500 / IC600 is a computer system designed for field operation, and it consists of five components: • • • • •

Device Control Module (DCM) Power Supply Unit and Hub Junction Module (Hub) Hydraulic Control Module (HCM) Engine Control Module (ECM) Unit Control Display (UCD)

Figure 2.1.1 Layout of IC500 / IC600 control system IC500 / IC600 controls the devices of the LT unit. The devices are: • • • • • • • • •

Feeder (LC/LC-Feeder) Crusher Main conveyor Side conveyor Magnetic separator Screen module Engine Hydraulic system Tracks

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IC500 / IC600 Instruction Manual IC500 / IC600 has three modes: a running mode, an administration mode and a service mode. The running mode is active when the machine is running normally. The administration mode is active when the user is making changes to the system. The service mode is active when an authorized person has entered a password to be able to change service parameters. 2.2

Run Mode

In run mode the system continuously monitors the machine functions and controls the operating devices. All functions are performed automatically and you do not need to interfere in the operation. You are only expected to give instructions if there is an emergency or malfunction when the system is run down. 2.3

Administration Mode

In administration mode you have access to certain system parameters. You can bring devices into use (magnetic separator, side conveyor, etc.) and change the values of the system parameters. You may change some parameters while the process is running, but some parameters require the process to be off. 2.4

Service Mode

In service mode the authorized user has access to all system parameters. Access is given with a password or with a hardware keylock.

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3 3.1

Display Windows Structure and Order of the Display Windows

Figure 3.1.1 Structure of display windows

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IC500 / IC600 Instruction Manual This structure will give you an idea of how the system is built. The figures refer to the number of windows. It will also show a path from one window to another. The explanations of the windows are given below: 0 1 1.1 1.2 1.3 1.4 1.5 1.6 2 3 3.1 3.1.1

Main window Unit information Feeder information Crusher information Engine information Hydraulics information Operation hour information Gearbox information (LT300HP) Help Process options Manual control Tracks movement

3.2 4

Manual control (LT300HP) Parameters: general, feeder, crusher, tracks, engine and hydraulics, update, alarms, language, supervisor access, contrast adjustment, time and units 5 Diagnostics / Troubleshooting 5.1 Track drive, control test (Radio button test) 5.2 Control keys and push button test 5.3 Log files 5.3.1 Alarm log 5.3.2 Diesel diagnostic trouble codes 5.3.3 Temperature history log 5.3.4 Parameter log 5.3.5 Factory settings (load/save) 5.4 Module program versions 5.5 HUB module 5.6 Device control module, XM1 input/output status 5.7 Device control module, XM2 input/output status 5.8 Device control module, XM3 input/output status 5.9 Engine control module XM1 input/output status 5.10 Engine control module XM2 input/output status 5.11 Engine control module XM3 input/output status 5.12 Hydraulic control module XM1 input/output status 5.13 Hydraulic control module XM2 input/output status 5.14 Hydraulic control module XM3 input/output status

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IC500 / IC600 Instruction Manual 3.2

General Information

UCD is mounted on the control panel of the unit. The UCD has a 16 bit, 4 MHz crystal display and five control keys (F1 – F5) which are used for the actual control operations. User interface gives you all the information you need about the system and the required actions.

F1 = Unit information

F2 = Help

F3 = Process options

F4 = Settings

F5 = Diagnostics/troubleshooting

Figure 3.2.1 Display The Help key function (F2) stays the same in every window. Thus you always obtain information on the window by pressing F2. 3.3

Display Screen

The system always opens to the main menu (window 0). The key symbols are displayed above the control keys. If the control key does not have any symbol above it, it does not have any function in that window. NOTE! The function of the control keys varies depending on the window you are in. In each display window you will find: • symbol of the window (excluding the main window) • running number of the window • time Use arrow keys F4 and F5 (not in the main window) to move to an action you want to. Choose or save the required information by pressing OK (F3). Version 2.5

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IC500 / IC600 Instruction Manual 3.3.1

Choosing the Language

Select the language in the display window 4 (see chapter 15). You do this by pressing the F4 function key in the main window. 3.3.2

Adjusting the Display Contrast and Brightness

Adjust the display contrast and brightness in display window 4 (see chapter 15). You do this by pressing the F4 function key in the main window.

4

Starting the Process

First, switch the power on with the unit key switch. The control system starts up when the power is switched on (see Fig. 5.1.1). Before starting the engine wait until main window appears. Turn the key switch to "Start engine" position and keep it there until the engine is running. Start the process by pressing the "Process start" –button in the control panel of the unit. (NOTE: The "Process start" –button is not in the UCD, see Fig. 5.1.1.) The system has a certain “Process start” sequence, which starts the devices of the unit in a specific order. Thus it is easy to use the unit. It also ensures that the devices are started in the correct order. There is a delay of 1 - 15 seconds between the start of each device. The message of the starting device is visible in the message field in the main window. You are able to start the process if (Message "Process enabled" in the message field): • • • • • • • •

Engine is running correctly Crusher is enabled Safety switches are not activated Hydraulic oil temperature is correct Hydraulic oil level is correct Hydraulic main valve is open The maintenance safety switch of the conveyor is not activated. Cone crusher lubrication oil temperature must be above 20oC/68oF

If the hydraulic oil temperature is below –10 oC (14 oF), the system will ask you whether to use the process cold start or the normal process start sequence. For more information, please refer to chapter 5, "Starting and Stopping", in the Instruction Manual of the unit.

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5

Stopping the Process

Stop the process by pressing the "Process stop" –button on the control panel of the unit. (NOTE: The "Process stop" –button is not in the UCD, see Fig. 5.1.1.) The “Process stop” sequence stops the devices of the unit in a specific order. The order is opposite to the start process sequence. The automatic stopping sequence ensures that the devices are stopped in the correct order. The delay between the shut down of each device varies from 5 to 45 seconds. If the process is disabled, the “Process stop” sequence is activated. For more information, please refer to chapter 5, "Starting and stopping", in the Instruction Manual of the unit.

Figure 5.1.1 Control center of the unit 1 2 3 4 5

Emergency stop Lubrication unit (option) Radio key Water pump (option) Display

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6 7 8 9 10

Process ON Key switch Signal horn Process OFF Work light

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6

Main Window (Run Mode Window)

When you start up the system the main window (run mode window) is displayed. In the main window you will see the key values of the crushing process. To access unit information, process options, settings or diagnostics, press the function key below the symbol. If you need more information about the main window press the help function key.

Figure 6.1.1 Main window with unit type LT95, LT105, LT1110, LT1213: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Feeder control % and control mode (M = manual, A = automatic) Crusher speed (rpm) Crusher pressure bar/psi Engine running speed (rpm) Engine load % Material capacity according to the belt scale (optional) Radio control / Drive box symbol Material level detector symbol visible when beam is blocked (C-Jaw only) Fuel amount Window number Time Unit information (=F1) Help (=F2) Process options (=F3) Settings (=F4) Diagnostics (=F5) Message field

Numbers 1 – 6 refer to the figures on the unit and on the window. Symbol field (7) shows whether the radio control or drive box is selected. If the crusher level sensor is blocked then that information is also shown in the symbol field. The message field (17) gives you information about the system status. Before the engine has started the message field informs you when the engine is ready for starting.

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Figure 6.1.2 Main window with unit type: LT200HP and LT300HP Explanations: 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Lifting conveyor feeder (LC-feeder) control % and control mode (M = manual, A = automatic) (LT300HP only) Lifting conveyor speed % (NOTE: M/A control method shown in position 1) Feed rate (Requested by the crusher cavity level * crusher speed, * crusher pressure) Crusher load kW Crusher setting mm / ‘’. Device pump pressure Radio control / Drive box symbol Cavity level symbol when high level Fuel amount Window number Time Unit information (=F1) Help (=F2) Process options (=F3) Settings (=F4) Diagnostics (=F5) Message field

Numbers 1 – 6 refer to the figures on the unit and on the window. Symbol field (7) shows whether the radio control or drive box is selected. If the crusher level sensor is blocked then that information is also shown in the symbol field. The message field (17) gives you information about the system status. Before the engine has started the message field informs you when the engine is ready for starting.

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Display messages during normal “Process start” phase: • • • • • • • • • • •

Process enabled Process starting Engine rpm increase to work rpm (10 sec ramp) Starting screen module conveyors (if equipped with s-module) Starting screen (if equipped with s-module) Starting magnetic separator Starting main conveyor Starting crusher Starting discharge conveyor Starting feeder Process running

If a cold start is selected, all of the above messages are shown except that the feeder is not started. The system shows a message: •

Process cold start, waiting for the machine to warm up.

When the machine has warmed up the feeder is started and the "Process running" message is shown. Messages are visible for 3 seconds after the "|Process running" status is achieved. Display messages during normal process stop phase: • • • • • • • • • •

Process stop activated Feeder stopped Discharge conveyor stopped Crusher stopped Main conveyor stopped Magnetic separator stopped Screen stopped (if equipped with s-module) Screen module conveyors stopped (if equipped with s-module) Engine to idle rpm Process stopped

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IC500 / IC600 Instruction Manual 6.1

Help-window

This is the Help-window of the main window. Press F2 in the main window and you obtain Help. To obtain more information, scroll the screen with arrow keys F4 (down) and F5 (up). All windows have their own help to assist and guide in unit operations.

Figure 6.1.3 Help-window

Press F1 to return to the main window.

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7

Unit Information

Press F1 in the main window to go to the unit information window.

Jaw

Impactor

Figure 7.1.1 Unit information (Jaw, Impactor, Cone)

Cone 1 2 3

4 5 6 7 8 9 10 11 12

Symbol of the window Feeder information (to the window 1.1) a) Jaw crusher information (to the window 1.2) b) Impact crusher information (to the window 1.2) c) Cone crusher information (to the window 1.2) Engine information (to the window 1.3) Hydraulic information (to the window 1.4) Time counters (to the window 1.5 ) Back (to the previous window) (F1) Help (F2) Enter (F3) Backwards (F4) Forwards (F5) Distribution gearbox information (LT300HP only)

Press F4 or F5 to select the data you want to enter. After this, press F3 and the device you want is selected. Return to the main window with F1.

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8

Feeder

Highlight the symbol of the feeder in the unit information window and press F3. You will obtain the feeder information window.

Jaw

Figure 8.1.1 Feeder information (Jaw, Impactor, Cone) 1

1c 2 3 4 5 6 7 8

9 9c 10 11 12 13

Impactor

Cone

Feeder speed ( LC-feeder) Symbol of the running status: = Stop = Running = Pause Lifting conveyor control voltage Manual/automatic operation Manual stop for feeder (start not enabled) Feeder speed decrease/increase Feeder valve control % Control voltage Crusher speed a) Number of material level alarms in a selected period of time (Automatic operation) (Jaw crusher only) b) Feed funnel up (Impact crusher only) c) Cone crusher material level in crushing chamber % (If digital sensor selected: level count / count time visible) Crusher pressure Crusher power kW Hydraulic oil temperature Feed rate % (generated by the IC600 ) Crusher high material level alarm count ( number of alarms / time period ) Secondary LT high load alarm

The values shown in this window are actual. NOTE: The parameters can not be adjusted in this window. Return to the previous window with F1.

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9

Crusher

Highlight the symbol of the crusher in the unit information window and press F3. You will obtain the crusher information window.

Jaw

Impactor

Figure 9.1.1a Crusher information (Jaw, Impactor, Cone)

1 2 3 4 5 6 7 8 9 10 11

Version 2.5

Crusher speed Number of material level alarms in a selected period of time Crusher operating hours Clamping pressure (Return rod cylinder pressure) Setting sensor Crusher pressure Control current of the jaw crusher hydraulic pump Status of the service platform control buttons + / - (setting) Status of the service platform control buttons 0 / 1 (setting direction) Control current of the impact crusher hydraulic pump Control current of the impact crusher adjust motor (LT1110 only)

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Cone

Figure 9.1.1b Cone crusher information 1 12 13 14 15

16 17 18

Crusher speed Clamping pressure ( 1 = ok , 0 = crusher start / feed prevented) Cooler symbol visible when cooler running Release pressure ( 1 = ok, 0 = crusher start / feed prevented) Lubrication pump running status: Pump speed with hydraulically driven lubrication pump 0 or 1 with electrically driven lubrication pump –Lubrication tank oil temperature C / F. Symbol is blinking when heater is on. Return oil temperature C/ F Feed state: Symbol of the running status: = Stop = Running = Pause

19 20 21 22 23 24 25 26

Feed rate % Crusher power kW Material level in crushing chamber % Crusher setting Counter shaft pressure 0 ( off ) 1 ( on ) Main conveyor running state Crusher running state Message field ( same messages as in main view ) Note: Cooling fan symbol will appear only when the lubrication oil cooler is controlled on.

The crusher parameters shown in this window, are actual measured values. NOTE: The parameters can not be adjusted in this window. Return to the previous window with F1.

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10 Engine Highlight the symbol of the engine in the unit information window and press F3. You will obtain the engine information window.

1 2 3 4 5 6

7 8 9 10 11 12

Figure 10.1.1 Engine information 1 2 3 4 5 6 7 8 9 10 11 12

Engine coolant temperature Engine load Engine oil pressure Engine operating hours Fuel consumption System voltage Engine speed, required Engine speed, actual Engine coolant level % (0 = no coolant, 1 = coolant) Engine intake air temperature Engine intake air restricted (Filter condition indicator) Cooler fan control current (LT200HP only)

These are the actual engine values. NOTE: The parameters can not be adjusted in this window. Return to the previous window with F1.

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11 Hydraulics Highlight the hydraulics symbol in the unit information window and press F3. You will obtain the hydraulics information window.

1 2 3 4 5

6 7 8 9

Figure 11.1.1 Hydraulics information

1. 2. 3. 4. 5. 6. 7. 8. 9.

Hydraulic oil temperature (circuit # 1) Device pump pressure (pump # 1) Crusher pump pressure Hydraulic oil filter (0 = OK/ 1 = not OK) Hydraulic oil level (1 = OK/ 0 = not OK) Device pump pressure ( pump # 2) Lifting conveyor rpm Main conveyor rpm Screen discharge conveyor speed

Actual hydraulics information. NOTE: The parameters can not be adjusted in this window. Return to the previous window with F1.

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12 Time Counters Highlight the time counters symbol in the unit information window and press F3. You will obtain the time counters information window.

Jaw

Figure 12.1.1 Time Counters (Jaw, Impactor, Cone) 1 2 3 4

Impactor

Cone

Tracks driving active hours Process operating hours Feeder operating hours a) Impact crusher operating hours b) Jaw crusher operating hours c) Cone crusher operating hours

These are actual operating hours.

NOTE: The time counters can not be adjusted.

Return to the previous window with F1.

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13 Process Options Press F3 in the main window and you will obtain the process options window.

Jaw

Figure 13.1.1 Process options selection page (Jaw, Impactor, Cone)

Impactor

Cone (LT200HP, LT300HP)

1

Magnetic separator off/on Side conveyor off/on Screen rotation (counter-clockwise / clockwise) 4 Hydraulic output on continuously (1) 5 Hydraulic output off continuously 6(6a) Hydraulic output on during the process 6b Hydraulic output active when lubrication oil heating required 7 Manual control of the devices 7c1 Manual control of the devices 7c2 Manual control of the cone crusher functions 8 Selection of impact crusher target speed 1, 2 or 3 (2) 8c Selection of cone crusher target speed 1,2 or 3 9 Selected target speed 10 Feed stop button (feeder & lifting conveyor stop) 11 Feed speed adjust buttons. (buttons work only if Manual feed mode is selected (ic5x0 parameter F5 = 0, IC6x0 F40=0) 12 Lubrication oil heating sequence activation / deactivation 13 Engine rpm adjusting when crusher is running (engine rpm can be adjusted between the limit CS92 - CS93) 14 Crusher rpm value

2 3

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IC500 / IC600 Instruction Manual Move in the window with F4 or F5. Confirm your selection with F3. For example, move with F4 or F5 to the magnetic separator off/on button and choose either one of them. Press F3 to save the information. In this way you are able to select whether the magnetic separator is on or not. NOTE: If you want to edit the process options during the process, their validation becomes active only on next “Process start” (e.g. if you want to run the process without the magnetic separator you are able to select the magnetic separator off (0), but the separator keeps running until the process is switched off.) (1)

Hydraulic driven generator for the cone crusher can be activated with this button. When oil temperature is above +20oC (+68oF), deactivate hydraulic output. (2) To edit target speed, please see crusher parameters C24, C25 and C26 in chapter 16.2 Press F1 to obtain the main window.

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14 Manual control of devices Highlight the manual control symbol in the process options window and confirm your selection with F3. You will obtain the manual control window. Manual control for cone crusher, see chp. 14.3. The safety devices of the unit will stop devices when activated from the hard wiring side. The activation of the safety device will not disengage the control, which has been set in the on position. Special care must be taken when the manual control is used.

Jaw

Figure 14.1.1 Manual control 1 Main conveyor off/on 2 Side conveyor off/on 3 Magnetic separator off/on 4 Feeder off/on a) 5 Jaw crusher off/on b) Impact crusher off/on 6 Engine speed adjustment 7 Screen off/on 8 Screen conveyors (2 pieces) off/on 9 Tracks movement 10 Scalper off/on (impact crushers only) 11 Lifting conveyor off/on 12 By pass conveyor (visible only if in use) 13 Return conveyor (visible only if in use)

Impactor

Cone

Use F4 and F5 to move in the window. Confirm your selection with F3. To obtain the track window (3.1.1) move with F4 or F5 onto the track symbol and press F3 to access the window. NOTE: This window allows you to set which of the devices is on or off. If you select 0, it means the device in question is OFF. Number 1 stands for ON.

NOTE: This control method should only be used if: ƒ the system is not able to run the process normally or ƒ the unit is being serviced Version 2.5

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NOTE: No interlocking is valid when the system is running under manual control. The material level indicator is unable to control the feeder. The function of the manual control sets the selected output on/off according to the window 3.1.

14.1 Starting the process with manual control (Jaw crusher / impact crusher) Start the engine as instructed in chapter 5.2, “ Starting the Diesel Engine”, in the Instruction Manual of the unit. 1

2 3 4 5 6 7 8 9

Increase the engine rpm to maximum (CAT C9 & C13 value 2100 rpm / Cummins 5,9 value 2300 rpm) by highlighting the + button on the left side of the engine symbol (see Fig. 14.1.1 number 6). Press F3 as long as the engine is running with the requested rpm. If the unit has a screen module, start the screen module conveyors (see Fig. 14.1.1, number 8). Highlight button 1 and activate it by pressing F3. Start the screen (see Figure 14.1.1, number 7). Highlight button 1 and activate it by pressing F3. Start the main conveyor (see Figure 14.1.1, number 1). ). Highlight button 1 and activate it by pressing F3. Start the crusher (see Fig. 14.1.1, number 5a/b). Highlight button 1 and activate it by pressing F3. Start the magnetic separator (see Fig. 14.1.1, number 3). Highlight button 1 and activate it by pressing F3. Start the side conveyor (see Fig. 14.1.1, number 2). Highlight button 1 and activate it by pressing F3. Start the feeder (see Fig. 14.1.1, number 4). Highlight button 1 and activate it by pressing F3. Start the scalper (see Fig. 14.1.1, number 10). Highlight button 1 and activate it by pressing F3. (Only when LT1110/LT1213 impact crusher is selected).

14.2 Stopping the process with manual control (Jaw crusher / impact crusher) 1 2 3 4 5 6 7 8 9

Stop the scalper (see Fig. 14.1.1, number 10). Highlight button 0 and activate it by pressing F3. (Only when LT1110/LT1213 impact crusher is selected). Stop the feeder (see Fig. 14.1.1, number 4). Highlight button 0 and activate it by pressing F3. Stop the side conveyor (see Fig. 14.1.1, number 2). Highlight button 0 and activate it by pressing F3. Stop the magnetic separator (see Fig. 14.1.1, number 3). Highlight button 0 and activate it by pressing F3. Stop the crusher (see Fig. 14.1.1, number 5). Highlight button 0 and activate it by pressing F3. Stop the main conveyor (Figure 14.1.1, number 1). ). Highlight button 0 and activate it by pressing F3. Start the screen (Figure 14.1.1, number 7). Highlight button 1 and activate it by pressing F3. Stop the screen module conveyors (see Fig. 14.1.1, number 8). Highlight button 0 and activate it by pressing F3. Decrease the engine rpm to minimum by highlighting the - button on the left side of the engine symbol (see Fig. 14.1.1 number 6) and stop the engine as instructed in chapter 5, “Starting and Stopping", in the Instruction Manual of the unit.

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14.3 Cone crusher manual controls Highlight the cone crusher manual control symbol in the process options window and confirm your selection with F3. You will obtain the manual control window.

1 2 3 4

6 7 8

5

Figure 14.1.2 Cone crusher functions 1 2 3 4 5 6 7 8

Lubrication oil heating off / on Lubrication oil pump off / on Lubrication oil cooler off / on Cone crusher off / on Engine rpm control off / on Dust removal fan, can be activated only if dust removal vibrator is not running (visible only dust removal is in use,) Dust removal vibrator, can be activated only if dust removal fan is not running (visible only dust removal is in use) Vibration chute (visible only if in use)

Return to the previous window (process options) with F1.

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14.4 Starting the process with manual control with cone crusher Start the engine as instructed in chapter 5.2, “ Starting the Diesel Engine”, in the Instruction Manual of the unit. 1

2

3

4 5

6

7 8

Increase the engine rpm to by highlighting the + button on the left side of the engine symbol (see Fig. 14.1.2 number 5). Press F3 as long as the engine is running with the 2100 rpm in Lt300HP(if rpm´s are not fully up, the electrical components will not start). Activate lubrication oil heating if oil temperature is below 20 °C/ 68 °F. Lubrication tank electrical heaters can operate internally with hydraulic driven generator or by external power source. Activate hydraulic driven generator separately. When lubrication oil temperature is above 20 °C/ 68 °F)/ 68 °F start the crusher lubrication pump. Highlight button 1 of the item #2 and activate it by pressing F3. Deactivate hydraulic driven generator. Start the main conveyor (see Figure 14.1.1, number 1). ). Highlight item #1 button 1 and activate it by pressing F3. Start the crusher (see Fig. 14.1.2, number 4). Highlight item # 4 button 1 and activate it by pressing F3 ( Note: the lubrication must be on going at least 2 min before starting the crusher ) Start screen module (see fig 14.1.1) highlight the item #7 button 1 and activate is by pressing F3 & screen module conveyors (see fig 14.1.1) highlight the item #8 button 1 and activate is by pressing F3. Start the LC feeder and / or lifting conveyor (see Fig. 14.1.1, number 4). Highlight items 1/11 button 1 and activate it by pressing F3. Start the cooling fan when lubrication oil temperature has exceeded 40 °C/ 104 °F

14.4 Stopping the process with manual control with cone crusher 1 2 3 4 5 6 7

8

Stop the material feed by disabling the feed lifting conveyor or LC feeder & lifting conveyor. Highlight items 1/11 button 0 and activate it by pressing F3. wait until crusher is free from crushed material Stop the crusher (Fig 14.1.2). Highlight the item #4 button 0 and activate by pressing F3 Keep lubrication on at least two minutes to cool down the bearing surfaces. Stop the crusher lubrication pump. (Fig 14.1.2). Highlight the item #2 button 0 and activate by pressing F3 Stop the cooling fan. Highlight the item #3 button 0 and activate by pressing F3 Stop screen module (see fig 14.1.1) highlight the item #7 button 0 and activate is by pressing F3 & screen module conveyors (see fig 14.1.1) highlight the item #8 button 0 and activate is by pressing F3. Stop main conveyor. (See Figure 14.1.1, number 1). ). Highlight item #1 button 0 and activate it by pressing F3

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15 Track-driving window (operation in service mode only) Highlight the track symbol in the manual control window and confirm your selection with F3. You will obtain the track-driving window. The purpose of the track-driving window is to make it possible to move the unit on a site by using the UCD. Stay away from the moving tracks! Special care must be taken when manual control is used. NOTE!Driving the tracks from the display is possible only in service mode (service lock open).

Figure 15.1.1 Track driving 1 2 3 4

Left track backwards Left track forward Right track backwards Right track forward

Left and right are defined from the feeder end of the unit. The “forward” instruction moves the unit in the direction of the main conveyor (the same direction as the crushing material moves in the unit). If you press the button continuously, the LT unit will move in the direction you want. You cannot use the forwards and backward functions simultaneously. Only minimum driving speed is possible when the unit is driven from this page. Return to the previous window (process options) with F1.

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IC500 / IC600 Instruction Manual 15.1 Track drive speed Slow speed is active when the process is running and track driving is allowed. It is also active when the engine rpm is below the T6 parameter (CAT C9 & C13: 1200 rpm / Cummins 5,9: 1500 rpm). Normal speed is active when neither slow nor fast speed is active. Fast speed is active when the engine rpm value is over the T5 parameter and both tracks are driven straight forward/backwards (CAT C9 & C13 value 1900 rpm – 2100 rpm / Cummins 5,9 value 2100 rpm – 2300 rpm). In other words fast speed is not active when turning the unit. It is forbidden to drive the unit with the UCD if the drive control box (cable) or radio control is in operation due to a high risk of personal injury. Because of the unit weight and its dimensions, special attention should be paid to safety issues if you drive the unit with the UCD.

Return to the previous window (manual control) with F1

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16 Parameters / service window Press F4 in the main window and you will obtain the parameter adjustment window.

Jaw

Figure 16.1.1 Parameters (Jaw, Impactor, Cone) 1 2 3

4 5 6 7 8 9

10 11 12 13 14 14c 15 16

Impactor

Cone

General parameters Feeder parameters a) Jaw crusher parameters b) Impact crusher parameters c) Cone crusher parameters Tracks parameters Engine parameters Alarm parametrization UPD (Module update) Language Service code: -lock open: access to user and service parameters -lock closed: access to user parameters Contrast adjustment Time Date Units (metric/imperial) Hydraulic overload parameters Cone crusher setting calibration page Lubricating unit and gearbox parameter Engine and hydraulics parameters

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IC500 / IC600 Instruction Manual 16.1 Editing contrast, time, date or units Highlight the required parameter with F4 or F5 arrow keys and select it by pressing F3 (OK). Adjust the parameter with F4 or F5 and confirm with F3 (OK).

16.2 Parameters There are two types of parameters: user editable parameters and supervisor access parameters.

NOTE: If a parameter has an "S" with it, it means that it is a service parameter and only an authorized person has access to it.

16.2.1 Service parameter adjustment • •

To adjust the Service parameters you will need to have the service lock opened The lock can be opened either with a code or with a service key

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16.2.2 User editable parameters •

The parameter can be adjusted by first pressing parameter is shown

•

The parameter values background color changes dark and the adjustment buttons appear

•

When the value is changed it is accepted by

•

Press

when the desired

a sufficient amount of times to return to main-page

IC500 / IC600 Instruction Manual 16.2.3 Parameters GENERAL GS1 DELAY BETWEEN DEVICE START. In the process start sequence the devices of the unit are started in certain order. This parameter is used to set the delay between device starts in the sequence. G2 DELAY AFTER THE FEEDER IS STOPPED WITH THE PROCESS STOP SEQUENCE. When the process stop sequence is started the feeder is stopped immediately. This parameter will affect the feeder stop delay after which the stop sequence continues to the next device. The delay is used to ensure that the devices are empty when they are stopped. GS3 DELAY BETWEEN THE SHUT DOWN OF THE DEVICES In the process stop sequence the devices of the unit are stopped in certain order. This parameter is used to set the delay between the stoppings of the devices in the sequence. GS4 VIBRATION CHUTE NOT IN USE This parameter is used to select the vibration chute in use. The vibration chute is under the crusher. It feeds main conveyor with the material coming from crusher. G5 GENERATOR IN USE This parameter is used to select the generator in use. If the unit is equipped with a fixed generator, it must be selected in use in order to enable all functions. The optional hydraulicdriven generator connected to a hydraulic power take off is not related to this parameter. G6 BYPASS CONVEYOR NOT IN USE G7 DUST REMOVAL IN USE This parameter is used to select the dust removal in use. G8 DUST REMOVAL FAN TIME This parameter is used to set the duration of the suction phase in the dust removal sequence. G9 DUST REMOVAL VIBRATING TIME This parameter is used set the duration of the vibration phase in the dust removal sequence. G10 RETURN CONVEYOR NOT IN USE This parameter is used to select the return conveyor in use. GS11 UNIT TYPE SELECTION. This parameter is used to select the type of the machine. In IC500: 1 = LT95 / LT105, 2 = LT1110 / LT1213 In IC600: 3 = LT200HP, 4 = LT300HP, 7 = LT300HP(B) GS12 RADIO TYPE SELECTION This parameter is used to select the type of radio, which is used. 0 = I/O-radio, 1 = CAN-radio. Used only in: IC500 Version 2.5

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GS13 LC-FEEDER IN USE This parameter is used to select the Lifting Conveyor Feeder in use. (1), not in use (0) Used in: LT300HP GS14 HYDRAULIC OUTLET IN USE This parameter is used to select the hydraulic output in use. GS15 SCALPER NOT IN USE The optional two stage feeder consists of a feeder and a scalper. The scalper can be equipped with either a vibrating grizzly or a roller grizzly. This parameter is used to select the vibration chute or the roller grizzly in use. The main difference in the control of these devices is the automatic jam removal sequence of the roller grizzly. G16 MAGNETIC SEPARATOR NOT IN USE This parameter is used to select the magnetic separator in use. When the separator is selected into use, the process selection button for the separator appears in window 3. G17 SIDE CONVEYOR NOT IN USE This parameter is used to select the side conveyor in use. When the conveyor is selected into use, the process selection button for the conveyor appears in window 3. Used with: jaw and impact crushers GS18 SEPARATE CRUSHER AUTOMATION (IC70) GS19 DUST REMOVAL WITH HYDRAULIC USE

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Feeder speed control is used to control the production of the unit. In high- or overload situations the feeder is slowed down, paused (restarted automatically) or stopped, depending on the situation. Continuous stopping and starting of the feeder wastes power, consumes more fuel and causes extra stops in crushing process. Thus a steady material feed (a correct feeder control value and proper unit loading) is a key factor when optimizing the production rate. Feeder speed and control modes The feeder has two control modes: Manual and Automatic (selected with parameter F5). In manual mode the control percent can be adjusted by operator from the service platform, IC display or optional radio control. When the feeder automatic mode is selected the IC calculates the feeder control according to: - Crusher drive pressure F8 – F9 & high pressure time delay FS10 (in C-jaw & NP) - Device pump pressure H1 (all) - Device pump 2 pressure H13 (LT300HP only) - Crusher speed FS11 – FS12 & Low speed time delay (in C-jaw & HP) - Hydraulic oil temperatures FS14 (all except HP), FS15 (all units), F33 (HP) - Secondary unit alarms F18 (all units) - High cavity level F16 (all), F43 – F45 (HP only) Feeder control mode affects only the control percent (=speed) - pause and stop conditions are utilized in both modes. Feeder speed varies between the minimum and maximum feeder speeds, which can be adjusted with the parameters F1-F2 (in C-Jaw & NP) and F26-F27 & F35-F36 (in HP). The feeder speed range is divided into a control range from 0 % to 100 %, where 0 % control corresponds to minimum speed parameter and 100 % control corresponds to maximum speed parameter. The control percent is displayed on the display in windows 0 and 1.1. The control range is set with the parameters mentioned above. Every time the feeder starts from stop, the feeder is always started with the minimum speed and it will run at that for a time set by the parameter FS17. After this time the feeder speed is raised to correspond to the active control value.

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Pause state When the feeder goes into the pause state, IC restarts the feeder automatically when the reason for the pause has disappeared. The feeder can be paused for the following reasons: - Crusher power draw is high; Over parameter F48 (HP only) - Crusher level detector (C-Jaw) If high material level is detected the feeder is set to the minimum speed. If the level is high longer than the delay, parameter F16, the feeder is paused. The level detector is taken into use with parameter F6.

NOTE: If the learning level detector is selected into use, the feeder speed is only decreased / increased by steps in a certain time period - Secondary LT pause request (All units) If a secondary machine is interlocked, the request to pause the primary feeder will set the primary feeder to minimum speed. If the request is active longer than the delay, parameter F18, the feeder is paused.

- Crusher low speed (C-Jaw only) If the crusher speed decreases under the crusher speed low limit (parameter FS12) the feeder is set to the minimum speed. If the feeder speed is low longer than the delay, parameter FS13, the feeder is paused. The feeder is restarted when the speed of the crusher rises over the limit FS12.

- Screen module conveyors low speed (if equipped with S-module) If the speed of product conveyor (main discharge belt) drops under the low limit (F42) the feeder is paused. If screen discharge conveyor speed is zero for a 3 seconds the process is disabled.

Stop state When the feeder goes into stop state, the user must restart the feeder manually. The feeder can only be restarted after the reason for stopping has disappeared. The feeder can be restarted either from the service platform or from optional radio control. The feeder can be stopped for the following reasons: - The user stops the feeder from the service platform, radio control or display - Secondary machine alarm Interlocked secondary unit sends an stop alarm message - Device pump pressure alarm If the pressure of the device pump 1 or 2 rises over the alarm limit, the feeder is stopped

- Hydraulic feed gate opening (NP) When the unit is equipped with scalper the feed gate opening uses the same valve with feeder. Therefore the feeder is paused while the feed gate is opened.

- Hydraulic oil temperature rises over the hydraulic oil temperature high limit (FS15) - Fuel level is at alarm limit (E3). Version 2.5

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IC500 / IC600 Instruction Manual - Parameter F68 is used to set whether the scalper also pauses with the feeder. When the scalper is paused with the feeder it is paused when the feeder is paused - not when the feeder goes to minimum speed. When the feed is restarted the scalper is started first and then the feeder.

Feeder automatic mode In the feeder automatic mode the IC controls the feeder control percent. Control is carried out in linear fashion (except in learning level detector mode). In other words the control is continuous. In the learning level detector situation the control range between minimum and maximum speed is divided into steps with parameter F56 - Crusher pressure (NP) - Level detector (C-Jaw & HP) {Learning level detector mode} - Hydraulic oil temperature (C-Jaw & NP) - Feed rate calculation (HP) - Secondary unit (interlock)

F1 FEEDER MINIMUM SPEED This parameter will affect the minimum speed of the feeder. The higher the value, the higher the actual feeder running speed. F2 FEEDER MAXIMUM SPEED This parameter will affect the maximum speed of the feeder. The higher the value, the higher the actual feeder running speed. Note: The allowed maximum running speed is adjusted separately. You can adjust this parameter without having to be afraid of damaging any components. F3 AUTOMATIC FEEDER SPEED CONTROL / SELF LEARNING TIMEBASE This parameter is part of the automatic feeder speed control. In the case of the jaw crusher the automatic feeder control can be understood as a self-learning material level detector. Automatic mode tries to keep the number of material level detector alarms constantly on a certain time base. The time base is adjusted with this parameter. Note: If the parameter value is set to 0 (zero), the self-learning feeder speed control will not be used. F4 AUTOMATIC FEEDER SPEED CONTROL / CRUSHER MATERIAL LEVEL COUNTER When automatic mode is selected (Parameter F5), the control system tries to keep the material level detector alarms constant. If the number of alarms is below the set value the speed of the feeder is increased. If the number of alarms is above the set value the speed of the feeder is reduced. You can adjust the level in the parameter F3. F5 AUTOMATIC FEEDER SPEED CONTROL / ON – OFF SELECTION This parameter is used to select the feeder automatic/manual control mode. Used with: jaw and impact crushers. Automatic feeder speed control = 1 Manual feeder speed control = 0 Note: If you want to use the automatic speed control, set the level detector as “on". Check that the material level detector is functioning. Version 2.5

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F6 CRUSHER MATERIAL LEVEL DETECTOR This parameter is used to select the crusher level detector in use. Level sensor ON = 1 Level sensor OFF = 0 F7 FEEDER SPEED INCREASE / DECREASE STEP IN THE FEEDER AUTOMATIC CONTROL MODE The speed of the feeder varies in order to keep the material level detector alarm counter at a given amount in a selected time base. F8 CRUSHER PRESSURE OK LIMIT. The feeder stays at full speed until the crusher pressure OK limit is achieved (if anything else does not limit the capacity). If the material to be crushed is very hard, you may lower this value in order to affect the feeder speed before the jaw crusher drops the speed (flywheel energy). F9 CRUSHER PRESSURE HIGH LIMIT. At this pressure level the feeder is stopped FS10 CRUSHER PRESSURE HIGH LIMIT TIME DELAY. The length of time the feeder will wait before feeder stop case of crusher high pressure. FS11 CRUSHER SPEED OK LIMIT. When the crusher speed goes below this rpm limit, the feeder will start to reduce speed FS12 CRUSHER SPEED LOW LIMIT. If the speed of the crusher falls down to the crusher speed low value the feeder is stopped. FS13 CRUSHER SPEED LOW LIMIT TIME DELAY. The length of time the feeder will run at a before stopping in case of crusher low speed. FS14 HYDRAULIC OIL TEMP OK LIMIT. The feeder stays at full speed until the hydraulic oil temperature OK limit is achieved (if anything else does not limit the capacity). When the hydraulic oil temperature achieves the value set by parameter FS14 the feeder speed will start to ramp down. FS15 Hydraulic oil temp HIGH limit. When the hydraulic oil reaches the temperature set by parameter FS15 the feeder will stop. If the hydraulic oil temperature rises +2 oC over the value set by parameter FS15 the process is disabled. F16 THE LENGTH OF TIME WHICH THE CRUSHER LEVEL MAY BE OVER THE HIGH LEVEL LIMIT BEFORE THE FEEDER IS PAUSED This parameter is used to set the delay that defines how long the feeder is running with a minimum speed before pausing when the crusher material level is high. FS17 FEEDER START MINIMUM SPEED TIME. The feeder is always started at minimum speed. F18 CRUSHER LEVEL HIGH ALARM TIME OF THE POSSIBLE SECONDARY LT

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IC500 / IC600 Instruction Manual This parameter is used to set the delay that defines how long the feeder is running with the minimum speed before pausing when the secondary machine load is high. If the secondary machine pause request is active longer than the delay, the feeder is paused. FS19 THE LENGTH OF THE FEEDER ACCELERATION AND DECELERATION RAMP IN SECONDS. FS20 FEEDER-HOPPER ANALOG LEVEL DETECTOR Distance in millimeters from the end of the sensor What corresponds the 4 mA output signal FS21 FEEDER-HOPPER ANALOG LEVEL DETECTOR Feeder hopper analog level detector range F23 FEED HOPPER LOW CAVITY LEVEL Material feed to the forward can be interrupted if there is no material o the feed hopper in order to keep crusher in choke feed during crushing F24 FEED HOPPER HIGH CAVITY LEVEL RANGE Material feed to the forward can be interrupted if there is no material o the feed hopper in order to keep crusher in choke feed during crushing F25 LIFTING CONVEYOR ACCELERATION AND DECELERATION RAMP TIME Time ramp from set minimum speed to maximum speed will effect how rapidly material level will increase or decrease above the cone crusher F26 LIFTING CONVEYOR MINIMUM SPEED Enables to set the conveyors feeding speed to the desired speed. Generally the speed should be so low that the crusher cavity level will lower rapidly. F27 LIFTING CONVEYOR MAXIMUM SPEED Enables to set the conveyor feeding speed to desired. Generally the speed should be set to the point where feed material will enable choke feed of the crusher. F28 FEED HOPPER ANALOG LEVEL DETECTOR IN USE Feeder hopper analog level detector in use / off F30 METAL DETECTOR STOP TIME Used to stop the metal exactly in the collecting point. If the value is set to zero the detector is not in use. F31 LIFTING CONVEYOR MINIMUM SPEED TIME When material high level detected lifting conveyor will continue to run with minimum speed the time set with this parameter. F33 HYDRAULIC OIL SLOW DOWN LIMIT Feed rate is reduced if the hydraulic oil temperature exceed parameter value F34 LIFTING CONVEYOR SPEED ALARM Optional lifting conveyor speed detector can be activated & adjusted to detect belt slip F35 LC FEEDER MINIMUM SPEED Version 2.5

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IC500 / IC600 Instruction Manual This parameter will affect the minimum speed of the LC feeder. The higher the value, the higher the actual feeder running speed. F36 LC FEEDER MAXIMUM SPEED This parameter will affect the maximum speed of the LC feeder. The higher the value, the higher the actual feeder running speed. F38 STOP DELAY BETWEEN LC FEEDER AND LIFTING CONVEYOR How long does the LC-feeder run after LC has stopped F40 LC-FEEDER CONTROL MODE 0 = Manual, 1 = Automatic F41 LC FEEDER MINIMUM SPEED START TIME LC-Feeder minimum running speed time F42 SCREEN MODULE DISCHARGE CONVEYOR SPEED SENSOR Optional speed sensor can be activated and adjusted with this parameter. 0 = speed sensor not in use. Speed sensor must be pulse type sensor what will pass the signals according the belt speed Conveyor speed can be observed from the hydraulic information page (page 1.4) F43 CRUSHER CAVITY LEVEL SENSOR Sensor type is selected with this parameter 0 = not in use, 1 = Analog sensor, 2 = Digital sensor F44 CAVITY LEVEL SENSOR CURRENT AT 0% Sensor polarity & range adjustments F45 CAVITY LEVEL SENSOR CURRENT AT 100% Sensor polarity & range adjustments F46 FEED POWER MODE Cone crusher power draw controls the material feed to the crusher F47 CRUSHER POWER OK LIMIT Cone crusher power limit when the material feed starts to derate. F48 CRUSHER POWER HIGH LIMIT Material feed is paused when power high limit is achieved F49 CRUSHER POWER HIGH FEED PAUSE DELAY To pause the material feed, cone crusher power draw must remain over the parameter F48 value longer than the time set with this parameter F50 CRUSHER LOW SPEED ALARM LIMIT If the crusher speed is too low the process is stopped. F89 CRUSHER LOW SPEED ALARM LIMIT When the crusher speed goes below this parameter limit the stopped

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CS1 CRUSHER MAX CURRENT The current control value of the crusher speed CS2 CRUSHER MINIMUM CURRENT. CS3 THE OVERLOAD PROTECTION TYPE SELECTION. This parameter is used to set whether the crusher has hydraulic or mechanic setting adjustment system. With hydraulic adjustment system the control system controls and monitors the pressure of the clamping cylinder. - Hydraulic setting adjustment (0) - Hydraulic overload protection (1) - Mechanical setting adjustment (2) CS4 CLAMPING CYLINDER MINIMUM PRESSURE. CS5 CLAMPING CYLINDER MAXIMUM PRESSURE. If the crusher is equipped with a hydraulic setting adjustment system (parameter CS3), the control system controls and monitors the pressure of the clamping cylinder. The clamping cylinder clamps the rotating jaw from the bottom to the setting adjustment mechanism. The control system tries to keep the pressure between the minimum and maximum clamping pressure. When the pressure drops to the minimum value the control system pressurizes the cylinder. The pressurization is stopped when the maximum clamping pressure is reached. These parameters are used to set the minimum and maximum clamping pressures. NOTE! The maximum value must be higher than the minimum. The cut off point for the charging of the return rod cylinder (clamping cylinder) circuit is set with this parameter. (The return rod creates a force which holds the pitman and the toggle plate clearance free against the frame). CS6 CRUSHER STARTING LOW PRESSURE ALARM LIMIT. If the crusher drive circuit does not raise the pressure above the set pressure limit, the jaw is disabled. By this function you are able to detect if the crusher v- belts or the crusher drive pump are damaged. CS7 CRUSHER STARTING LOW PRESSURE ALARM DELAY. The time for how long the system can start the crusher before it sets an alarm due to low pressure in the hydraulic drive circuit. CS8 CRUSHER STARTING HIGH PRESSURE ALARM LIMIT. The crusher starting pressure is observed and if the pressure is above the value of parameter CS8 the crusher is stopped.

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IC500 / IC600 Instruction Manual CS9 CRUSHER STARTING HIGH PRESSURE ALARM DELAY. The time for how long the system can start the crusher before it sets an alarm due to high pressure in the hydraulic drive circuit. This delay makes it possible to start an empty crusher. If the delay is set too long it is possible that the crusher v-belts will lose their grip and the v-belt will burn. CS10 LOW CLAMPING PRESSURE ALARM LIMIT. If the crusher is equipped with a hydraulic setting adjustment system (parameter CS3), the control system controls and monitors the pressure of the clamping cylinder. The clamping cylinder clamps the rotating jaw from the bottom to the setting adjustment mechanism. This parameter is used to setthe low clamping ressure limit. If the pressure drops under the limit, the crusher is stopped immediately, process is disabled, and alarm 4 is launched. CS11 CRUSHER OVER PRESSURE ALARM DELAY. The process is disabled if the crusher pressure draw is above the alarm limit (CS12) longer than the time set by parameter CS11. CS12 CRUSHER OVER PRESSURE ALARM LIMIT. The process is disabled if the crusher pressure draw exceeds the pressure set by this parameter and stays higher longer than the time set by parameter CS11. CS13 CRUSHER START RAMP TIME. When the crusher is started by the process or from the service platform the crusher acceleration is rather slow. (The crusher swing function uses a different ramp). The parameter CS13 is the time for how long the crusher drive pump current will accelerate from the parameter C2 (start current value) to the crusher running current value parameter C1. CS14 CRUSHER STOP RAMP TIME. The time for how long the current set in parameter C1 will decelerate before it reaches the value set in parameter C2. CS15 ULTRASONIC SETTING SENSOR (NOT AVAILABLE) Setting sensor 4 mA value (mm). Used with hydraulic overload protection. CS16 ULTRASONIC SETTING SENSOR (NOT AVAILABLE) Setting sensor signal range (Ultrasonic) Used with hydraulic overload protection. CS17 CRUSHER OVERLOAD WHEN SETTING IS N% OF FULLY OPEN The crusher and process are disabled if the setting value opens more than the value set by parameter CS17. CS18 NORMAL SETTING MOVEMENT DURING CRUSHING. This parameter defines the allowed setting measurement hysteresis before correction in mm. The hydraulic overload will return to this setting if it is changed. C19 CRUSHER SPEED SENSOR ON (1) / OFF (0). Version 2.5

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IC500 / IC600 Instruction Manual If the crusher speed sensor is damaged it can be temporarily bypassed by taking it out of use with this parameter. C24 CRUSHER TARGET SPEED 1 The target speed 1 of the crusher can be adjusted with this parameter. Default: Depends on the unit type. Please refer to the parameters help file. C25 CRUSHER TARGET SPEED 2 The target speed 2 of the crusher can be adjusted with this parameter. Default: Depends on the unit type. Please refer to the parameters help file C26 CRUSHER TARGET SPEED 3 The target speed 3 of the crusher can be adjusted with this parameter. Default: Depends on the unit type. Please refer to the parameters help file CS27 CRUSHER SPEED SENSOR PULSES PER ROUND. This parameter is used to set the value of how many pulses the speed sensor sends when the crusher rotates one round. CS28 CRUSHER PUMP ZERO SPEED 1. When selected crusher target speed 1 is in use the crusher drive pump control current will accelerate to this parameter value. As soon as the value is achieved the control system observes the crusher speed and if the sensor is functional the target speed control will be used. NOTE: If the parameter C36 is selected to 0 or if the crusher speed sensor is damaged the crusher drive pump control current remains in the value given with this parameter CS29 ADJUST CRUSHER MOTOR ZERO SPEED 1. This parameter is only used in LT1110. When selected crusher speed 1 is in use and the crusher has been accelerated to pump zero speed 1 (parameter 28) the adjustment motor keeps the crusher speed stabile with this parameter. The IC system then monitors and if necessary changes the adjustment pump angle to maintain the correct crusher auto speed. NOTE: If the parameter C36 is selected to 0 or if the crusher speed sensor is damaged the crusher drive pump control current remains in the value given with this parameter CS30 CRUSHER PUMP ZERO SPEED 2. When selected crusher target speed 2 is in use the crusher drive pump control current will accelerate to this parameter value. As soon as the value is achieved the control system observes the crusher speed and if the sensor is functional the target speed control will be used. NOTE: If the parameter C36 is selected to 0 or if the crusher speed sensor is damaged the crusher drive pump control current remains in the value given with this parameter

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IC500 / IC600 Instruction Manual This parameter is only used in LT1110. When selected crusher speed 2 is in use and the crusher has been accelerated to pump zero speed 2 (parameter 30) the adjustment motor keeps the crusher speed stabile with this parameter. The IC system then monitors and if necessary changes the adjustment pump angle to maintain the correct crusher auto speed. NOTE: If the parameter C36 is selected to 0 or if the crusher speed sensor is damaged the crusher drive pump control current remains in the value given with this parameter CS32 CRUSHER PUMP ZERO SPEED 3. When selected crusher target speed 3 is in use the crusher drive pump control current will accelerate to this parameter value. As soon as the value is achieved the control system observes the crusher speed and if the sensor is functional the target speed control will be used. NOTE: If the parameter C36 is selected to 0 or if the crusher speed sensor is damaged the crusher drive pump control current remains in the value given with this parameter CS33 ADJUSTMENT CRUSHER MOTOR ZERO SPEED 3. This parameter is only used in LT1110. When selected crusher speed 3 is in use and the crusher has been accelerated to pump zero speed 3 (parameter 32) the adjustment motor keeps the crusher speed stabile with this parameter. The IC system then monitors and if necessary changes the adjustment pump angle to maintain the correct crusher auto speed. NOTE: If the parameter C36 is selected to 0 or if the crusher speed sensor is damaged the crusher drive pump control current remains in the value given with this parameter CS34 CRUSHER SPEED CHANGE HYSTERESIS When crusher is running with auto speed control, the crusher actual speed can vary between hysteresis limits. If the crusher actual rpm value exceeds the limit (+/- this parameter value) crusher speed will be adjusted CS35 CRUSHER TARGET SPEED RAMP When crusher speed is changing, the reaction time can be adjusted with this value C36 CRUSHER AUTO SPEED Autospeed in use = 1 Autospeed not in use = 0 CS37 CRUSHER IDLING POWER LIMIT Idling power is used to detect that he crusher is empty of material before stopping the crusher

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IC500 / IC600 Instruction Manual CS39 CRUSHER HYD. MOTOR V-BELT PULLEY DIAMETER Value is used to calculate power CS40 CLAMPING FAULT DELAY Alarm delay time before the clamping fault alarm appears CS41 RELEASE FAULT DELAY Alarm delay time before the release fault alarm appears CS42 CRUSHER EXCESSIVE POWER ALARM LIMIT Power limit by with the process stops to protect the cone crusher CS43 CRUSHER EXCESSIVE POWER ALARM DELAY Alarm delay time before the release fault alarm appears CS44 CRUSHER SOFT START TIME CS45 CRUSHER STARTER DELAY CS46 HP-SETTING CHANGE PER TOOTH Value how much does the setting change by one tooth step CS47 CRUSHER DRIVE TYPE This selection is used to select the correct drive type, depending on the machine CS48 DIESEL ENGINE SIZE This value defines the diesel engine power (kW) CS49 UNIT POWER DRAW WITHOUT CRUSHER This value defines the diesel engine power (kW) draw without crusher CS50 HYDRAULIC PUMP SIZE This value defines the hydraulic pump size CS60 CRUSHING HOURS TO NOTIFY USER ABOUT BEARINGS LUBRICATION. This parameter is used to set the interval between the service notifications on the lubrication of crusher bearings. After the crusher has been running for this time, the system lauches the alarm 131 to remind the operator. CS61 CRUSHING HOURS TO NOTIFY USER ABOUT COUNTER WEIGHT LINER AND ARM LINERS CLEANING. CS62 CRUSHER TARGET SPEED CHANGE ALLOWED ”0” = not allowed, “1” allowed

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Tracks can be driven from the drive box, (optional) radio control, and the display. If radio operation is selected from the main control panel, other controls cannot be used for driving. If the drive box is connected and radio control is not selected, the drive box can be used to drive the unit. The display can be used for driving in service mode when other driving devices are not present and process is stopped. Driving is prevented if: - Hand valves are activated - Screen module is connected and process has been activated - There is a problem with track drive outputs and feedbacks Driving with a long main conveyor (unit without vibration chute) With a long main conveyor the bottom side of the conveyor has to be lifted before driving. The conveyor is lifted after engine start when a driving device is either connected or track control is activated. Track driving is possible after the conveyor has been lifted for five seconds. The conveyor descends when it is started. During process the conveyor is not lifted. The hydraulic power take off is controlled with the same valve as main conveyor lifting, and these functions cannot be used simultaneously. The hydraulic power take off is deactivated when main conveyor is lifted. For safety reasons the user must restart the hydraulic power take off himself window [3]. Driving speeds There are three different drive speeds for tracks. Slow speed is active when process is not stopped or when engine rpm is less than the value of parameter T6. Parameters T8 - T11 are used to adjust the track speed so that the machine moves straight forward/backward with proper speed. Normal speed is active when engine speed is higher than the value of parameter T6. Fast speed is active when engine speed is higher than the value of parameter T5 AND both tracks are driven in the same direction. In other words the fast speed is no longer active when the unit is turning.

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T1 MIN VALUE FOR RIGHT TRACK BACKWARD How much the spool moves from central point when engine rpm's are below the normal speed and right drive lever pulled backwards T2 MIN VALUE FOR RIGHT TRACK FORWARD How much the spool moves from central point when engine rpm's are below the normal speed and right drive lever pulled forward. T3 MIN VALUE FOR LEFT TRACK BACKWARD How much the spool moves from central point when engine rpm's are below the normal speed and left drive lever pulled backward. T4 MIN VALUE FOR LEFT TRACK FORWARD How much the spool moves from central point when engine rpm's are below the normal speed and left drive lever pulled forward. From T1 to T4: Adjust the value so that the track motion is 0,25m/sec.

T5 FAST SPEED TRACKING RPM LIMIT This parameter is used to define the engine speed at which fast track driving speed is automatically activated. Fast speed is not active while the unit is turning or screen module is connected. The parameter value has to be greater than T6. Used with: jaw and impact crushers T6 NORMAL SPEED TRACKING RPM LIMIT This parameter is used to define the engine speed at which normal track driving speed is automatically activated. The parameter value has to be lower than T5. T7 TRACK STOP RAMP The stop time of the unit can be adjusted with this parameter. The ramp is not in use when driving at slow speed. TS13 FAST SPEED ALLOWED / NOT ALLOWED This parameter prevents the fast drive to activate, e.g. if screen module is connected, "0" = not allowed, "1" = allowed

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E1 ENGINE MIN SPEED This parameter sets the minimum speed for the engine. ES2 ENGINE MAX SPEED This parameter is used to set the maximum speed for the engine. For example, hydraulic pumps can set requirements for maximum speed in addition to the engine. E3 FUEL LEVEL ALARM LIMIT When the fuel level drops below the alarm limit, the alarm is displayed and material feed is immediately shut down. The user can restart the feed from service platform or radio control. The fuel level indication will not prevent the unit from running out of fuel. ES4 FUEL LEVEL SENSOR MINIMUM OUTPUT VOLTAGE. This parameter is used to set the voltage of the fuel level sensor when fuel tank is empty. Note the operation voltage of the fuel sensor is 5 VDC. ES5 FUEL LEVEL SENSOR MAXIMUM OUTPUT VOLTAGE. This parameter is used to set the voltage of the fuel level sensor when fuel tank is full. ES6 MINIMUM PWM VALUE FOR THROTTLE CONTROL. If the engine speed is not controlled with J1939 it is possible to use PWM control. PWM control is not used in LT 105(S). ES7 MAXIMUM PWM VALUE FOR THROTTLE CONTROL. If the engine speed is not controlled with J1939 it is possible to use PWM control. PWM control is not used in LT 105(S).

ES8 COOLER CONTROL IN USE Engine cooler control observes engine coolant and charge air temperatures and adjusts the fan speed depending on the need. The control value is calculated for both temperatures and the one which demands more cooling is taken in use. If the control is not in use the fan rotates with maximum speed. Parameters ES9 - ES15 set the limits for the control. This parameter is used to select the cooler control in use. ES9 COOLER MAXIMUM MA-VALUE (MINIMUM SPEED) The cooler fan minimum running speed is adjusted with this parameter. ES10 COOLER MINIMUM MA-VALUE (MAXIMUM SPEED) The cooler fan maximum running speed is adjusted with this parameter.

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ES11 COOLANT TEMPERATURE OK LIMIT ES12 COOLANT TEMPERATURE HIGH LIMIT When the coolant temperature rises over the ok limit the cooling fan speed starts to rise from the minimum speed. The speed is raised relative to the temperature until the temperature reaches the high limit, in which point the fan is running with maximum speed. When the temperature drops, the fan is decelerated in a similar way. These parameters are used to set the ok and high limits for the coolant temperature. ES13 CHARGE AIR TEMP TEMPERATURE OK LIMIT ES14 CHARGE AIR TEMP TEMPERATURE HIGH LIMIT When the charge air temperature rises over the ok limit the cooling fan speed starts to rise from the minimum speed. The speed is raised relative to the temperature until the temperature reaches the high limit, in which point the fan is running with maximum speed. When the temperature drops, the fan is decelerated in a similar way. These parameters are used to set the ok and high limits for the charge air temperature. ES15 COOLER RAMP SPEED FASTNESS MA / SEC The fastness of the cooling fan control change can be set with this parameter. ES16 DIESEL ENGINE TYPE “0” CAT, “1” Cummins,

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HYDRAULIC PARAMETERS H1 DEVICE PUMP PRESSURE ALARM LIMIT This parameter is used to set the high pressure limit for the device pump 1.

HS2 HYDRAULIC OIL TEMPERATURE SENSOR GAIN(MV/100°C) This parameter is used to set how much [mV] the voltage value of the hydraulic oil temperature sensor changes when the temperature changes 100 °C. HS3 HYDRAULIC OIL TEMPERATURE SENSOR ZERO POINT This parameter is used to set the voltage value of the hydraulic oil temperature sensor which corresponds to 0 °C temperature.

HS4 HYDRAULIC OIL TEMPERATURE LIMIT FOR MONITORING OIL FILTER The hydraulic oil filter condition observation is based on the pressure measurement of the filter. In addition to accumulated dirt, also the viscosity of the hydraulic oil affects the pressure. Hydraulic oil viscosity varies according to the oil temperature.With cold oil the pressure of the filter might give the impression that the filter is clogged even though the reason for the high pressure was stiff oil. This parameter is used to set the limit for hydraulic oil temperature over which the filter is monitored. If hydraulic oil is changed to an oil with different viscosity grading, the value of the parameter has to be changed respectively. Used with: jaw and impact crushers ISO 32 ------ 10 oC ISO 46 ------ 20 oC ISO 68 ------ 30 oC HS5 CRUSHER PRESSURE SENSOR 4 MA VALUE This parameter is used to set the pressure value that corresponds with the 4 mA output from the pressure sensors of the pumps. With this parameter you are able to trim the sensor’s zero-point HS6 CRUSHER PRESSURE SENSOR RANGE This parameter is used to set range for the pressure sensor. HS7 CLAMPING PRESSURE SENSOR 4 MA VALUE This parameter is used to set the pressure value that corresponds with the 4 mA output from the pressure sensors of the pumps. With this parameter you are able to trim the sensor’s zero-point HS8 CLAMPING PRESSURE SENSOR RANGE This parameter is used to set range for the clamping pressure sensor. HS9 DEVICE PUMPS AND LIFTING CONVEYOR PRESSURE SENSOR 4 mA VALUE This parameter is used to set the pressure value that corresponds with the 4 mA output from the pressure sensors of the device pumps.

HS10 DEVICE PUMPS AND LIFTING CONVEYOR PRESSURE SENSOR RANGE This parameter is used to set the range for the pressure sensors of the device pumps. HS11 TOGGLE PRESSURE SENSOR 4 MA VALUE This parameter is used to set the pressure value that corresponds with the 4 mA output from the pressure sensors of the pumps. With this parameter you are able to trim the sensor’s zero-point Version 2.5

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HS12 TOGGLE PRESSURE SENSOR RANGE This parameter is used to set range for the pressure sensor. H13 DEVISE PUMP #2 PRESSURE LIMIT This parameter is used to set the high pressure limit for the device pump 2. Used with: jaw and impact crushers H14 MAIN CONVEYOR SPEED ALARM This parameter is used to set the low speed limit for the main conveyor. Process is disabled when the speed drops below the limit.

H16 DEVICE PUMP 1/2/3 PRESSURE HIGH Feed stopped (0) / paused (1) HS17 HYDRAULIC OIL COOLER START TEMP The hydraulic oil cooler is started when the hydraulic oil temperature rises over the start limit. This parameter is used to set the start limit. Used with: jaw and impact crushers HS18 HYDRAULIC OIL COOLER STOP TEMP The hydraulic oil cooler is stopped when the hydraulic oil temperature drops under the stop limit. This parameter is used to set the stop limit. Used with: jaw and impact crushers H19 HYDRAULIC OIL COOLER AUTOMATIC CLEANING This parameter is used to set the automatic hydraulic oil cooler cleaning to use. -When selected in use, the automatic cleaning sequence rotates the hydraulic oil cooling fan to the reverse direction for 10 seconds during process start. HS22 LC-FEEDER OIL VOLUME FLOW HS23 LC-FEEDER IDLE PRESSURE HS24 SCREEN MODULE OIL VOLUME FLOW HS25 SCREEN MODULE IDLE PRESSURE HS26 PUMP1 IDLE PRESSURE HS27 PUMP 1 OIL VOLUME FLOW

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These parameters are used only with: LT200HP, LT300HP LS1 LUBRICATION TANK OIL TEMPERATURE SENSOR 4MA VALUE This parameter is used to set the temperature value that corresponds with the 4 mA output of the lubrication oil temperature sensor. LS2 LUBRICATION TANK OIL TEMPERATURE SENSOR RANGE This parameter is used to set the range for the lubrication oil temperature sensor. If the parameter value is set to zero the sensor is not in use. LS3 LUBRICATION RETURN OIL TEMPERATURE SENSOR 4MA VALUE This parameter is used to set the temperature value that corresponds with the 4 mA output of the lubrication oil temperature sensor. LS4 LUBRICATION RETURN OIL TEMPERATURE SENSOR RANGE This parameter is used to set the range for the lubrication oil temperature sensor. If the parameter value is set to zero the sensor is not in use. LS5 LUBRICATION TANK OIL HEATERS, HEATERS OFF LIMIT This is the temperature limit on which the lubrication oil heaters are turned off LS6 LUBRICATION RETURN OIL TOO HOT, FEED STOP LIMIT This is the temperature limit on which the feeder is stopped because lubrication oil is too hot LS7 LUBRICATION RETURN OIL TOO HOT, CRUSHER ALARM LIMIT This is the temperature limit on which the crusher is stopped because lubrication oil is too hot LS8 COUNTER SHAFT PRESSURE ALARM DELAY This delays the countershaft lubrication pressure alarm LS9 LUBRICATION PUMP LOW SPEED LIMIT This limit is the lowest allowed speed for lubrication pump LS10 LUBRICATION OIL COOLER ON TEMPERATURE LIMIT LS11 LUBRICATION OIL COOLER OFF TEMPERATURE LIMIT. LS12 LUBRICATION PUMP MOTOR TYPE “0” =hydraulic motor, “1” =electric motor, default “0” LS13 LUBRICATION TANK TEMP PROCESS ENABLED LIMIT LS14 LUBRICATION PUMP RUNNING TIME AFTER CRUSHER HAS STOPPED Version 2.5

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LS15 LUBRICATION PUMP SPEED SENSOR DETECTED PULSES PER ONE ROUND LS16 LUBRICATION OIL COOLER MOTOR TYPE “0” hydraulic, “1” electric motor, LS17 OIL HEATING HYDRAULIC PUMP RAMP TIME. IF SET TO ZERO NOT IN USE, LS18 LUBRICATION PUMP SPEED ALARM DELAY This delays the lubrication pump speed low alarm

These parameters are used only with: LT300HP KS1 DELAY BEFORE NEW START ATTEMPT IS POSSIBLE This parameter is used to set a delay between crusher start attempts. Frequent starting is prevented to avoid the clutch from being damaged. KS2 GEARBOX OIL TEMPERATURE ALARM LIMIT When the gearbox oil temperature rises over the alarm limit, the process is disabled and alarm 100 is launched. This parameter is used to set the alarm limit. K3 GEARBOX OIL TEMPERATURE WARNING LIMIT This parameter is used to set the warning limit of the gearbox oil temperature. When the limit is exceeded a warning message is shown. KS4 ENGINE RPM AT CLUTCH ACTIVATION This parameter is used to set the engine speed at which the clutch is activated during the crusher start sequence. During crusher start the control system controls the engine speed and the hydraulic valves of the gearbox. The parameter value must be higher than engine minimum speed + 20 rpm. KS5 CHOKE TIME This parameter is used to set the duration of the crusher soft start. In other words it sets the time how long the choke is active. During crusher start the control system controls the engine speed and the hydraulic valves of the gearbox. KS6 DELAY BEFORE CLUTCH SLIP % IS CHECKED DURING CRUSHER START Clutch slip is checked twice during the crusher start sequence: after soft start (after choke deactivation) and after the engine speed has been raised to the selected operating speed. This parameter is used to set the time period after both cases before the slip is checked. KS7 CLUTCH SLIP % ALARM LIMIT If the clutch slip percent rises over the alarm limit and stays there longer than the delay set by parameter (KS15), the clutch is released, the process is disabled, and alarm 101 is launched. The clutch slip percent is calculated by comparing the crusher drive axle (in the gearbox) speed and engine speed. Crusher speed does not have an effect on the clutch slip percent. This parameter is used to set the alarm limit.

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IC500 / IC600 Instruction Manual KS8 CRUSHER DRIVE AXLE SPEED SENSOR This parameter is used to set the crusher drive axle speed sensor in use. KS9 CLUTCH LOW PRESSURE ALARM LIMIT If clutch pressure drops under the alarm limit, the clutch is released, process is disabled, and alarm 103 is launched. This parameter is used to set the alarm limit. KS10 GEARBOX OIL TEMPERATURE SENSOR 4mA VALUE This parameter is used to set the temperature value that corresponds with the 4 mA output of the gearbox oil temperature sensor. KS11 GEARBOX OIL TEMPERATURE SENSOR RANGE This parameter is used to set the range for the gearbox oil temperature sensor. If the parameter value is set to zero the sensor is not in use. KS12 CLUTCH PRESSURE SENSOR 4MA VALUE This parameter is used to set the pressure value that corresponds with the 4 mA output of the clutch pressure sensor. KS13 CLUTCH PRESSURE SENSOR RANGE This parameter is used to set the range for the clutch pressure sensor. If the parameter value is set to zero the sensor is not in use. KS14 CRUSHER DRIVE AXLE SPEED SENSOR DETECTED PULSES PER ONE ROUND This parameter is used to set how many pulses the speed sensor sends when the crusher drive axle rotates one round. KS15 DELAY FOR CLUTCH SLIP % ALARM WHEN GEARBOX IS RUNNING This parameter is used to set the time how long the clutch slip percent can be higher than the alarm limit (parameter KS7) before the alarm is launched.

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16.3 Alarm parameter In the Alarm parameter view window you can determine which alarm messages are shown or hidden in case of an alarm. To change the alarm status, service mode must be active. ON = 1, OFF = 0. These alarms are also saved in the system’s alarm log (18.1).

NOTE: If an alarm is turned off and that specific alarm has caused a malfunction, there will be no record of it and finding the cause of the malfunction will become very difficult. You can access the alarm parameters from the Parameter/service window (4) by selecting the HUB icon with the arrow keys (F4, F5) and pressing OK (F3). The middle view of the alarm parameter window shows the alarm description. The box on the right indicates the value of the alarm. The box on the left indicates the number of the alarm parameter. Use the arrow keys to move to the alarm that you want to adjust and press OK. Use the + / buttons (F4, F5) to enable (1) or disable (0) an alarm and press OK. Press F1 to return to the previous window.

NOTE: For more information on the alarm messages and the alarm log refer to chapter 18.1.

16.4 This chapter is reserved for future use

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IC500 / IC600 Instruction Manual 16.5 Cone crusher setting calibration window (Cone crushers only) Due to material wear the crusher actual setting will enlarge during the crushing process. Calibration of the setting is recommended at least in every 40 h of operation. Fast and correct setting changes are easily done when the actual setting is maintained in the setting calibration window.

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Figure 16.5 Cone crusher calibration page 1 2 3 4 5

Setting value Operating hours after the last setting calibration Time & date of last setting calibration kWh consumed after the last setting calibration Calibration window

16.5.1 Setting calibration With the new liners (liner contact method) 1 Make sure that the process is switched off. 2 Install the crusher control panel on the service platform 3 Make sure that the crushing chamber is clean. 4 Activate the crusher lubrication as instructed in chap.14.3 4 Turn the bowl to setting decrease direction 5 When the crusher head turns stop turning the bowl. 0-mm setting is achieved. 6 Return to the control panel and open page 4.1 7 Activate calibration by pressing F3 button. 8 Adjust the new measured actual crusher setting value to the calibration window by adjusting the actual value with buttons F4 & F5. (See fig 16.5 item 5) 9 Confirm the new value to the control system by pressing button F3. 10. Set the desired setting from the crusher control panel. NOTE: Check the allowed minimum setting from the instruction manual Nordberg 100, 200, 300,400,500 cone crushers.

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(Used liners: No liner contact before the A-limit according to chapter 3.13 of the instruction manual Nordberg 200 and 300 cone crushers) 1 2 3 4 5 6 7

Check the setting according to instruction manual Nordberg 200 and 300 cone crushers / chapter 3.11. Compare the measured setting to the setting value #1 in window 4.1. If a difference is noticed in actual setting and display value, calibrate the setting. Activate calibration by pressing F3 button. Adjust the new measured actual crusher setting value to the calibration window by adjusting the actual value with buttons F4 & F5. Confirm the new value to the control system by pressing button F3. Set the desired setting from the crusher control panel.

NOTE: Check the allowed minimum setting from the instruction manual Nordberg 200 and 300 cone crushers.

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IC500 / IC600 Instruction Manual 16.6 Diagnostics You obtain the diagnostics window by pressing F5 in the main window. This is the main window for diagnostics. In this window you can select whether you want to view basic diagnostics (tracks, buttons and log files) or detailed diagnostics (connectors of each module). For example, the tracks symbol (Fig. 17.1.1, number 1) opens the track drive diagnostics window.

Figure 17.1.1 Diagnostics

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Tracks (window 5.1) Control keys window 5.2) Log files (window 5.3) Module program versions (window 5.4) CAN2 bus parameters Status of information by each connector of the device control module Status of information by each connector of Hub junction module Status of information by each connector of engine control module Status of information by each connector of hydraulics control module

Move with F4 and F5 to the box that you want to see and select it with F3. Return to the main window with F1.

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IC500 / IC600 Instruction Manual 16.7 Track Drive Diagnostics You can obtain the track drive diagnostics window by selecting the tracks symbol in the diagnostics main window.

Figure 17.1.2 Track drive diagnostics 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

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Drive box / radio control Left track "forward" control received (radio/drive box) Left track "backward" control received (radio/drive box) Right track "forward" control received (radio/drive box) Right track "backward" control received (radio/drive box) Left track control percentage Left track control voltage percentage Right track control percentage Right track control voltage percentage Left track forward output. When activated, the triangle is black. Left track backward output. When activated, the triangle is black. Right track forward output. When activated, the triangle is black. Right track backward output. When activated, the triangle is black. Engine rpm down or feeder off with radio control received Engine rpm up or feeder on with radio Engine rpm down output. When activated, the triangle is black. Engine rpm up output. When activated, the triangle is black. Tracking controls active in radio Crushing controls active in radio Feeder speed down control received from radio Feeder speed up control received from radio

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IC500 / IC600 Instruction Manual This window shows you the most important data for track driving. The window is also the diagnostics window for the drive box. The selected control (drive box or radio) is shown in this window (see Fig. 17.1.2, number 1). You will also see the control percentages for the proportional valves, as well as the control voltage area. Engine rpm and increasing/decreasing of the engine speed are also indicated. 16.8 Push Button Test You will obtain the push button test window by selecting the control button symbol in the diagnostics main window.

Figure 17.2.1 Push button test (depending on selected LT unit) 1 2 3 4 5 6 7 8 9

Feeder off/on / Feed on/off Feeder speed decrease / increase Feed decrease / increase Crusher off/on (jaw crusher only) Crusher swing clockwise / counter clockwise (jaw crusher only) Crusher setting increase / decrease (jaw crusher only) Engine key switch, start, running status Process key switch off/on Radio control off/on Feed funnel up (impact only)

This window allows you to check whether the buttons in the remote control function normally. For instance, if you press feeder on/off button of the service platform, the function is indicated by a highlighted feeder on (number 1) symbol at this window. To carry out the service platform test you need an assistant to activate the button in the service platform, as the button needs to be pressed and its status read simultaneously. Return to the previous window by pressing F1.

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17 Log Files In window 5 selecting symbol "log files" (figure 17.1.1, number 3) you will obtain the log files window (5.3).

Figure 18.1.1 Log files 1 2 3 4 5

Alarm history Diesel diagnostics trouble codes Temperature history log Factory settings Parameter log

From window 5.3 you have access to windows: 5.3.1 (Alarm log) 5.3.2 (Diesel diagnostics trouble codes) 5.3.3 (Temperature history log) 5.3.4 (Parameter log) 5.3.5 (Factory settings). Return to the previous window by pressing F1.

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IC500 / IC600 Instruction Manual 17.1 Alarm log In the log files window select number 1 to obtain the alarm log window.

Figure 18.1.2 Alarm log When a malfunction occurs, the system shows an alarm message window and saves the information about the alarm in the alarm log database. The database consists of the date, time, alarm code and number of alarms. If the same alarm occurs sequentially, only the first and last alarms and the number of alarms are saved. The maximum number of alarms in the database is 100. The date of the last reset is saved. How to use the alarm messages and the alarm log: When the system gives out an alarm message, read it and try to understand it. If you do not understand the meaning of the alarm or do not know how to fix the problem, you can get additional information by pressing F2 (help) to access the alarm message’s help view window while the alarm message is active. You can find a list of alarms (the number of alarms depends on the selected unit type) by going to the Parameters/service window (4) and choosing the Alarm icon (Fig 16.1.1, number 6) by highlighting it and pressing OK. Here the alarm help view can be accessed by pressing the F2 button. Example on how to use the alarm log: Problem: A malfunction occurs that stops the process. You know the approximate time when the malfunction occurred but you do not know what alarms occurred before and after the malfunction. Solution: From the alarm log you can find out the dates, times, alarm codes and the number of times the alarms have occurred. Use the alarm log to look up all the alarms that occurred near the time the malfunction occurred, this way you can narrow down the cause. If you need further information on how to deal with the problem, refer to chapter 16.3. The complete list of alarms and their corresponding alarm codes can be found in chapter 17.1.1. Return to the previous window by pressing F1.

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IC500 / IC600 Instruction Manual 17.1.1 Alarm list 1-active, 0-passive, not shown Alarm # 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

Crusher over pressure Crusher pressure rising too fast on start Clamping pressure Toggle plate condition Crusher pressure rising too slow on start Crusher speed rising too slow on start Crusher speed slow Hydraulic oil temperature high feeder stopped Fuel level low No connection to diesel engine Engine red stop Engine amber warning Hydraulic oil level low Hydraulic oil filter clogged Hydraulic oil main valve closed Hydraulic oil temperature high Main conveyor safety switch left Main conveyor safety switch right Crusher critical Overload Conveyor maintenance safety switch Screen over size conveyor safety switch Screen under size conveyor safety sw. Side conveyor safety switch left side Side conveyor safety switch right side Drive box remote stop Radio remote stop Emergency stop pressed from control panel Emergency stop pressed from service platform Emergency stop pressed from engine module Emergency stop pressed from hydraulic centre Wrong program in one of the I/O-modules Ultrasonic sensor not in range Setting pressure sensor not in range Device pump pressure sensor not in range Toggle plate pressure sensor not in range ECM-module missing HCM-module missing DCM-module missing Device pump pressure high Crusher pressure sensor not in range Setting sensor detected overload

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LT95/LT105

LT200HP

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Toggle plate failure Bypass conveyor safety Bypass conveyor motor overload Return conveyor safety switch Return conveyor motor overload Generator voltage Generator thermistor Generator frequency Cone crusher feedback Vibration chute motor overload Feeder hopper level sensor not in range Metal detected Engine air filter clogged Lifting conveyor safety Device pump 2 oil pressure high Belt tensioning failure, controlled output HCM XM1.1 is not active! Belts are loosened or pre-tensioning is ongoing Side conveyor motor overload Crusher stop without ramp Feed authorization lost Lifting conveyor speed low Device pump 2 oil pressure sensor out of range Impactor crusher slow speed alarm Impactor cover open alarm Impactor speed fault or jammed crusher FB fault Cone crusher in service mode Process disabled: cone crusher alarm Connection between IC570 and IC70 is lost Wintermode with internal power supply is activated. Main conveyor low speed Engine cooler current feed back fault! Cooler to the max speed. Charger fault, System voltage low Screen discharge conveyor jammed or speed sensor fault Lubrication oil tank temperature sensor not in range process disabled: Lubrication tank oil too cold Lubrication return oil temperature sensor not in range Lubrication oil too hot Crusher speed sensor fault or crusher jammed HP crusher slow speed

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HP crusher hydraulic pump feedback fault HP crusher excessive power limit alarm Clamping pressure fault Release pressure fault countershaft pressure fault lubrication oil level low lubrication pump low speed alarm Analog cavity level sensor not in range Lubrication pump safety device tripped setting sensor A fault setting sensor B fault clutch pressure switch alarm Lubrication oil cooler safety device tripped Oil heating alarm due to lifting conv. safety or conv. maintenance switch Too short time since last start attempt Clutch pressure sensor not in range Clutch pressure sensor is not in use Gearbox oil temperature high Clutch slip % too high Crusher axle speed sensor fault Clutch pressure alarm Dust removal motor overload Electric outlet motor protection Engine: coolant temperature Engine: oil pressure Engine: coolant level Engine: fuel filter blocked Device pump 3 pressure high Device pump 3 pressure sensor not in range Magnetic separator motor overload Hand valves active Gearbox oil temperature sensor not in range Crusher drive axle speed sensor not in use. Clutch slip % cannot be monitored! Uncontrolled crusher movement: Possible gearbox failure! Gearbox start failed Gearbox start failed again. Frequent starts may damage the clutch! Gearbox oil temperature sensor is not in use Clamping pressure sensor not in range Clamping pressure high Crusher must be stopped (0 rpm) before belts can be loosened Additional emergency stop 1 pressed Additional emergency stop 2 pressed Track driving failure, uncontrolled HCMoutput is active! Left track feedback fault

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IC500 / IC600 Instruction Manual 127 128 129 130 131 132 133 134 135 136 137 138

139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160

Right track feedback fault Distribution gearbox failure, uncontrolled output ECM XM2.1 is active! Main conveyor motor overload Vibration chute motor overload SERVICE NOTIFICATION: Check autolube / lubricate crusher bearings Crusher idling power high Crusher speed low too long, clutch is released Engine speed low Roller grizzly jammed Feeder feedback fault Feed stop, crusher setting adjusting activated SERVICE NOTIFICATION: Clean accumulated material from counter weight liner and arm liners Screen under size conveyor left safety switch Screen under size conveyor right safety switch Screen left side conveyor left safety switch Screen left side conveyor right safety switch Screen left side conveyor jammed or speed sensor fault Screen right side conveyor left safety switch Screen right side conveyor right safety switch Screen right side conveyor jammed or speed sensor fault Screen return conveyor left safety switch Screen return conveyor right safety switch Screen return conveyor jammed or speed sensor fault Screen conveyors maintenance switch Screen feedback fault Screen under size conveyor feedback fault Screen side conveyor feedback fault Screen module disconnected Crusher dust seal air blower circuit monitoring fault Control centre dust seal air blower circuit monitoring fault Water pump circuit monitoring fault Setting sensor signal not in range Crusher main shaft in highest allowed position Crusher main shaft in lowest allowed position

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IC500 / IC600 Instruction Manual 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192 193 194 195 196

Minimum setting reached Setting not changing Adjusting pump circuit monitoring fault Crusher high pressure Crusher high power Crusher stopped, lubrication pump not running Crusher stopped, excessive temperature fault from switch Crusher stopped, excessive adjusting pressure Crusher stopped, excessive crusher power Crusher stopped, crusher not idling within 5 minutes Crusher stopped, pressure and power measurement fault Lubrication return oil temperature switch fault Excessive lubrication return oil temperature Crusher stopped, excessive lubrication return oil temperature Crusher stopped, excessive low crusher speed Crusher stopped, low crusher speed Crusher adjusting pressure sensor signal not in range Crusher power calculation fault Uncontrolled crusher movement Crusher drive belts has slipped Bypass conveyor circuit monitoring fault Engine stopped, excessive high hydraulic oil temperature Crusher Maximum power Crusher Maximum pressure Generator Frequency measurement fault Generator Voltage measurement not in range Lubrication oil pressure rise fault Lubrication oil pressure fault Lubrication pump circuit monitoring fault Lubrication oil pressure switch device fault Lubrication oil filter clogged Adjustment oil filter clogged Dust removal fan motor circuit monitoring fault Dust removal vibration motor circuit monitoring fault Heater 1 circuit monitoring fault Heater 2 circuit monitoring fault

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IC500 / IC600 Instruction Manual 197 198 199 200 201 202 203 204 205 206 207 208 209 210 211 212

213

Lubrication oil cooler slow speed circuit monitoring fault Lubrication oil cooler fast speed circuit monitoring fault Engine excessive temperature. Return conveyor circuit monitoring fault Side conveyor circuit monitoring fault Process stopped, external power supply connected Winter mode OFF: Power supply not connected Winter mode Off: Manual control activated Winter mode advised to be used: Lubrication return oil excessive cold Contact calibration sequence interrupted Contact calibration not possible, liners too worn. ACM module missing Engine derated High fuel temperature High inlet air temperature Engine rpm must be at working rpm before generator can supply power for the electric motors Material in crusher on start! Clutch or drive belts may damage.

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The list of alarms can also be found in the Parameters/service window (4) by highlighting and choosing the Alarm icon.

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IC500 / IC600 Instruction Manual 17.2 Diesel Diagnostic Trouble Codes (Active and Stored) In the log files window select number 2 to obtain the engine trouble code log window.

Figure 18.2.1 Diesel diagnostic trouble codes This window shows you the engine trouble codes. By pressing the function key F3 you will be able to select whether to see the active trouble codes (DM1) or previously active (stored) trouble codes (DM2). By default the window always shows the DM1 page first. With F4 and F5 you will be able to scroll the screen. Return to the previous window by pressing F1. Example on how to use the Diesel diagnostic trouble codes: In the DM1 window you can see all active trouble codes concerning the diesel engine. By crossreferencing the SPN and FMI to the list in Appendix 2 you can determine what the problem is. The count tells you how many times a specific trouble code has been active. SPN 111 Translation: SPN FMI Cnt

FMI 1

Cnt 1

= Coolant level = Data valid but below normal operational range - most severe level = Trouble code has been active one (1) time

Engine diagnostic codes according to SAE J1939 are shown in Appendix 2. SPN: Suspect parameter number FMI: Failure mode identifier Refer to Engine Instruction manual.

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IC500 / IC600 Instruction Manual 17.3 Temperature History Log In the log files window select number 3 to obtain the temperature log window.

Figure 18.3.1 Temperature history log The number of module temperatures that are below –40 oC (-40 oF) or above +70 oC (158 oF) is registered in this window by each module. Also, the number of hydraulic oil temperatures that exceed –25 oC (-13oF) and +85 oC (185 oF) is registered. Return to the previous window by pressing F1. 17.4 Parameter Log In the log files window select number 4 to obtain the parameter log window.

Figure 18.4.1 Parameter log In the parameter log window you can see the changed parameters and the date and time when they were changed. You can also see the old and new values. Using the arrow keys you will be able to scroll the screen. Return to the previous window by pressing F1.

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IC500 / IC600 Instruction Manual 17.5 Factory parameters In the log files window select number 5 to obtain the factory parameter window.

Figure 18.5.1 Factory parameters

Select load/save with arrow keys F4 or F5. Confirm your selection by pressing F3 (OK). The Load function will reset the factory parameters.

Saving and loading are only allowed in service mode.

Return to the previous window by pressing F1.

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IC500 / IC600 Instruction Manual

18 Module Program Versions In the diagnostics main window select number 4 (Module program versions) to obtain this window.

Figure 19.1.1 Module program versions

This window shows you the module program versions and the date of the program. In this window you cannot enter any information. 1 2 3 4 5

Device control module Engine control module hydraulic control module Hub junction module Display control unit

Return to the previous window by pressing F1.

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IC500 / IC600 Instruction Manual

19 Reading Input/Output Modules Data Select the Hub XH4 connector of the modules shown in window 5 and this window will be opened.

Figure 20.1.1 Input/output data by connectors 1 2 3

Module Number of the terminal / pin Input/output value

The window shows all pins in the selected connector. A detailed list can be found in the Help file. Value is either 0 (no voltage in the input/output), 1 (input/output active, voltage sent or received), mA-value or V-value.

Help file will contain information on all terminals. You can also use unit electrical diagrams to locate terminals.

Return to the previous window by pressing F1.

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IC500 / IC600 Instruction Manual

20 Replacing a module 20.1 Replacing a control module If a defected control module is found it can be replaced with a new one. After it is replaced and the control system is restarted, the UCD will download the operating program into the module. NOTE: This function is recommended only to be used by Metso Minerals Service

After the control module replacement has been completed, all parameter values must be checked. Remember that supervisor parameters can only be edited in service mode! Please contact Metso Minerals for further information. 20.2 Replacing a display module (UCD) If the new module has a different program or program version it will automatically propose to update the HUB and I/O modules. (Refer to instructions in chapter 20.3) The UCD must be programmed before it is sent to the site. 20.2.1 Updating the HUB and I/O modules Activate the module update function by highlighting the start button and operating the OK key (Fig. 2.3.1.1). This function will take approximately 20 min.

WARNING: DO NOT INTERRUPT the downloading process after the update function has started by turning off the power. This might lead to uncontrollable situations in the I/O modules.

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IC500 / IC600 Instruction Manual

21 Troubleshooting In a fault situation IC helps the user to solve the problem. The alarms and the corresponding help texts give more information on the problem, which makes it easier to find the cause. If the pop-ups of the alarms have already been acknowledged, the lauched alarms can be viewed through the alarm log. In that case the help texts of the alarms can be accessed through the alarm parametrization window. The message field in the main window also offers information when the system prevents a function. In engine-related problem cases the engine trouble code list (SPN/FMI) helps. The buttons of the service platform, main control panel, drive box, and radio controller, related inputs, and some of the outputs can be easily tested in the button test window and the track drive diagnostics window. The statuses of the inputs and outputs of other controls can be viewed in the diagnostic windows of the I/O modules. The purpose of the pins is presented in the help windows and in Appendix 2 of this manual. The electric diagrams of the unit can also be used to locate the correct pinns. Chapter 17.1.1 presents list of all alarms. If the IC-system does not start at all, check the battery voltage, main switch and related fuses.

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IC500 / IC600 Instruction Manual Engine diagnostic codes

Appendix 1 / 1 (8)

ENGINE DIAGNOSTIC CODES SPN ( Suspected Parameter Number ) PID 0 1(1) 2(1) 3(1) 4 5(1) 6(1) 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 Version 2.5

Parameter Single data character length parameters Request parameter Invalid data parameter (see appendix A) Transmitter system status (see appendix A) Transmitter system Diagnostic (see appendix A) Reserved - to be assigned Underrange warning condition (see appendix A) Overrange warning condition (see appendix A) Axle # 2 lift air pressure Brake system air pressure low warning switch status Axle lift status Axle slider status Cargo securement Brake stroke status Entry assist position/deployment Entry assist motor current Fuel supply pump inlet pressure Suction side fuel filter differential pressure Engine oil level remote reservoir Extended range fuel pressure Extended range engine oil pressure Extended range engine coolant pressure Engine ECU temperature Extended engine crankcase blow-by pressure Generator oil pressure Generator coolant temperature Air conditioner system status # 2 Estimated percent fan speed Percent Exhaust gas recirculation valve # 1 position Percent accelerator position # 3 Percent accelerator position # 2 Crankcase blow-by pressure Transmission range position Transmission splitter position Clutch cylinder position Clutch cylinder actuator status Shift finger actuator status # 2 Clutch plates wear condition Transmission tank air pressure Second fuel level (right side) Tire pressure check interval Engine retarder switches status Cruise control switches status Pressure switch status Ignition switch status Attention/warning indicator lamps status 79/93

IC500 / IC600 Instruction Manual Engine diagnostic codes 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95

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Appendix 1 / 2 (8)

Inlet air heater status Vehicle wet tank pressure Retarder status Extended range barometric pressure ABS control status Air conditioner system clutch status/command # 1 Throttle position Engine intercooler temperature Transmission synchronizer clutch value Transmission synchronizer brake value Shift finger actuator status # 2 Transmission range switch status Transmission actuator status # 2 Shift finger actuator status Shift finger gear position Shift finger rail position Parking brake actuator status Retarder inhibit status Transmission actuator status # 1 Direction switch status Service brake switch status Vehicle enabling component status Shift request switch status Torque limiting factor Two speed axle switch status Parking brake switch status Idle shutdown timer status Blower bypass value position Auxiliary water pump pressure Maximum road speed limit Steering axle temperature Axle # 1 lift air pressure Forward rear drive axle temperature Rear rear-drive axle temperature Road surface temperature Washer fluid level Particulate trap inlet pressure Air start pressure Road speed limit status Road speed Cruise control status Cruise control set speed Cruise control high-set limit speed Cruise control low-set limit speed Power takeoff status PTO oil temperature Percent accelerator pedal position Percent engine load Output torque Fuel delivery pressure Fuel filter differential pressure

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IC500 / IC600 Instruction Manual Engine diagnostic codes 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145

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Appendix 1 / 3 (8)

Fuel level Water in fuel indicator Engine oil level Engine oil filter differential pressure Engine oil pressure Crankcase pressure Boost pressure Turbo speed Turbo oil pressure Intake manifold temperature Air inlet pressure Air filter differential pressure Barometric pressure Coolant pressure Engine coolant temperature Coolant level Coolant filter differential pressure Governor droop New battery current Alternator current Brake application pressure Brake primary pressure Brake secundary pressure Hydraulic retarder pressure Hydraulic retarder oil temperature Engine retarder status Engine retarder percent Clutch pressure Transmission oil level Transmission oil level high/low Transmission filter differential pressure Transmission oil pressure Double data character length parameters Component-specific request Injector metering rail # 2 pressure Power specific fuel economy Exhaust back pressure Mass air flow Average fuel rate Wheel speed sensor status Extended range fuel delivery pressure (absolute) Auxiliary vacuum pressure reading Auxiliary gage pressure reading # 1 Auxiliary absolute pressure reading Tire pressure control system channel functional mode Tire pressure control system solenoid status Trailer # 1, tag # 1, or push channel # 1 tire pressure target Drive channel tire pressure target Steer channel tire pressure target Trailer # 1, tag # 1, or push channel # 1 tire pressure Drive channel tire pressure

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IC500 / IC600 Instruction Manual Engine diagnostic codes 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192 193(1) 194

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Steer channel tire pressure Average fuel economy (natural gas) Instantaneous fuel economy (natural gas) Fuel mass flow rate (natural gas) PTO engagement control status ATC control status Number of ECU resets Crankcase pressure Auxiliary input and output status # 2 Auxiliary input and output status # 1 Injector timing rail pressure Injector metering rail pressure Battery potential (voltage) - switched Gas supply pressure Main shaft speed Input shaft speed Transmission range selected Transmission range Attained Injection control pressure Compass bearing Rated engine power Alternator potential (voltage) Battery potential (voltage) Cargo ambient temperature Cab interior temperature Ambient air temperature Air inlet temperature Exhaust gas temperature Fuel temperature Engine oil temperature Turbo oil temperature Transmission # 1 oil temperature Front axle weight Rear axle weight Trailer weight Cargo weight Trip fuel Fuel rate (instantaneous) Instantaneous fuel economy Average fuel economy Power takeoff speed Power takeoff set speed Idle engine speed Rated engine speed Engine speed Transmission output shaft speed Variable and long data character length parameters Multisection parameter Transmitter system diagnostic table (see appendix A) Transmitter system diagnostic code and occurrence count table

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IC500 / IC600 Instruction Manual Engine diagnostic codes 195 196 197 198 199 200 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218 219 220 221 222 223 224 225 226 227 228 229 230 231 232 233 234 235 236 237 238 239 240 241 242 243 244 245

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Diagnostic data request/clear count Diagnostic data/count clear response Connection management Connection mode data transfer Traction control disable state Reserved - to be assigned Reserved - to be assigned Reserved - to be assigned Reserved - to be assigned Reserved - to be assigned Reserved - to be assigned Reserved - to be assigned Reserved - to be assigned Reserved - to be assigned ABS control status, trailer Tire temperature (by sequence number) Tire pressure (by sequence number) Tire pressure target (by sequence number) Wheel end assembly vibration level Vehicle wheel speeds Brake temperature Wheel bearing temperature Fuel tank/nozzle identification State line crossing Current state and country Engine torque history Anti-theft request Anti-theft status Auxiliary A/D counts Immobilizer security Reserved for text message acknowledged Reserved for text message to display Reserved for text message display type Speed sensor calibration Total fuel used (natural gas) Total idle fuel used (natural gas) Trip fuel (natural gas) DGPS differential correction Unit number (power unit) Software identification Total idle hours Total idle fuel used Vehicle identification number Velocity vector Vehicle position Change reference number Tire pressure by position Tire temperature by position Component identification Trip distance Total vehicle distance

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IC500 / IC600 Instruction Manual Engine diagnostic codes 246 247 248 249 250 251 252 253 254 255

256 (0) 257(1) 258(2) 259(3) 260-361 362(106) 363(107) 364(108) 365(109) 366(110) 367(111) 368(112) 369(113) 370(114) 371(115) 372(116) 373(117) 374(118) 375(119) 376(120) 377(121) 378(122) 379(123) 380(124) 381(125) 382(126) 383(127) 384(128) 385-405 406(150) 407(151) 408(152) 409(153) 410(154) 411(155) 412(156) 413(157)

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Appendix 1 / 6 (8)

Total vehicle hours Total engine hours Total PTO hours Total engine revolutions Total fuel used Clock Date Elapsed time Special parameters Data link escape Extension Single data character length parameters (modulo 256 value identified in parentheses) Request parameter Cold restart of specific component Warm restart of specific component Component restart response Reserved (page 2) to be assigned Percent exhaust gas recirculation valve # 2 position Hydraulic retarder control air pressure HVAC unit discharge temperature Weighing system status command Engine oil level high/low Lane tracking system status Lane departure indication Distance to rear object (reverse) Trailer pneumatic brake control line pressure Trailer pneumatic supply line pressure Remote accelerator Center rear drive axle temperature Alternator AC voltage Fuel return pressure Fuel pump inlet vacuum Compression unbalanced Fare collection unit status Door status Articulation angle Vehicle use status Transit silent alarm status Vehicle acceleration Double data character length parameters Component-specific request Reserved (page 2 ) -to be assigned HVAC blower motor speed Axle group full weight calibration Axle group empty weight calibration Axle group weight Extended range road surface temperature Recirculated engine exhaust gas differential pressure Recirculated engine exhaust gas temperature Net vehicle weight change

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IC500 / IC600 Instruction Manual Engine diagnostic codes 414(158) 415(159) 416(160) 417(161) 418(162) 419(163) 420(164) 421(165) 422(166) 423(167) 424(168) 425(169) 426(170) 427(171) 428(172) 429(173) 430(174) 431(175) 432(176) 433(177) 434(178) 435(179) 436(180) 437(181) 438(182) 439(183) 440(184) 441(185) 442(186) 443(187) 444(188) 445(189) 446(190) 447(191) 448(192) 449(193) 450(194) 451-497 498(242) 499(243) 500(244) 501(245) 502(246) 503(247) 504(248) 505(249) 506(250) 507(251) 508(252) 509(253)

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Appendix 1 / 7 (8)

Air conditioner Refrigerant low side pressure Air conditioner refrigerant high side pressure Evaporator temperature Gross vehicle weight Transmission # 2 oil temperature Starter circuit resistance Starter current (average) Alternator/generator negative cable voltage Auxiliary current Extended range net battery current DC voltage Auxiliary frequency Alternator/generator field voltage Battery resistance change Battery internal resistance Starter current peak Starter solenoid voltage Starter negative cable voltage Starter motor voltage Fuel shutoff solenoid voltage AC voltage Cargo ambient temperature (by location) Trip sudden decelerations Trailer # 2, tag # 2, or push channel # 2 tire pressure target Trailer # 2, tag # 2, or push channel # 2 tire pressure Extended range boost pressure # 1 Extended range boost pressure # 2 Auxiliary temperature # 1 Auxiliary temperature # 2 Auxiliary gage pressure reading # 2 Battery # 2 potential (voltage) Cylinder head temperature bank B (right bank) Cylinder head temperature bank A (left bank) Passenger counter Variable and long data character length parameters Page 2 multisection parameter Reporting interval request Bridge filter control Reserved (page 2) -to be assigned Send keypress command Driver interface unit (DIU) object/form command Intersection preemption status and configuration Signage message Fare collection unit - point of sale Fare collection unit - service detail Annunciator voice message Vehicle control head keyboard message Vehicle control head display message Driver identification Transit route identification Mile post identification

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Appendix 1 / 8 (8)

Special parameters 510(254) Page 2 data link escape 511(255) Page 2 extension (1) = these PIDs are superseded by PIDs 194, 195 and 196

FMI (Failure Mode Identifier) 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 – 30 31

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Data valid but above normal operational range - most severe level Data valid but below normal operational range - most severe level Data erratic, intermittent or incorrect Voltage above normal or shorted to high source Voltage below normal or shorted to low source Current below normal or open circuit Current above normal or grounded circuit Mechanical system not responding or out of adjustment Abnormal frequency or pulse width or period Abnormal update rate Abnormal rate of change Root cause not known Bad intelligent device or component Out of calibration Special instructions Data valid but above normal operating range - least severe level Data valid but above normal operating range - moderately severe level Data valid but below normal operating range - least severe level Data valid but below normal operating range - moderately severe level Received network data in error Reserved for SAE assignment Not available or condition exists

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IC500 / IC600 Instruction Manual I/O List

Appendix 2 / 1 (7)

Input/Output List

HUB Input/Output data

Terminal/no = explanation XH4/1 = +24V (System supply) XH4/2 = +24V (System supply) XH4/3 = Not in use XH4/4 = Not in use XH4/5 = Not in use XH4/6 = Not in use XH4/7 = Not in use XH4/8 = Not in use XH4/9 = Ground XH4/10 = Ground XH4/11 = Emergency stop, control centre XH4/12 = Emergency stop, service platform XH4/13 = Emergency stop, engine module XH4/14 = Emergency stop, hydraulic module XH4/15 = BSL XH4/16 = CAN2 H XH4/17 = CAN2 L XH4/18 = RS485 H XH4/19 = RS485 L XH4/20 = Not in use (additional e-stop) XH4/21 = Not in use (additional e-stop) XH4/22 = Ref + XH4/23 = Ref -

Terminology: AI = Analog input AO = Analog output PI = Pulse input FB = Feedback O/ = Output O-PWM = Pulse Width Modulation output BSL = Boot sequence line

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Appendix 2 / 2 (7)

DCM Input/Output data

Terminal/no = explanation XM1/1 = O/Primary feeder authorization pause XM1/2 = O/ Dust removal unit vibrator XM1/3 = O/ Dust removal unit fan XM1/4 = Key switch on start position XM1/5 = Not in use XM1/6 = Not in use XM1/7 = Process start button XM1/8 = Process stop button XM1/9 = Ground XM1/10 = Ground XM1/11 = Ground XM1/12 = Fuel level sensor /AI XM1/13 = (+24 V) output to sensors/switches etc. XM1/14 = Metal detector alarm XM1/15 = O/ screen support legs up XM1/16 = O/Crusher running XM1/17 = Not in use XM1/18 = Sound alarm horn XM1/19 = Not in use (electric outlet protection OK) XM1/20 = Radio operation selected XM1/21 = Feeder support legs are down (LT300HP only) XM1/22 = O/Primary feeder authorization XM1/23 = Lifting conveyor safety switch

XM2/1 = Hydraulic hammer operating switch XM2/2 = Not in use XM2/3 = Not in use XM2/4 = Not in use XM2/5 = Secondary LT level high, feeder paused XM2/6 = Secondary LT level alarm, feeder stopped XM2/7 = Feeder bottom heater (not available) XM2/8 = Not in use XM2/9 = Secondary LT connected XM2/10 = Feeder speed + (service platform) XM2/11 = (+24 V) Not in use XM2/12 = Feeder speed – (service platform) XM2/13 = Ground XM2/14 = Ground XM2/15 = Ground XM2/16 = Feeder start (service platform)

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Appendix 2 / 3 (7)

XM2/17 = Feeder stop (service platform) XM2/18 = Setting increase (service platform) Feed funnel down (service platform) XM2/19 = Setting decrease (service platform) Feed funnel up (service platform) XM2/20 = Crusher off (service platform) XM2/21 = Crusher on (service platform) XM2/22 = Crusher swing normal direction (service platform) XM2/23 = Crusher swing reverse direction (service platform

XM3/1 = +12 V XM3/2 = +5 V XM3/3 = Ground XM3/4 = Ground XM3/5 = Drive box right track forward XM3/6 = Drive box left track forward XM3/7 = Drive box right track backward XM3/8 = Module identification /AI XM3/9 = +12 V XM3/10 = +5 V XM3/11 = Ground XM3/12 = Ground XM3/13 = Drive box left track backward XM3/14 = Crusher setting sensor /AI XM3/15 = BSL XM3/16 = Crusher speed /PI XM3/17 = Crusher level high XM3/18 = LT200HP lifting conveyor rotation detector XM3/19 = Drive box engine rpm + XM3/20 = Drive box engine rpm – XM3/21 = Drive box connected XM3/22 = Drive box remote stop XM3/23 = Not in use

Terminology: AI = Analog input AO = Analog output PI = Pulse input FB = Feedback O/ = Output O-PWM = Pulse Width Modulation output BSL = Boot sequence line

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Appendix 2 / 4 (7)

ECM Input/Output data

Terminal/no = explanation XM1/1 = O/ Flash alarm XM1/2 = O/ Vibration chute XM1/3 = O/ Distribution gearbox “choke” XM1/4 = By pass conveyor electric motor protective switch ok XM1/5 = FB/ Engine cooler control XM1/6 = Not in use XM1/7 = Generator voltage protection circuit alarm XM1/8 = Air filter condition XM1/9 = Ground XM1/10 = Ground XM1/11 = Ground XM1/12 = AI / Cone crusher analog / digital cavity level XM1/13 = (+24 V) XM1/14 = O/ Lubrication tank oil temperature ok. / Return conveyor XM1/15 = O/ HP crusher XM1/16 = O/ HP crusher soft start XM1/17 = Not in use XM1/18 = Counter shaft pressure XM1/19 = Lubrication oil level XM1/20 = Not in use (RADIO) XM1/21 = Electric driven lubrication pump protective switch ok XM1/22 = Side conveyor electric motor protective switch ok XM1/23 = Return conveyor electric motor protective switch ok

XM2/1 = O/ Crusher speed normal direction (current in mA) O/ Impact crusher hydraulic pump valve ………….O/ distribution gearbox clutch valve XM2/2 = O/Crusher speed reverse direction (current in mA) O/Impact crusher hydraulic adjust motor valve XM2/3 = FB/Crusher speed both directions (current in mA) FB/Impact crusher hydraulic pump valve XM2/4 = FB/Impact crusher hydraulic adjust motor valve XM2/5 = O/Engine start XM2/6 = O/Engine stop solenoid XM2/7 = O/Horn XM2/8 = Generator frequency alarm XM2/9 = Generator thermistor alarm XM2/10 = O/ hydraulic cooler fan / lubrication oil cooler fan XM2/11 = (+24 V) XM2/12 = Hydraulic oil temperature /AI XM2/13 = Ground XM2/14 = Ground XM2/15 = Ground XM2/16 = Hydraulic oil filters

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Appendix 2 / 5 (7)

XM2/17 = Hydraulic oil level XM2/18 = Hydraulic oil main valve XM2/19 = Clamping pressure switch XM2/20 = Release pressure switch XM2/21 = Distribution gearbox clutch pressure switch XM2/22 = PWM / Engine cooler control XM2/23 = O/ cone crusher lubrication pump

XM3/1 = +12 V XM3/2 = +5 V XM3/3 = Ground XM3/4 = Ground XM3/5 = Cone crusher lubrication tank oil temperature XM3/6 = Crusher pressure /AI XM3/7 = Cone crusher lubrication oil return oil temperature XM3/8 = Module identification /AI XM3/9 = +12 V XM3/10 = +5 V XM3/11 = Ground XM3/12 = Ground XM3/13 = AI/ Distribution gearbox clutch pressure XM3/14 = Not in use XM3/15 = BSL XM3/16 = PI/ crusher speed XM3/17 = PI/ Cone crusher setting sensor A XM3/18 = PI/ Cone crusher setting sensor B XM3/19 = PI/ Crusher drive shaft speed XM3/20 = PI/ Speed of hydraulic driven lubrication pump XM3/21 = Vibrating chute motor protective switch ok XM3/22 = Hydraulic pump safety device XM3/23 = Electric driven lubrication oil cooler fan motor protective switch ok

Terminology: AI = Analog input AO = Analog output PI = Pulse input FB = Feedback O/ = Output O-PWM = Pulse Width Modulation output BSL = Boot sequence line

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Appendix 2 / 6 (7)

HCM Input/Output data

Terminal/no = explanation XM1/1 XM1/2 XM1/3 XM1/4 XM1/5 XM1/6 XM1/7

= O/Screen hydraulic valve CW (clockwise) = O/Screen hydraulic valve CCW (counter-clockwise) = O/Screen conveyors hydraulic valve = Side conveyor safety switch, right side = Not in use = Not in use = O/LS pressure discharge valve O/Impact magnetic separator or side conveyor on XM1/8 = O/Hydraulic power take off (PTO) valve XM1/9 = Ground XM1/10 = Ground XM1/11 = Ground XM1/12 = Not in use XM1/13 = (+24 V) XM1/14 = O/Hand valves hydraulic valve XM1/15 = O/Main conveyor hydraulic valve XM1/16 = O/Magnetic separator hydraulic valve XM1/17 = O/Side conveyor hydraulic valve XM1/18 = Screen module connected XM1/19 = Screen module safety switch, oversize conveyor XM1/20 = Screen module safety switch, undersize conveyor XM1/21 = Side conveyor safety switch, left side XM1/22 = Main conveyor safety switch, right side XM1/23 = Main conveyor safety switch, left side

XM2/1 XM2/2 XM2/3 XM2/4 XM2/5

= O/Fast track drive hydraulic valve = O/Scalper / Lifting conveyor = Not in use = Not in use = O/Feeder valve power-line O/Impact funnel up with scalper valve power-line XM2/6 = O/Left track valve power-line XM2/7 = O/Right track valve power-line XM2/8 = O-PWM/Feeder control value O-PWM/Impact funnel up with scalper control value ………….O/ PWM LC feeder XM2/9 = O-PWM/Left track control value XM2/10 = O-PWM/Right track control value XM2/11 = (+24 V) XM2/12 = AI/ Hydraulic oil temperature circuit #2 XM2/13 = Ground XM2/14 = Ground XM2/15 = Ground

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IC500 / IC600 Instruction Manual I/O List

Appendix 2 / 7 (7)

XM2/16 = O/ Setting increase hydraulic valve O/ Impact funnel up if not scalper ………….O/ return conveyor XM2/17 = O/Setting decrease hydraulic valve …………..O/ by pass conveyor XM2/18 = Conveyors maintenance switch XM2/19 = Not in use XM2/20 = Not in use XM2/21 = Hand valves XM2/22 = O/Clamping cylinder – pressurize, hydraulic valve XM2/23 = O/Clamping cylinder – unpressurize, hydraulic valve …………..PWM / Lifting conveyor

XM3/1 = +12 V XM3/2 = +5 V XM3/3 = Ground XM3/4 = Ground XM3/5 = Belt scale /AI (FUTURE PLAN) XM3/6 = Toggle pressure /AI (FUTURE PLAN) …………..AI / Feed hopper level sensor XM3/7 = AI/ Component pump pressure XM3/8 = Module identification XM3/9 = +12 V XM3/10 = +5 V XM3/11 = Ground XM3/12 = Ground XM3/13 = Not in use XM3/14 = Clamping pressure /AI XM3/15 = BSL XM3/16 = Feeder speed /PI XM3/17 = Main conveyor speed /PI XM3/18 = Toggle plate condition XM3/19 = PI/ Screen discharge conveyor speed XM3/20 = Return conveyor safety switch XM3/21 = Impact crusher cover open limit switch / by pass conveyor safety switch XM3/22 = Lifting conveyor feeder motor protective switch ok XM3/23 = Not in use

Terminology: AI = Analog input AO = Analog output PI = Pulse input FB = Feedback O/ = Output O-PWM = Pulse Width Modulation output BSL = Boot sequence line

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