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Where ever you are currently attending this webinar please ensure you are fully aware
of the nearest exit and are aware of any site specific regulation along with the relevant
muster point in case of emergency .

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Emergency Stop System

• To be used in the event of emergency conditions. – regular use of the emergency

stop may cause damage to machine.

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• The emergency stop system is used to prevent harm to any persons or machinery in
the event of hazardous situation, the system must be checked for functionality
regularly.

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• Emergency stops are used to end this hazardous situation by stopping the machine
engine which in turn stops the machine function.

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• Machine E/Stop systems consist of two normally closed control circuits (One
positive and one Negative). These circuits must remain closed during machine
operation.

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• Emergency stops are fitted within these circuits.

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• When either circuit is broken the engine will be instantly stopped.

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• When a stop is pressed both of the circuits will be broken.

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12 volt screener stop systems.

Both circuits should be a closed loop in order for the machine to operate.

If either circuit is broken, or the K3 and/or K4 relay are de-energized by the machine
controller, cutting the fuel and stopping the engine.

System consists of one 12 volt supply is passed through the E/stop circuit along with a
secondary 0 volt connection to ground.

With both circuits in a closed state, and both fuel relays are energized relay contacts will
supply 12v and 0v to activate the fuel pump.

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Screener Track Controllers

Pressing the emergency stop button on the wired handset will cause the machine
controller to stop the engine.

Fault registered on the display screen will be “Doglead handset, engine stop requested”

This is achieved by breaking a normally closed contact within the handset which is hard
wired to the control system, if the wired controller is disconnected from the machine a
dummy plug containing a link wire must be fitted to complete the circuit.

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Pressing the emergency stop button on the radio handset will signal the machine
controller to request engine stop.

Due the stop request being transmitted as a radio frequency the radio stop cannot be
considered as an emergency stop.

Fault registered on the display screen will be “Radio tracking handset, engine stop
requested”

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Possible Faults

• Emergency stop button contacts damaged or stuck in the open condition - (Check
both stop circuits including wired controller or dummy plug).

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• Damage to the emergency stop connection lines - (Check for broken cable or short
circuits).

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• Fuse in the supply line blown due to high current draw – (Check condition of supply
fuse F6).

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• Fuel pump relays not energized preventing fuel supply – (Test for K3 and K4 relay
functions).

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If Machine Stop Fault becomes active;

Test;

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• Continuity around E/Stop channel 1

Test between pin 1 and pin 2 within junction box, expect Zero Ohms

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• Continuity around E/Stop channel 2

Test between pin 5 and pin 6 within junction box, expect Zero Ohms

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• Continuity between E/Stop channel 1 and 2

Test between pin 1 and pin 6 within junction box, expect no connection

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Additional tests to be preformed.

Test;

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• Check 5 Amp fuse condition (F6 within the control panel)

Supply voltage into the E/stop circuit

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• Positive (12V) supply on K3 relay pin 30 using a common ground reference

Supply voltage will be present with ignition on

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• Ground (0V) connection on K4 relay pin 30 using a common ground reference

Ground connection should be present

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Test supply and ground connection to the engine fuel pump and ensure its operation.

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24 volt crusher stop systems

The emergency stop monitor will constantly check the condition of the machine
emergency stop system for broken or short circuit.

This system includes the wired control handset which is hard wired into the emergency
stop circuits and therefore constantly monitored.

A fault will fault is triggered on the display screen. “Machine Stop Pressed”

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The emergency stop monitor will become active when the emergency stop circuits are
both closed (healthy) and the reset button has been pressed.

• Power supply – A1/A2 Fuse lamp illuminated

24 Volt supply on A1
0 Volt connection on A2

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• Reset Button
24 Volt signal supplied from S39
Delivered back to S33 when reset button is pressed

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• E/Stop channel 1 – K1 lamp illuminated
Connection from S11
Closed loop connected to S12

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• E/Stop channel 2 – K2 lamp illuminated
Connection from S21
Closed loop connected to S22

If both emergency stop circuits are in a healthy (Closed) state, when the reset button
is pressed all three lamps will be present and the relay contacts will close.

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The emergency stop monitor is used to control electrical supplies, both to the engine
ECM and the main control power relays.

These power supplies are required to allow the engine to run continuously during
operation.

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Both emergency stop circuits are constantly monitored during operation, if either circuit
is broken during operation the engine will be stopped.

Only when E/stop circuits are healthy and the reset button is pressed will the engine be
available to start.

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The emergency stop monitor will deactivate in the event of supply voltage dropping
below 20 Volts. This means if the machine batteries are in poor condition, as the engine
is cranked power drawn may be enough to trigger and machine stop fault.

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Pressing the emergency stop button on the radio handset will signal the machine
controller to request engine stop.

Due the stop request being transmitted as a radio frequency the radio stop cannot be
considered as an emergency stop.

Fault registered on the display screen will be “Radio Stop Pressed”

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Possible Faults

• Emergency stop button contacts damaged or stuck in the open condition.

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• Damage to the emergency stop connection lines (broken cable or short circuit).

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• Fuse in the supply line blown due to high current draw.

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• Emergency stop monitor will not reset or unit is damaged.

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One or both channel lamps missing

• Indicating one or both emergency stop loops are broken (button contacts damaged
or stuck in the open condition).

Test;

• Continuity around E/Stop channel 1

Disconnect wires from S11 and S12 expect Zero Ohms

• Continuity around E/Stop channel 2

Disconnect wires from S21 and S22 expect Zero Ohms

• Reset Button - 24 Volt signal to S33 when reset button is pressed.

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All lamps missing – Power and Channel

Test;

• Power supply - 24 Volt supply on A1 & F14 fuse condition

• Ground connection - 0 Volt connection on A2

• Short circuit between E/Stop channel 1 and 2 (Self protect)

Remove circuit connections from emergency stop monitor and scroll the power.

• Check for connection between wire removed from S11 and wire removed from S22.

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In Summary

• Machine E/Stop systems consist of emergency stop buttons linked together by two
normally closed control circuits.

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• When either of the circuits are broken and the engine will be instantly stopped.

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• When using a mechanical engine the fuel supply is cut, stopping the engine from
operation.

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• When using electronic engines the supply signal is removed to the engine ECM
stopping the engine.

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In Summary

• Emergency stop buttons are designed to lock once pressed holding both safety
circuits open.

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• When using an emergency stop monitor the fault will need to be reset during every
key on by using the reset button.

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• Emergency stop circuits can be tested easily using basic tooling.

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• Lamp on the emergency stop monitor can be used to diagnose system faults.

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Key take away points

• Emergency stops are to be used only in the event of emergency conditions.

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• By pressing any emergency stop the engine will be stopped.

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• Fault displayed upon the display screen will indicate which system has stopped the
engine.

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• Poor battery condition can cause E/stop systems to trigger a fault.

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• Radio control systems are not a part of E/stop circuit.

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