Electrical - J1175 - Troubleshooting - v1 (Read-Only)
Electrical - J1175 - Troubleshooting - v1 (Read-Only)
Electrical - J1175 - Troubleshooting - v1 (Read-Only)
TROUBLESHOOTING AGENDA
System Troubleshooting
Common Issues
Starting
ESTOP Faults
Hetronic
STARTING PROBLEMS
-If there are no active faults on screen and the system 24.00
has booted up successfully then the next step is to look at
the Starter solenoid within the power unit.
-This starter solenoid energises upon turning the
starter key.
-To check the functionality of this solenoid, use a
Multimeter to check voltage between the;
-RED & WHITE wire (+VE)
-BROWN & WHITE Wire (-VE)
-This Voltage should be 24V when the key
is being held.
THE BASICS
-If not then check all heavy duty fuses in this line, and
connections back the whole way to the battery, there is a bad
connection / break somewhere in this line.
-Is the engine turning but not firing? If so the issue is non electrical and related to
fuelling or some onboard engine problem. Check the messenger for fault codes or the
diagnostic lamp.
-If not there is an active fault / or bad connection, check to see if K6 relay is
engaging after pre-start siren
-If it is then check 5A Fuse no (5), check starter solenoid in power unit is coming
on with key crank, and check voltage at starter & starter GND connections. If the
starter is receiving a 24v signal (6mm red wire) but still not turning then it may be
sticking / faulty.
ESTOP FAULTS
THE BASICS
ESTOP FAULTS
*START HERE*
Å Channel 1 read to the left Channel 2 read to the right ->
PROLEMATIC STOP PROBLEMATI LED CH1 – Remains OFF when LED CH2 – remains OFF when PROBLEMATI PROLEMATIC STOP
C CABLES shorting the following terminals on shorting the following terminals on C CABLES
the K1 Relay the K1 Relay
K1 Relay, is either powered off / faulty / S11 – S12 S21 – S22 K1 Relay, is either powered off / faulty /
has SHORT on channel(s) check PWR LED has SHORT on channel(s) check PWR
LED
PROLEMATIC STOP PROBLEMATI LED CH1 – Remains OFF when LED CH2 – Remains OFF when PROBLEMATI PROLEMATIC STOP
C CABLES shorting the following terminals on shorting the following terminals on C CABLES
the DIN rail the DIN rail
PROBLEMATIC STOP PROBLEMATI LED CH1 – comes ON when LED CH2 – comes ON when shorting PROBLEMATI PROBLEMATIC STOP
C CABLES shorting the following DIN rail the following DIN rail terminals C CABLES
(cores) terminals (cores)
*START HERE*
Å Channel 1 read to the left Channel 2 read to the right ->
PROLEMATIC STOP PROBLEMATI LED CH1 – Remains OFF when LED CH2 – remains OFF when PROBLEMATI PROLEMATIC STOP
C CABLES shorting the following terminals on shorting the following terminals on C CABLES
the K1 Relay the K1 Relay
K1 Relay, is either powered off / faulty / has S11 – S12 S21 – S22 K1 Relay, is either powered off / faulty /
SHORT on channel(s) check PWR LED has SHORT on channel(s) check PWR LED
PROLEMATIC STOP PROBLEMATI LED CH1 – Remains OFF when LED CH2 – Remains OFF when PROBLEMATI PROLEMATIC STOP
C CABLES shorting the following terminals on shorting the following terminals on C CABLES
the DIN rail the DIN rail
PROBLEMATIC STOP PROBLEMATI LED CH1 – comes ON when LED CH2 – comes ON when shorting PROBLEMATI PROBLEMATIC STOP
C CABLES shorting the following DIN rail the following DIN rail terminals C CABLES
(cores) terminals (cores)
A
-The two TCA’S provide pump control,
translating the CAN messages from the PLC
controller, into drive signals for the A & B B
pump coils. The signals to both coils are
balanced.
CAN High
-The ESP sensor provides feedback to the
CAN Low
TCA on the current position of the pump
swash plate, this position is them maintained 12v Supply
through constant ‘dithering’ of the A & B coil GND
currents to ‘hold’ the swash plate at its GND
desired ‘COMMANDED’ position.
SNR GND
-There are a number of different elements SIGNAL
combined in this part of the system that
provide the pump control (TCA Inputs and SNR +VE
0utputs)
INPUTS
TCA Pump Control
#46 #47
TCA Errors / Faultfinding
14 LHS TCA S2 SHORT #46 LHS – Left Hand Side (46 is normally referred to as the LHS TCA
15 LHS TCA POWER SUPPLY #46 as it is mounted to the left inside the control panel)
16 LHS TCA ESP SUPPLY #46
17 LHS TCA S1 OPEN #46 RHS – Right Hand Side (47 is normally the RHS TCA)
18 LHS TCA S2 OPEN #46
19 LHS TCA S1 OFFSTATE #46 ESP - This is the swash plate sensor positioned as identified on
20 LHS TCA S2 OFFSTATE #46 the pump (previous slide)
21 RHS TCA TRACKING ERROR #47
22 RHS TCA ESP RANGE #47 S1 – S1 is one of the control solenoids on the pump section (A)
23 RHS TCA ESP RATE #47
24 RHS TCA ESP NEUTRAL DRIFT #47 S2 – S2 is the other control solenoid on the pump section (B)
25 RHS TCA S1 SHORT #47
26 RHS TCA S2 SHORT #47 OPEN - The TCA does not see any load (the circuit is open/broken)
27 RHS TCA POWER SUPPLY #47
28 RHS TCA ESP SUPPLY #47 SHORT - The TCA sees a load with little/no resistance/ Short circuit.
29 RHS TCA S1 OPEN #47
14 LHS TCA S2 SHORT #46 (9) & (21) Tracking Error – This is not as sometimes assumed an
15 LHS TCA POWER SUPPLY #46 error directly associated with the tracks of the machine itself.
16 LHS TCA ESP SUPPLY #46 TRACKING in this case refers to the ‘tracking’ or ‘monitoring’ of
17 LHS TCA S1 OPEN #46 the position of the pump SWASH plate.
18 LHS TCA S2 OPEN #46
19 LHS TCA S1 OFFSTATE #46 The swash plate drives the pistons within the pump. If a critical
20 LHS TCA S2 OFFSTATE #46 error occurs within the pump; causing the swash plate to drive
21 RHS TCA TRACKING ERROR #47 ‘ON’ without being commanded; the TCA through the ESP sensor
22 RHS TCA ESP RANGE #47 recognises that the swash plate is outside of its allowed error
23 RHS TCA ESP RATE #47 limit and reacts by shutting down the pump. This is a safety
24 RHS TCA ESP NEUTRAL DRIFT #47 critical feature of the pump.
25 RHS TCA S1 SHORT #47
26 RHS TCA S2 SHORT #47 As the hydrostatic pumps are both utilised while the machine is
27 RHS TCA POWER SUPPLY #47 being moved ‘tracked’ if a pump ‘tracking error’ occurs; customers
28 RHS TCA ESP SUPPLY #47 automatically assume that there is some issue with the
29 RHS TCA S1 OPEN #47 tracks/tracking mode itself. It is important to distinguish this.
30 RHS TCA S2 OPEN #47
Pump commands
The pump command is distinguished on the PLC as a value of between 0 and 1000
CRUSHER CRUSHER
ROTATION ROTATION
FORWARD NEUTRAL REVERSE
50% FWD
This is a J1175 Pump operating; when the This is a J1175 Pump operating; that has
jaw is completely jammed with material. suffered a tracking error on one side
TCA – Possible Fault conditions
9 LHS TCA TRACKING ERROR #46 (10) & (22) - The TCA ESP Range fault is when the output
10 LHS TCA ESP RANGE #46 of the swash sensor is beyond the legal range (above 90%
11 LHS TCA ESP RATE #46
or below 10%) of the sensor supply voltage.
12 LHS TCA ESP NEUTRAL DRIFT #46
29 RHS TCA S1 OPEN #47 (19)(20) & (31)(32) - The off state errors are a internal
30 RHS TCA S2 OPEN #47 solenoid current monitoring circuit fault and can't be
31 RHS TCA S1 OFFSTATE #47 checked from the outside of a unit.
32 RHS TCA S2 OFFSTATE #47
TCA TRACKING Errors
-First indication of what exactly is causing a TCA Tracking error; can be obtained from the
‘CONFIGURATION MODE’ under node inputs / outputs.
As we have identified tracking errors to be associated with the pump, and the difference between
its commanded and actual positions; from this screen; we can see where the pump is being asked to
go to and the position it is currently in.
#46 #47
TCA – TRACKING ERROR
As tracking errors are associated with the swash plate position there are a
number of electrical and mechanical possible causes for this fault.
-No Signal / Incorrect signal from the ESP Sensor itself (actual position of
zero normally indicates a disconnected sensor)
-Sudden – De-swash within the pump; (loss of charge pressure causing pump/one
half to return to neutral position. I1312 dump valve switching off can cause this,
Also IPOR kicking in will de-swash the pump, if this happens we do not
‘electrically’ that this has happened and therefore get a tracking error)
-This error can be flagged by issues else where in the system, checking the
machine alarm history will indicated if a tracking error is the primary event, or
secondary cause by for example and ESTOP being pushed during crushing.
There are many other conditions that will cause tracking errors these are just a
few pointers
TCA TRACKING Errors
This basic investigation will determine the cause of the fault; to one of three
areas, the TCA’S the Pump or the Cables
TCA TRACKING Errors
NODES – Faultfinding
-There are two fault codes that reference / inform the user of faults on the CAN bus.
However; other faults can be ‘flagged up’ due to the CAN signal being lost, sensor faults
& outputs that are not working can all be associated with losses of CAN network signals.
-For this reason; with any fault associated with a node input/output it is good practice to
check the PWR and DIA LED’s on each individual node.
-CAN Node errors and CAN Bus errors are all associated with the CAN network;
these errors can be flagged by;
-Incorrect network resistance
-Loose / Badly connected cables & T blocks
-Moisture ingress into Nodes
NODES Faultfinding
NODES – Faultfinding
-Nodes should indicate their status at all times when machine is powered up. This is
achieved through the (PWR) LED on the front of the Unit
NODES Faultfinding
NODES – Faultfinding
FAULT
33. CAN BUS Error
X X X
ERROR
GO TO configuration mode – (node inputs / outputs) – CAN Nodes (F6)
Observe ‘Node diagnosis’ page X
Faults will be indicated by the existence of ‘X’ on the section with an error. Any nodes
showing an error physically check the LED on that node for errors (green flashing
light etc).
Pushing (F6) reset will reset all nodes and will clear all faults, for currently active
faults the error will return after the reset cycle has expired
FIX
1. For an error that doesn’t return, it is intermittent, and is likely to be a cable loose /
worn / damaged. See checking CAN network section
2. For a currently active fault – there is a fault with the can network. Check the nodes
that are showing faults, and the associated cables.
3. For a node with no LED’s on; check the power (DC volts) at this node (inside the
node cover) – If there is power, and good connection but no node life – node faulty
4. If there is no power then check the associated fuses / circuit breakers (from 24V Constant
schematic) that power the can nodes and switch power; also check the CAN T Pieces Power
and cable integrity.
24V Switch Power
(nodes 2&3)
CAN Network
SUMMARY
-CAN Node errors and CAN Bus errors are all associated with the CAN network;
these errors can be flagged by;
-Always check node LED’s before Key OFF or using RESET when the error
has been flagged.
This error signifies that the R360 Controller has lost communication with some /
All of the units that it ‘Expects’ to see transmitting on the CAN bus.
FAULT
02. Communication Lost With R360
ERROR
This error indicates that the R360 controller has momentarily or permanently lost communication with / does not
‘see’ some or all of the components that it expects to be transmitting unto the CAN network.
This is quite a wide ranging error and can be caused by any faulty component on the CAN Bus, Intermittent /
permanent losses of connection on the can bus, poor fitting / loose can network connections, faults with
individual Nodes / or just specific components on specific nodes / losses of network resistors etc.
FIX
1. Reset the CAN network from the Configuration/NodesInputsOutputs/(F6)CAN_NODES/(F6) RESET
2. For a currently active fault – the reset will fail to fully clear the error; In this case refer to R360 document;
checking network resistance, T-Pieces and connections.
3. Intermittent faults will be cleared by using the reset, and most common causes are loose cables/connections.
Try to distinguish patterns that will help track down the cause; does the error only appear when starting a
specific function? Or during moments of high vibration? Or only on wet days? (indicates moisture ingress that
is corrupting network messages.
CAN Network
FAULT
ERROR
Error indicates that the oil in the tank is low; or there is some fault with the level gauge itself or between there and the PLC.
FIX
1. Check the oil level in the tank
2. If the Oil level is ok check the input on the node (NODE 4 Channel 1) should be ON when oil level is OK. Try shorting out
the terminals on the tank level sensor to see if this light comes on and off. If this works ok the sensor must be faulty.
(LIGHT on node will be ON when the oil is low) Check the Nodes I/O page in config menu.
3. Ensure that the NODE is functioning correctly (Green LED id flashing) if the node is not communicating then no
information from the hydraulic sensor can be received by the PLC. And you need to check out the CAN network.
CAN Network
FAULT
05. Main Conveyor Under-speed
ERROR
The main conveyor is running too slow, the belt is jammed, the wheel is not engaged properly on the belt,
the cable has become worn through or broken,
FIX
1. Check the speed wheel flashing in the PLC IO page in configuration menu, this indicates good signal
2. Check the power at the speed-wheel on PINS 1 & 3, check continuity from PIN4 to Wire 20. If this is all
good then ensure that wheel is seated on and turning with the belt
4. Check integrity of Speed wheel sensor itself and the On Board diode replace as necessary. Contact
Finlay if you wish to temporally switch off the speed sensor to continue working until replacements arrive.
5. Crusher Speed Fault
FAULT
ERROR
The crusher is running too slow – the sensor or cable are damaged, or the sensor is loose or too far away from the
toothed wheel target.
FIX
1. Check the clearance of the sensor with the toothed wheel, it should be quite close; and secure approx 3mm
2. Check the I/O screen for the Nodes; Node 3 Channel 3. This should be seen as ON when the sensor can see that
the crusher is running fast enough. The sensor can be adjusted to switch ON at a different speed point; however It
should not be necessary after it has been factory set; and you will have to measure the speed of the chamber with a
tachometer to ensure that it is running fast enough.
7. Crusher High Pressure Fault
FAULT
ERROR
The crusher is has become blocked or the pressure in the crushing chamber has been above the
pressure high set point for the duration of the crusher high pressure time.
FIX
2. Watch the pressure on the screen while running; and if necessary change application, Crusher soft
Rock, Hard rock / Demolition / Recycle. This will kick out the feeder earlier on the pressure scale and
therefore avoid overfilling the Jaw.
8. Radio Stop Fault
FAULT
08. Radio Stop Fault
ERROR
Crusher FULL REMOTE (F6) has been activated but Hetronic receiver does not ‘see’ a healthy signal
from the handset. Or the Receiver is OFF/FAULTY/DAMAGED
FIX
1. Ensure the customer is initialising the remote control in the correct sequence. [ PULL OUT stop
button, SWITCH ON remote and wait for healthy signal (flashing green) THEN switch on remote
enable (F6)
a. Make sure remote battery is well charged
b. Check functionality of remote stop button (pulling in and out, with remote ON will change rate of
flash of GREEN LED) if this does not happen, button in broken / remote is damaged from previous
(twisting) of the button. If warranty is not to be claimed on the unit then remove rear cover and check
integrity of STOP button wiring)
2. Check Hetronic Receiver for Power
FAULT
39. Hydraulic Oil Temperature Fault
ERROR
On start-up the system runs a checking routine that checks the integrity of the hydraulic oil sensor. If the
system finds that the sensor is drawing too much current; this error is flagged
FIX
1. Ensure that the node is communicating correctly; if the node is faulty or has intermittent power then it
can cycle in/out of this routine and the system can flag up this error. Check other functions on the node,
ensure they are working properly.
2. It is possible to flag up this fault by switching on the key; then switching in on and off immediately.
Ensure that when switching the Key off, you wait fro the system to shutdown fully, THEN restart. This will
avoid getting the system out of sync
3. There is an actual fault with the sensor itself. It can be switched OFF temporarily with the Key code.
While you await a replacement
40. Crusher Pressure Sensor Fault
FAULT
ERROR
This error indicates that there is some fault with the sensor.
FIX
1. Check on screen to see what value the sensor is giving you. Check the sensor and
connecting ‘pipe’ to the T block physically
2. Unplug the sensor, the machine can be utilised without the sensor; but performance will
be down as it will NOT compensate for load