TEREX FINLAY C-1550

ELECTRICAL COMPONENTS &

SCHEMATICS

Rev-00

Author: Herbie Jones

Date: 03/03/2011
Subject to change without notice
 MAIN CONTROL PANEL

PDM Screen

E-Stop
Ignition Switch

CAT Diagnostic plug

MAIN CONTROL PANEL

Engine information plug

Tracking lead
Power connection plug
Work lighting (Option)
Aux Gland
Belt weigh (Option)
Tele radio remote
Hydraulic oil cooler #1

Hydraulic oil cooler #2

E - Stops
PT Tech clutch oil cooler
Hydraulic engine fan
Cone Lube oil cooler
Lube oil flow meter
PT Tech Clutch
Belt speed wheel
Work light switch
Node cable # 8
Allow upstream
Node cable # 4
Radio remote charge socket
Node cable # 5
Downstream clear
MAIN CONTROL PANEL

Circuit Breakers
Load Dump
Q1 – Q 17
Module

Relays K5 – K10 Terminal Rail

R360
PLC PDM Screen

Safety Relay K1

Main Contactors K4 Relay

K2 & K3
 CIRCUIT BREAKERS
Q1.Engine ECM
Q2.Hydraulic oil cooler # 1 Bus bars

Q3.Hydraulic oil cooler # 2

Q4.Clutch cooler
Q5.Lube oil cooler
Q6.Aux Supply
Q7.Work lights (Option)
Q8.Radio remote charge socket
Q9.PT tech clutch
Q10.Key switch supply
Q11.PDM screen
Q12.Starter Motor Main Solenoid
Q13.Battery switched
Q14.Belt weigh (Option)
Q15.E – Stop monitor relay
Q16.CAN Switch power # 1
Q17 CAN Switch power # 2
 RELAYS

K1 - E – Stop safety monitor

K2 - Main contactor

K3 - Main contactor

K4 - Engine shutdown
RELAYS

K5 - Engine enable

K6 - Hydraulic oil cooler

K7 - PT. Tech clutch cooler

K8 - Lube oil cooler

K9 - Upstream feed

K10 - Maintenance clear

 ENGINE & PANEL PLUGS

Engine ECM module plug

connections to & from main panel.

Track control dog

lead cable

Power
plug Engine Information Plug
MAIN FUSES - LOCATION

The 4 main inline fuses are located inside the engine enclosure.
GLOSSARY OF TERMS
IGNITION SWITCH CIRCUIT BREAKERS EMERGENCY STOP BUTTONS

CONTACTOR / RELAY
COIL & SWITCHES LOAD DUMP MODULE
WIRE FROM
FUNCTION TO PLC
GLOSSARY OF TERMS

STARTER MOTOR
MAIN FUSE
MAIN SOLINOID MALE & FEMALE SOCKET

RESISTOR
TERMINAL RAIL RE-WIRE ABLE
CONNECTION POINTS CABLE END
 SCHEMATIC - READING
 To navigate through each of the schematic pages we use a grid reference system with numbers along the top of
the page and lettering down the side.
 E.G. Schematic Page 1(Below) cable no. 200 will now be seen again on Page 2. grid reference A1.
 SCHEMATIC - READING

 (E.G) On page 5 of the schematic at reference B5 & B6 you can see two of the switches in the K2 contactor
and also just below that the reference Page 5 F4 this is the entire switches in that K2 Contactor.
 Where the relay/contactor coil is shown on the schematic below their will be a breakdown of all the switches
inside that relay/contactor.
EMERGENCY STOPS

Terminal Panel plug Terminal

Rail & socket Rail

The emergency stops around the machine consist of two wires which leave the
main panel go through an E-Stop then return to the panel terminal rail, then leave
the panel again to go to another E-stop and so on.
E-STOP MONITOR RELAY
Main panel
E-Stop
N/C Contacts

E-Stop
Channel 1

Channel 2

Channel 1

Channel 2

 The above shows the layout of how the E-Stop circuit is wired.
 Chanel 1&2 leave the E-Stop monitor relay & go through the
panel E-Stop first and then continue through the terminal rail to each
(Shown as example only!!!) of the other E-Stops.
 E-STOP MONITOR RELAY
The monitor also has a reset (Supply) Channel 1  If there is an emergency stop
loop which is an additional 24v+ pushed on the machine the E-Stop
Channel 2
safety feature to check that K2 & monitor will cut the power to the K2
K3 are working properly. & K3 contactor coils which in turn
cuts the power to the K4 relay coil
(Example.) (Engine shutdown) and will stop the
When going to start up the engine.
machine, switch on the ignition,  For the engine to be re-started the
if either K2 or K3 contactor were ignition will first have to be switched
damaged and stuck (Welded off for a few seconds and then
shut) in a constant /energised switched on again, the pushed E-
position the safety monitor relay Stop should be reset this in turn will
would not let the engine start up Channel 1 re-enable the E-Stop monitor relay &
as pin S33 would see constant 0v - then energise K2 & 3 contactors,
(Ground) Channel 2 only then can the engine be started
power and the safety monitor
would see a fault with one or up if no other faults are active.
both of the contactors.
PDM SCREEN & PLC
 PLC

Although most of the machine

functions run through the CAN
Bus system there are also
some that are hard wired
directly into the PLC both System CAN Bus (CAN Open)

Inputs & Outputs. Engine CAN Bus (J1939)

Tracking dog lead functions.

Main conveyor speed wheel.
PLC plug. Cone lube oil flow meter.
Down stream clear interface.
E-Stop healthy signal.
Engine kill.
These are all wired on the input
side of the PLC.
 PDM SCREEN

Figure 1

Figure 2
CAN Bus cables to PLC

The PDM screen has two power supplies

one is on the key switch to power (Figure 1)
the screen up & the other (Figure 2) is a
constant power from the batteries to allow
the PDM to save any settings when switching
off that have been made during the day.

Ground -
NODE BLOCK
What is a Node Block?
A Node block is an Input/Output module or ‘Communication centre’ in the
CAN-BUS system which can be located next its respective functions which it
controls such as sensors, solenoids and sounders etc.
The node blocks when integrated with the PLC system, allows for efficient fault
finding in the control system.

2 Types of Node Block used

 CR2031- An ‘OUTPUT’ Node, hence receives information from the PLC and
switches on a particular function such as a solenoid, beacon or sounder etc.
 CR2033- An ‘INPUT & OUTPUT’ Node, hence receives information from a
particular component such as a sensor or transducer and transfers it back to
the PLC, also receives information from the PLC and switches on a particular
function such as a solenoid, beacon or sounder etc.
 CR2031 & CR2033 Node blocks are NOT interchangeable, only Node
blocks with the same CR number can be swapped around, but note that
reprogramming needs to happen to the respective nodes.
NODE BLOCK
 When the ignition is switched on, the Power LED ‘PWR’ should turn
constant green for 4-5 seconds then constantly flash. If the LED stays
constant green, this may mean that the Node has lost its CAN signal.
 If the diagnostic LED ‘DIA’ comes on constant, then there is a
communication error with the Node.
 The Output node has yellow LED’s indicating that when permanently on,
the respective function is switched on such as a solenoid.
NODE BLOCK

 With an Input and Output Node CR2033, the left hand side of the node
will have 2 LED’s per channel, indicating that an input or output can be
connected here.
 The Input being the top LED, & and the Output being the Bottom LED.

Top LED
Bottom LED
 CAN BUS
The Node Network requires 5 different wires to operate, all
contained within a single main cable.
1. Supply – Power to operate the node
2. CAN_H – CAN Information
3. CAN_L – CAN Information
4. CAN_Switch power #1(For powering up solenoids etc)
for Nodes 1,2 & 3.
5. CAN_Switch power #2(For powering up solenoids etc)
for Nodes 4 & 5.
6. Constant ground (Negative)

CAN Cable # 8 to ‘T’ pieces

for Nodes 1,2 &3

CAN Cable to Node #4

CAN Cable to Node #5

CAN_SWITCH POWER
 CAN_ Switch power is a 24v auxiliary power supply for operating functions which require
a higher amperage (E.g.) Solenoid coils, the PLC sends out a signal to the Node which
then switches on a solenoid using the switch power (Similar to the way a relay would work.)
 For safety reasons the switch power supply runs through K2 & K3 allowing all functions
to stop immediately in an emergency stop situation.

If a node does not require Switch Power

all 3 power connection points must be
bridged together.

3 Power
Connections
Linked With A
Bridge

Can Switch No Can

Power Switch Power
 NODE BLOCKS 1 – 3

120 Ohm
Resistor #1
CAN_ Bus ‘T’

Cable #8
 NODE BLOCKS 4 – 5
 On the CAN_BUS lines
there are two 120 Ohm
resistors fitted in parallel to
give a resistance of 60 Ohms
(Approx.) to help filter out any
interference,
 There is one resistor in
Nodes 4 & 5 are Node 3 & one in Node 5 both
plugged directly into
side of main panel. are at each end of the CAN_
network.
 These can be checked
anywhere on the system with
a multi meter measuring
resistance between wires 14
& 32 with the ignition switched

120 Ohm off.

Resistor #2
NODE CR2031 – OUTPUT ONLY
Here is a breakdown of the pins on a CR2031 Output Node

No Connection
Current Reading (Proportional solenoid)
Ground / Negative
Voltage out +24v
Used for some types of moulded
connectors. (Non re-wire able type)

1 2
Amp meter (Used to give
actual Current read back 5
Proportional solenoids e.g.
(Feed Conveyor)
4 3

Pins shown looking directly at

the Node channel socket.
 NODE CR2033 – I/O NODE
Here is a breakdown of the pins on a  Pin 2 is a Analogue signal input E.g.
CR2033 Input /Output Node.
Cone level sensor, Pressure
transducers, Temperature sensors etc.
 Pin 4 is for Digital signal inputs E.g.
Voltage out +24v On/Off signals such as Hydraulic oil &
Analogue Signal Lube oil level switches, Lube oil filter
Ground / Negative blockage switch etc.
Digital Signal  Pin 2 will send back the actual value
Used for some to the PDM screen as below. (Figure1)
types of moulded
connectors. (Non
re-wire able type) 1 2
5

4 3

Pins shown looking directly at

the Node channel socket.
(Figure1)
 NODE - SETUP

Bus bar

 If a fault had developed with either CR2031 or CR2033 they can

only be replaced with a Node of the same CR Number.
Example!!
 If you had a faulty Node #4 (CR2033) and had to replace it is only a
matter of programming the new node (CR2033) via the 3 dials shown
opposite. And checking the position of the bus bar and input channels.

 LHS Dial –CAN Signal Baud rate, Always set at #4.

4 0 4
Centre Dial-The number of the Node being replaced this case Node
#04 so set it at 0.
RHS Dial- Set at #4.
Baud Rate
Node No.
(Always set at #4)
 FIRST STAGE IGNITION

 During the initial stage of engine start,

with the key switch in the ignition position,
power passes through K2 & K3.
 Engine enable relay K4 is controlled by
the PLC. If the PLC senses a problem with
the machine (e.g. hydraulic oil level low etc.)
K4 will not energize and the machine will not
start until the problem has been rectified.

SMMS
 STARTING THE ENGINE

 When the PDM screen has finished booting up

and there are no active faults the PLC will energise
the K4 coil to give the SMMS ground. The Key
Switch can be turned and held in the crank position.
 Power goes through K2 & K3 to the + ve side of
the SMMS, the engine starter engages and the
engine cranks.
 When the engine has started the key is released
and returns to the ignition position.
 ENGINE SHUTDOWN
In an emergency stop situation the engine is switched off by grounding Pin 44 (Remote
Shutdown) or cutting power to the engine ECM ,this is done a few methods.
PLC sees E -stop & cuts power to K5 engine enable relay cutting power to engine ECM
K4 looses power through K2 & K3 and grounds Pin 44

PT Tech Clutch

Engine ECM

K1
 TRACKING DOGLEAD
Power supply
wire 135 Track control box

The track lead operation buttons are hardwired

directly into the top of the PLC.
TRACKING REMOTE

Flashing green LED

indicates that the CAN
signal is being received.
(This is required for
operation)

Green solid LED indicates

signal is being transmitted
on CAN network. (This is
required for operation)
Remote control receiver.

The Hetronic receiver sends the signals on the CAN Bus

system to the PLC and then on to the Nodes.
 SENSORS

Hydraulic temperature sensor Lube oil temperature sensor Hydraulic oil level
located on upper part of return located on lubrication tank. sensor located on top of
manifold. the tank, this is a (N/O
circuit

The temperature sensors work on a range of between 4 & 20 mA, if the sensors feedback reading is out of this
range then this will trigger a temperature sensor fault alarm.
SENSORS

Main belt speed wheel sensor runs on the return Lube oil level sensor located on top of

side of the belt & sends back a Frequency lubrication tank,

measured (Hz) to the Plc. This is also a (N/0) circuit.

If the belt speed drops below a given frequency

‘Main conveyor under speed’ fault will be displayed
on the screen.
 SENSORS

Proximity sensor

Feed conveyor proximity

sensors location.

These sensors give the PLC information on the position the feed
conveyor either Direct feed, Pre-screen or Metal purge positions.
Pickup tab
CLUTCH SENSORS
Clutch control block The PT Tech clutch body incorporates two sensors input &
output speed sensors these are used primarily to detect if
there is any slippage.

PT Tech clutch PT Tech output shaft PT Tech input shaft

control module speed sensor speed sensor
 ENGINE MAINTENANCE RESET
Maintenance due is a warning controlled by the engine ECM and informs the operator that a 250 hour service is
due on the engine. When the service has been completed the message is cleared by grounding pin 06 on the
ECM. This is controlled by an output sent from the PLC to energise relay K10 to give a ground connection. Note!!
After completing a maintenance reset, switch off the ignition for a few seconds & reboot again to clear the alarm)

PLC OUTPUT RELAY K10 CONTACT K10 RELAY

 WELDING ON THE MACHINE

Switch off the main isolator Remove the engine ECM Remove the two plugs
& lock out located on the plugs on the side of the from the PT Tech control
side of power unit. engine. module located in the
main cabinet.
Think Safety!!

Disconnect the  Ensure there is no danger of conveyor belts, oil or grease

antenna and around the area that could catch fire.
power plug from
the Hetronic  When welding ensure the earth of the welder is located on the
remote receiver piece to be welded!!!
located in the main
cabinet.  Welding current still has the possibility to travel through
bearings bushings etc. damaging journals and shorting their life
expectancy.
WELDING ON THE MACHINE

Metal Detector body. Node 5 is located above the

cone lubrication tank.

If any welding is to be carried out on the feeder the same procedure on the previous slide should
adhered to with the addition of removing the metal detector cable from Node 5 Ch4.
(Note!!) At no time should any welding be done to the metal detector body.
C-1550 SCHEMATICS
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